Germinated or Malted for Doubling of Farm income

1. Germinated and malted foods for economic
growth
Er. A.Poshadri
M.Tech (Food Tech.)
SMS-Food Technology
Prof. Jayashankar Telangana State Agriculture University
Email: poshadri_fst@yahoo.co.in
Cell No: +919492828965

2. ROAD MAP
• Food Production scenario/Malted
foods marketing trends in India
• Why Germinated foods/Malted
foods
• Malted foods/beverages: economics

3.  The Indian food and grocery market is the world’s sixth largest, with
retail contributing 70 per cent of the sales.
 The Indian food processing industry accounts for 32 per cent of the
country’s total food market, one of the largest industries in India
 Food Processing sector is ranked fifth in terms of production,
consumption, export and expected growth
 The online food delivery industry grew at 150 per cent year-on-year
 The Indian gourmet food market is currently valued at US$ 1.3 billion
and is growing at a Compound Annual Growth Rate (CAGR) of 20 per
cent.
 India's organic food market is expected to increase by three times by
2020#.

4. Food Production in the year 2016-17
Crop
India Production in
Million Tonnes
% of production
from T.S
Barley 1.85 Nil
Sorghum 6 1.26
Ragi 2 0.03
Bajra 9.5 0.06
Small millets 0.5 0.21
Maize 24.5 7.15
Green gram 1.87 3.02
Bengal gram 9.6 0.52
Soybean 13.6 1.85
Red gram 3.62 2.90
Black gram 2.5 0.70

5. Country 2015-16 2016-17 2017-18
Qty (MT) Rs. Crore Qty (MT) Rs. Crore Qty (MT) Rs. Crore
Total 3,318.00 8.81 1,99,987.00 276.59 2,10,378.82 290.73
Source: http://agriexchange.apeda.gov.in
**Export worth of Cereals in the year 2017-18 is 395.83 crores
Importing of Barley

6. Malting
• Malting is the limited controlled germination of grains in moist
air, which results in the mobilization of amylases, proteases, and
other enzymes which hydrolyze and modify the grain
components and its structure
• Malting is a three-stage process involving steeping, germination,
and kilning
• Malting reduces protein but improves the quality of protein
• Malting also improves the availability of minerals, free sugars,
vitamin B and ascorbic acid by reducing the level of anti-
nutritional factors.
• It also imparts desirable flavour and taste to the product

8. • Malted foods and beverages are popularly known as health
drinks and functional foods in India
• India, the world largest Malt –based drinks market, accounts
for 22% of the world’s retail volume sales
• India malted food drinks market stood at $ 1.2 billion in 2016
and is projected to surpass $ 3 billion by 2022.
• India's malted drink market is expected to grow with a CAGR
of 17.4% for next six years

10. Types of Malts
 Extracts,
 Syrups
 Liquid or dry
 Diastatic
 Non-Diastatic
 Dark coloured
 Light coloured

11. • Malt Syrup and Malt Extract are terms used for the thick and sticky
water extract of germinated barley or other cereal grains.
• Malt Extract and Malt Syrup are brown, sweet, gluey liquids which
may or may not contain diastatic enzymes
• Malt powders are called diastatic and non diastatic.
• In diastatic malts active enzymes transform starches into sugars and
this powder is used when baking bread.
• Non diastatic malt powder has no active enzymes, and is commonly
used in malt drinks for enhancing flavour.
• Malted milk is a dry gruel made from a mixture of malted barley,
wheat flour, and whole milk, which is evaporated until it forms a

12. Applications of Malt
• Baked foods: biscuits, cakes, some varieties of bread rolls,
waffles, pancakes ,
• Confectionery & chocolate based foods : chocolate syrups
• Soya milk and other beverages
• Infant foods,
• Ice-cream,
• Vinegar
• Pet foods
• Pharmaceuticals.
• Yoghurt/Dairy foods

13. Strength  Higher food Production
Rising per capita income coupled with increasing awareness among
consumers
Rapid urbanization is driving consumerism in Tier-II & Tier-III cities
growing penetration of malt based drinks manufacturing companies in
rural areas
Tailor made flavors and region specific tastes
Weakness 1. Except barley, no other cereal based malt foods/drinks in the market
2. Malted Product have limited shelf life
3. Doesn’t mix well with cold milk
Opportunity  Production of malt from composite cereals and millets
 Better MSP for millets
 Untapped rural markets
 Designed foods for malnourished children's
 Rising milk demand in future
 Better product packaging and preservation
 India to be the youngest nation by 2025
 Doubling of farm income
•Threats •Product taste variations
•Competition from multinational companies
•Lactose intolerance among consumers
•Increasing diabetic cases in India
SWOT Analysis

