Small Scale Production of Tuti Fruitee
Vijay
Kumar Shah
shahvk55@gmail.com +91 99353
60033
WhatsApp A 091 98397 84033
INTRODUCTION:
Tuti Fruitee is a small raw papaya cube impregnated
with colored sugar syrup and other additives.
Care should be taken that during processing
cellular structure in not damaged and pieces remain crisp and succulent. A good Tuti Fruitee will be:
i)
Pieces
having sharp edges and retaining its shape.
ii)
Will
be crisp and will not leave any fibrous residue in mouth.
iii)
It
will be of bright color and not dull in appearance
iv)
There
will be minimum free syrup on surface and they will not be sticky.
FOOD LAWS:
Following acts
covers Tuti Fruitee:
Fruit products Order (F.P.O.)
Prevention of Food Adulteration Act.
Packaging Commodities Act.
It is mandatory to
obtain a license under F.P.O. before commencing production.
As per law Tuti
Fruitee should have
Brix :
minimum 68
Preservative : maximum 250 PPM sodium Benzoate
Color : maximum 0.2 Gms/Kg of finished product.
Other desirable
characteristics are:
pH :
3 to 3.5
Invert Sugar : 33% to 50%
Size of pieces : 5 to 6 mm cubes.
Free from seeds, peels and other
foreign matters.
RAW MATERIALS :
Basic raw
materials are followings:
i)
Raw
Papaya
ii)
Sugar
iii)
Conditioning
agents: salt, alum etc.
iv)
Chemical Additives: food color, preservatives,
food acids, bleaching agents etc.
Raw Papaya:
Papaya of any
variety is good. Even latex extracted
papaya is suitable for manufacturing Tuti Fruitee. They should be firm and white inside. A few
yellowish papaya is not objectionable, provided they are firm. Soft papayas are total loss during
processing. Size of papaya is immaterial, but larger papaya will give more
yields. Ask for papaya of over 750 gms
only.
Papaya provides
basic structure to hold sugar syrup, and the crisp crunchy texture. It is white
so it is easily colored. It is not
having any prominent taste or flavour of its own, so it blends well with any
product in which it is added. Again it
withstands the physical and mechanical shocks while processing of the product
very well. Any other fruit/vegetable,
which can fulfill this requirement, will serve the purpose. Ash gourd is
another suitable fruit, but it requires more careful handling. Bottle gourd, red pumpkin etc. has also been
tried, but they prove a poorer substitute. Carrot may be good.
Sugar:
Use S 30
grade. It should not have many black
specks and should yield light colored transparent syrup. However do not go for costly sugar of large
crystal size. Better select a mill that
produces good quality sugar.
Sugar provides the
sweetness. It also helps in
preservation. It is most costly ingredient of Tuti Fruitee.
Salt:
It should be white
and free from dirt and insoluble matters.
Dissolve a spoonful of salt into water in a glass beaker. Solution
should be white, transparent and without settled or suspended impurities.
Salt is not a
direct additive. It is used as conditioning
agent and as a preservative. The raw
papaya stock can be held in brine for a long time. Even over a year. The lactic
fermentation, which takes place in brine, provides a desirable elasticity to
fruit cells that enables it to withstand further handling better. It leaches out the undesirable raw papaya
flavour. However salt is a nuisance too.
It creates effluent disposal problem, as salt water spoils the land for
agriculture purpose and pollutes the
underground water. It is important to work out a method to eliminate salt. Lime
has been tried, but still salt is most common as it is not only a conditioning
agent, but preserves raw papaya to act
as buffer stock.
Alum:
It should be free
from iron. Normally commonly available
alum is reddish, which indicates presence of iron. Potash Alum is good.
Alum provides the
mechanical strength to the fruit pieces, so that the cellular structure does
not collapse under osmotic pressure. If
the water hardness in the factory is high, or the product has been held too
long in the brine, it is not needed. One
has to judge and standardize its use by experience. It does give sharp edges and shine to the
product.
Sodium
Benzoate:
Use only food
grade and with ISI mark. Ganesh
Benzoplast products are good.
It is more
convenient to use it in solution form.
Dissolve 1 Kg of sodium Benzoate into 2 Liter of boiling hot water. It will yield 2.5 L of solution of 40%
strength, Weight/volume.
100 ml of this solution
= 40 Gms of sodium benzoate
100 GMS sodium benzoate = 250 ml of solution.
As per law both
sodium benzoate and sulfur di oxide are permitted. But sulfur di oxide will bleach the color of
Tuti Fruitee hence only sodium benzoate is used.
Citric Acid:
Citric acid must
be good. Sometimes it has buffer salts, that interferes with sugar inversion.
Often it is adulterated with alum. Fruit acid like malic or even acetic can be
used.
Prepare a solution
of 50% strength weight/volume. Dissolve
1 Kg of acid into 1.4 Liter of boiling hot water. It will yield 2 Liter of solution.
100 ml of this solution =
50 Gms of acid
100 Gms acid = 200
ml of solution.
Citric acid acts
as anticristylising agent by inverting part of sugar in situ. It also lowers pH thus helps in preservation
as sodium benzoate is more effective at lower pH. It is recommended to use
liquid glucose to control sugar crystallization, but it is a costlier
proposition.
Food Color:
Any color with
good shade and purity is good. Idacol is a good brand in India. It is more
economical to use basic dye rather than blended colors. Normally basic dyes are
of 85% to 90% strength, while the blended colors are available in 20% to 30%
strength.
Color provides the
attractive look to Tuti Fruitee and also makes the product in which it is added
colorful.
Red :
Carmoisine or Ponceau 4R or a blend of two depending on the shade desired. Ponceau 4R is of lighter shade while
Carmoisine is darker.
Green :
A blend of Tartrazine and Brilliant Blue FCF is good. The ratio of two can be
worked out depending on the shade desired.
More of tartrazine will be light green, while vice versa will be darker.
The
other blue color permitted is Indigo Carmine. It is much economical but it
fades within a short time, so it should never be used. Fast Green FCF is another
color to be tried, but it is not easily available in our country. Apple Green of Idacol is good amongst blended
color available.
Yellow :
Tartrazine
Orange :
Sunset Yellow.
Prepare 10%
solution by dissolving 1 Kg color into 10 L of boiling hot water solution.
100 ml of this solution
= 10 Gms of color
100 Gms color = 1 Liter of solution.
4) Process Flow Chart:
(A) Brining of papaya Cubes:
Receive and weigh Papaya
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(Mechanical peeling) (Manual
Peeling)
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Feed whole papaya in machine and
peel Halve papaya
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Trim and halve Blanch |
Deseed and inspect Brine for 5-6 days
Peel and deseed
(Imported Dicer) (Indian
Dicer) 
Brine
for 5-6 days Inspect
Cube Cube Cube
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|
|
Brine Brine Brine
Preparation of Tuti Fruitee
Brined papaya cubes
|
Debrine
Alum Blanch
and Cool
Sugar Add sugar and leave overnight |
Syrup, color,
Preservative, acid cook to desired brix store
Drain
Syrup syrup
Cool and dry Tuti Fruitee
Pack
5)
Recipe:
A retreat recipe is given. As their will
be always left over syrup from previous batches, it is used in
subsequent lots. Followings are the
recipe of Tuti Fruitee with only sugar and with half the sugar replaced with
syrup.
Recipe Of Tuti Fruitee
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|
With only sugar
|
With Sugar + Syrup
|
|
Blanched Papaya Cubes
|
100 Kg
|
100 Kg
|
|
Sugar
For mixing
first day
|
70 Kg
|
70 Kg
|
|
During
Cooking
|
70 Kg
|
-
|
|
Syrup of 70 brix during cooking
|
-
|
100 KG
|
|
Citric Acid
|
200 GMS
|
100 GMS
|
|
Sodium Benzoate
|
40 GMS
|
20 GMS
|
|
Color
|
40 GMS
|
20 GMS
|
Finish at 72 Brix (of syrup)
It will yield
Tuti Fruitee 115 – 120 Kilo
Syrup of 70 brix 80 -
85 Kilo
Total 200 Kilo
The product
produced as per above recipe will confirm to Indian Food Laws.
Recipe with various other proportions of sugar and
syrup can be similarly worked out. It is observed that 140 Kilo sugar/100 kilo
pieces will keep the pieces fully submerged into syrup until end.