14. Gaps noticed  Reality V/S claims against nutritional value by Malted health food
drinks
No substantial data of TDS (Total diet studies) for different age
segment covered by the industry
Low penetration in rural area and high prices for low volume
The basic raw material for this industry is Barley, Cocoa, sugar, Wheat
flour, SMP
Promotion of malted foods/drinks through collaboration of
Government and NGO’s may bridge the gap of malnutrition in children

15. FSSAI standards for malt food products
Parameters Malted milk food with out cocoa
powder
Malted milk food with cocoa
powder
Moisture
Not more than 5 per cent by
weight.
Not more than 5 per cent by
weight.
Total protein (N ×6.25) db
Not less than 12.5 per cent by
weight.
Not less than 11.25 per cent by
weight.
Total fat (db) Not less than 7.5% by weight Not less than 6% by weight.
Total ash (db)
Not more than 5% by weight Not more than 5% by weight
Acid insoluble ash
Not more than 0.1 per cent by
weight
Not more than 0.1 per cent by
weight
Solubility Not less than 85% by weight. Not less than 80% by weight.
Cocoa powder (db) - Not less than 5.0% by weight.

16. Test for starch Negative
Bacterial count
Not more than 50,000 per
gram
Not more than 50,000 per gram
Coliform count Not more than 10 per gram Not more than 10 per gram
Yeast and mould count absent in 0.1 gm
Salmonella and Shigella absent in 0.1 gm
E.Coli absent in 0.1 gm
Vibrio cholera and
V.Paraheamolyticus
absent in 0.1 gm
Faecal streptococci and
Staphylococcus aureas
absent in 0.1 gm

17. Malt Based Foods or Malt Food
• The product obtained by mixing malt (wort or flour or malt
extract) of any kind obtained by controlled germination of
seeds (cereals and/or grain legumes), involving mainly steeping
germination and kiln drying processes with other cereal and
legume flour with or without whole milk or milk powder,
flavouring agents, spices, emulsifying agents, eggs, egg
powder, protein isolates, protein hydrolysates, edible common
salt, liquid glucose, sodium or potassium bicarbonate minerals,
amino acids and vitamins.
• It may contain added sugar and/or cocoa powder and
processed in such a manner to secure partial or complete
hydrolysis of starchy material in the form of powder or
granules or flakes by drying or by dry mixing of the ingredients.

18. Parameters Malted based food/malted food
Moisture Not more than 5 per cent by weight.
Total protein (N ×6.25) db Not less than 7.0 per cent by weight.
Total ash (db)
Not more than 5% by weight
Acid insoluble ash Not more than 0.1 per cent by weight
Total plate count Not more than 50,000 per gram.
Coli form count Not more than 10 per gram
Yeast and Mould Count Not more than 100 per gram

19. Parameters Malted based food/malted food
E.Coli Absent in 10 gram
Salmonella and Shigella Absent in 25 gram
Alcoholic Acidity Not more than 0.30 per cent
Vibrio cholera and V.Paraheamolyticus
absent in 0.1 gm
Faecal streptococci and Staphylococcus
aureas
absent in 0.1 gm

20. Packaging materials
• Hermetically sealed tin containers or glass bottles
• Moisture-proof containers – such as rigid containers made from
high-density polyethylene (HDPE) or containers made from
flexible packaging material such as laminates of paper,
polyethylene and aluminium foil.
• Most of the brands in India are packed in HDPE or polypropylene
(PP) material or glass jars.

21. Consumer Desires
• Good and Healthy Foods
• Available all year round
• Sufficient Supply
• Conveniently packaged
• Sold in (super) markets
• Long shelf life
• Always Fresh
• Appealing taste & Appearance

22. Market Challenges
• Globalisation
• New distribution strategies
• New Processing Technologies
• New Materials
• New Risks
• Climate Change
• Energy Efficiency
• Water Supply
• Greed- Fraud

23. Possible areas of for development of malt based foods
and beverages
• Instant Breakfast mixes
• Multi grain Malt foods/weaning mixes
• Malted cereals crispies
• Seasonings applications
• Bakery Products:
-- Biscuits/ Cookies/cakes/Bread and Rolls
• Confectionery: Malt spreads, Malt based chocolate spreads,
Energy dense table spreads
• Ice creams: Multi grain malt ice cream
• Other Culinary Applications

24. Pilot plant on Cereals Products
Equipment Units Rs. in Lakhs
1.Destoner/mini Cleaning unit 01 1.8
2. Mini SS Mill 01 3.0
3. Vibrosifter 01 2.0
4. Frying Unit 01 0.8
5. Mini Roaster 01 1.5
6. SS ribbon blender (300 lit) 01 2.0
7.Weigh filler 01 5.0
8. Planetary mixer (15 Lit) 01 0.2
9. Saladin box 01 3.0
10. SS silo’s optional 01 2.5
11. Band sealer 01 0.2
12. Inkjet machine 01 1.8
13. Miscellaneous (Balances, Trolley,
testers, SS vessels, Scoops, brushes)
01 1.2
Total cost 25.0

25. Cost Benefit analysis estimate of preparing 125 kg
batch of Instant Malted Foods per day
S.No Ingredients Quantity
Required in
kg
Unit Cost of the
ingredients
(in Rs.)
Total Cost
(in Rs.)
1 Cereals and Millets 100 kg Rs. 30 per kg 3000.00
2 Edible Oil 12 lit Rs. 80 per kg 960.00
3 HVO/Fats/SMP 12 lit Rs. 110 per kg 1320.00
4 Gram dhals 4.0 kg Rs. 80 per kg 320.00
5 Sugar 1.5 kg Rs. 40 per kg 60.00
6 Iodized salt 2.5 kg Rs. 9 per kg 22.50
7 Spices and condiments 2.0 kg Rs. 150 per kg 300.00
8 Other food additives 0.15 kg Rs. 220 per kg 33.00
9 Met PET laminated rolls 1.2 kg Rs. 320 per kg 384
10 Processing cost ( 15 % of the total raw materials) 959.95
Cost Price (1250 pouches of each 100g) 7359.45
Sale price (1250 pouches of each 100g @ 10/- Rs ) 12500.00
Profit per batch of 125 kg 5140.55

26. Marketing strategy/Plan including product sale
 Promote as Healthy convenient foods through the local retail
shops by test marketing with complimentary products such as
pickles, chutney and culinary powders etc.
 Distribution of the products through local grocery shops and
explore the convinces use of products
 Direct selling of the products through distribution in local retail
out lets of nearby villages and towns
 Target corporate and public sector canteens, college, school and
hostel canteens, railways and bus station outlets, tourism related
catering facilities to promote the health benefits of germinated

27. Out of home (OOH):
• Target parlours and food courts in malls, multiplexes
etc.
• Explore the option of dispensing the value added
cereal based drinks/foods through the vending
machines in OOH locations.

32. Tribal
Villages
Average weight in kg
ICMR
Standard
Weight in Kg
for 4-6 years
Average Height in cm
ICMR
Standard
Height in cm
for 4-6 years
1st
day 60th
day
13.5 to 16.5
1st
day 60th
day
87.3-107 cm
Sakera-B 14.15 14.66 95.5 95.68
Sheikguda 13.85 14.8 97.56 97.93
Dhamana
Guda
14.23 15.3 98.95 99.55
Average test
Group
14.1 14.96 0.84 kg 97.3 97.7 0.4 cm
Normal
group
13.18 13.35 0.41kg 96.1 96.3
0.2cm
**Age 4-6 years: Per day 40g of millet based nutrient dense food for 90 days
(given 100 packets per children through ANGANWADI: 18 members from the selected
3 villages )

33. DFRL-SWEETENED MILLET MIX

34. MILLET SWEETENED COOKIE MIX

35. ICRISAT- Supplementing tribal children's with the following millet based malted foods

36. Conclusion
• With a huge production base, India can easily become
one of the leading malt food suppliers to the world
while at the same time serving the vast growing
domestic market of over a billion people.
• India’s large market size with growing incomes and
changing life styles also creates incredible market
opportunities for food producers, food processors,
machinery makers, food technologists and service
providers in this sector.

37. Thank You