So total quantity of sugar from syrup + dry sugar
should be in that ratio.
Syrup darkens the
color of Tuti Fruitee, so use it cautiously. Maximum 50% of sugar is replaced
by syrup.
Normally do not
use any syrup in Yellow Tuti fruitte. In red Tuti Fruitee besides red both
yellow and orange syrup can be used. Yellow syrup can be used in any color Tuti
Fruitee
Other additives
are added based on dry sugar in the lot, as syrup already contains these
chemicals. Calculate total quantity of sugar to be added in the lot, and
calculate quantity of additives to be added as bellow:
Color 30 gms/100 Kilo sugar rounded to 40 Gms for 140 Kilo
sugar
Sodium Benzoate 30 gms /100 Kilo sugar rounded to 40 gms
for 140 Kilo sugar.
Citric acid 150 gms/100 kilo sugar rounded to 200 Gms for 140 kilo sugar.
Tuti Fruitee of lower brix
Although not
permitted by law many manufacturers do make Tuti Fruitee of lower brix due to
competition. As these are bound to ferment and also mould will grow, quantity
of Sodium Benzoate is raised even above 1000 PPM to preserve it.
They often use
less sugar, so that sugar syrup dries out in the pan itself while cooking.
However, this creates another problem.
As all the pieces will not get same amount of sugar. The pieces in the bottom of the pan is likely
to remain longer in contact with syrup, and thus absorb more sugar, and pieces
on top vice versa.
Our suggestion is
to use sufficient sugar so that there is sufficient syrup formed to keep all
pieces submerged until the end of cooking. There will be no loss of sugar as
the excess sugar added will be recovered in the form of syrup, but quality will
be more uniform and better.
If final batch
weight is 2 times the quantity of pieces, there will be sufficient syrup to
keep pieces submerged. The calculation for sugar can be made as bellow:
2 x desired brix x weight of pieces
Weight of sugar =
100
For example:
Papaya Cubes = 100 Kilo Desired Brix = 55 Syrup = nil
Sugar required is {2x 55
x 100} / 100 = 110 kilo.
Other additives in low brix Tuti Fruitee
In a batch of 100
kilo pieces it should be as bellow:
Color : 40
Gms.
Citric acid : 200 Gms.
Sodium Benzoate: 200 Gms.
Now if sugar syrup
from previous batches are used it will contain part of the additives added in
that batch. So that should be taken into account otherwise concentration of
these will increase excessively.
Therefore, it is
easiest to add additives based on sugar only. For example:
A typical recipe of 55 Brix Tuti Fruitee is as
bellow:
Recipe of
Low Brix Tuti Fruitee
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|
Sugar only
|
With 50%syrup of
55 brix
|
|
Blanched Papaya
cubes
|
100 Kilo
|
100 kilo
|
|
Sugar- while
mixing
|
70 kilo
|
55 kilo
|
|
Sugar- while
cooking
|
40 kilo
|
-
|
|
Syrup of 55 brix
|
-
|
100 Kg
|
|
Citric Acid
|
200 gms
|
100 gms
|
|
Sodium Benzoate
|
200 gms
|
100 gms
|
|
Color
|
40 gms
|
20 gms
|
End brix 55
to 57
Yield Tuti Fruitee 100 to 105
kilos
Syrup of 55 brix 100 to 95 kilo
Similar recipe can
be worked out for any desired brix and combinations.
6) The Process
i) Receipt of
Papaya:
The fruits are
generally transported loose in truck/tempo. It is weighed on weigh bridge/platform
balance. It should be preferably
unloaded on pucca floor. Unloading them
on ground is not desirable, as there are chances of small pebbles being
embedded in the papaya flesh, which will later break the knife of cutting
machine.
ii) Peeling:
a)
Mechanical
peeling: It is done in abrasive peeler.
Whole papaya is fed into it where it is rotated and rubbed against emery
stones, which rubs off outer peel. The papaya is then trimmed to remove
remaining peel. It washes papaya too.
As papayas are large fruits, the machine should be of large diameter,
minimum 1 meter diameter, otherwise breakage would be more. It will peel
approximately 10 MT papayas in 4-5 hours.
All contact parts should be of SS as iron will eventually rust which
will contaminate the fruits, and Tuti Fruitee made with it will be of dark
color. In smaller machine, there will be insufficient peeling and also more
breakage.
The peeler generates lot of effluent water rich in BOD. The peeling
losses are also more upto 40% even, the peeler keeps off rubbing the fruit, and
once the hard peel is removed, the inner soft flush is removed very fast. So
any over peeling results in heavy losses.
There is a tendency amongst workers to overpeel to save on trimming
which is a laborious work. So this
tendency should be watched.
b)
Hand
Peeling:
Papaya contains papain enzyme, which are very corrosive to hand. Papaya is cut into two halves. If there is
long stem, it is also removed. Fruits
are then blanched in boiling water for 4-5 minutes and immediately cooled with
water sprays. This process will
inactivate the enzyme. Cutting fruits
into two facilitates heat penetration during blanching , minimizes tendency for
floating of fruit, It is also necessary for removal of seeds.
The fruits are then dipped into 10% brine solution for 4 to 6 days to
soften peel. They are then peeled with potato peeling knives.
It is observed that if papaya is kept for long in brine, the enzymes
get sufficiently inactivated and does not affect hand, but boiling does facilitate
peeling
Hand peeling is laborious, but it generates
only solid waste, which is easier to dispose off. It is either put into waste yard and allowed
to rot, or spread on ground to sun dry and then burnt. As it contains salt, it cannot be used for
manure.
iii) Deseeding:
The seeds must be
removed. They are undesirable. Particularly black seeds look like insect
head in the cakes and sweets. The
brinning loosens the seed, so it is better done after that. Papaya is knocked against floor or any hard
surface, to remove seeds. The remaining
are then removed by the pointed head of peeling knife.
Cutting papaya
into broad rings and then putting them on a vibratory table is also tried.
iv) Cubing:
Most of the Indian machines are able to handle only brine-cured
papaya. Machine peeled papaya should be
cubed after brine curing. Hand peeled
papaya can be straightway cubed as they are already brine cured. Ensure before dicing that papaya pieces are
free from peel and seeds.
v) Sieving:
It is desirable to have pieces of uniform size. A two-deck sieve is
used. The top deck removes oversize pieces, which are fed back to dicer for
cutting. The lower deck removes
undersize pieces.
The undersize pieces besides spoiling the appearance of Tuti Fruitee,
creates problem during draining of syrup. These should be discarded. However, they can be accumulated in brine and
later converted into Mini Tuti Fruitee that is liked by Ice-cream
manufacturers.
vi) Brining:
Normally 10% brine is used. It
is used 2-3 times and then discarded. Too much salt is waste of money and will
also make debrinning more difficult.
Only if pieces are to be kept in brine for over a month or so brine
strength should be over 14% and pH bellow 4.0 (After equilibrium). Addition of
0.5 to 1 Kilo KMS/ cubic meter of storage tank is benefitial. It will
improve brightness.
Papaya
should be brined in large plastic tank. For large quantity cement tank may be
used. They should be made of RCC with
suitable waterproofing. Brick tanks are
not suitable, as brick is porous. The
tanks should be lined inside with acid alkali proof tiles or with Mandana
Stones, which are resistant to salt and are economical. Care should be taken while fixing
tiles/stones. Normally a little cement
is used to fix them with walls, leaving lot of empty space behind
tiles/stones. Brine gradually seeps
through joints behind the tiles and eats away into cement, making the tanks
leak after sometime. So sufficient
cement, with little extra water than normal, is put on the tank surface and
tiles/stone is pressed against this, making the cement ooze out of stone
joints, thus ensuring that there is no gap behind for a the brine to enter.
Joints are coated with acid alkali proof epoxy paint, further making the tank
leak proof. The tanks should be constructed over ground level and an outlet
should be in the bottom of tank to drain out brine and also help in cleaning of
tank.
vii) 2nd brining:
It is desirable to brine cubes at least for 5 – 7 days before
processing them into Tuti Fruitee.
For storing cubes of papaya, for a short period 100 L wide mouth HDPE
carboys are ideal. These are brought
near the cubing machine filled and moved over to curing yard where they are
filled with brine solution of desired strength.
These are kept for desired number of days, and then moved to the
processing hall. These are easily moved either by rolling or on drum trolleys.
vii) Blanching
The papaya cubes are washed with one or two changes of water to remove
salt partially. They are cooked for 15
to 40 minutes in boiling water to soften them, and then cooled with one or two
changes of water.
Often alum is
added @ 250 gms to 500 gms/100 Kilo pieces.
350 Gms is a common dose. Too much alum will cause astringent taste.
Blanching time will vary. We can try 30 minutes and then as per result
time can be decided. Pieces should become soft, but should not crush under mild
pressure. The exact time well vary and with experience, it will be determined.
The water is drained by putting blanched cubes on any perforated surface
or in Bamboo basket. They should not be
unnecessarily pressed to remove extra water.
Pieces should not taste saltish after completion of the above process.
Centrifuging can be tried.
ix) Sugaring:
Mix part of sugar with the blanched pieces and leave overnight Usually
70 Kilo of sugar is mixed with 100 Kilo of pieces. This will draw out part of water from pieces
and sugar will enter into cubes, raising the brix to 40-42, without use of any
heat. Keep it covered so that it does not get contaminated by fly or otherwise.
Of course, exact quantity of sugar will depend on the recipe
x) Cooking:
Next day whole mass is transferred to cooking pans and start
cooking. Add remaining sugar/syrup in
it. In case whole mass cannot be accommodated
in the pan add syrup gradually as the concentration proceeds.
Citric acid is added 30 minutes before end point and other additives
(preservative and color) 10 minutes later.
As already mentioned add these in solution form. It is easier to measure and also ensures
complete solubility and proper distribution in the batch.
The addition time of chemicals is very important. Citric acid is added so that a part of sugar
is inverted. It is a time and
temperature controlled process. If added
too late there may be insufficient inversion, and chances are that sugar will
crystallize, making the appearance of Tuti Fruitee poor. Sometimes the whole mass of Tuti Fruitee will
be converted into one solid block, joined by the sugar crystals. If added too early, over inversion of sugar
will take place causing stickiness and darkening.
The batch size is so adjusted that whole lot should be ready in 50 to
75 minutes. Over cooking, will darken
the product by sugar caramalisation and under cooking will give it a raw taste
and texture.
XI) The end point:
As it takes time to penetrate syrup inside pieces, brix of Tuti Fruitee
is lower by 1 or 2 degree from that of syrup. So it is desirable to finish the
cooking at syrup brix that is higher by 1-2 degree than desired, that is at 72
brix to get final 70 brix.
As explained the prism of referectometer should be dry and clean. Even a very thin film of moisture on prism or
a thin film of dried syrup from previous batch will cause major error in
reading. Take out small sample in
shallow metal dish and cool it quickly within a couple of minutes to room
temperature and then check its brix.
As double check, test with brix hydrometer too. They are available in the range of 30-60 and
60-90. Keep aside some syrup and let cool
to room temperature. Check with
hydrometer and compare with refrectometer reading. However as this is a slow process on line
test is with refrectometer only.
xii) Cooling and drying:
The syrup is drained on a perforated sheet. The hot mass is transferred on a perforated
sheet kept over a receptacle for syrup and drained for a couple of
minutes. It is then transferred over a
cooling table for cooling and drying,
Cooling tables are usually made of 4’ x 8’ aluminum sheet, with ends
raised a couple of inches. They are kept
inclined to one side to collect syrup that is still there. Often fans/room coolers are used to
facilitate cooling. The Tuti Fruitee is
spread over these tables in 2” thick layer and occasionally stirred. They should cool and dry within 1-2 hours.
It is preferable to keep these tables in dry area that is fly
proof. Basket centrifuge working at low
RPM can be used to dry Tuti Fruitee. It is better to use centrifuge with
removable basket for hygienic purpose and ease of operation.
xiii) Filling: The Tuti
Fruitee is usually filled in polypropylene pouches of appropriate size as per
market demand. 1 kilo is common pack, but other sizes are also packed. The bags are sealed and placed into carton,
which is again sealed.
On storage, Tuti Fruitee looses moisture, and weight. While selecting packing material for long
storage, this should be considered.
7) Special quality point:
i)
Iron
contact is not desirable. It darkens color.
It may come from machines, dirt, water and ingredients. So ensure that:
a) Machines are having all contact parts free
from Iron. Stainless steel, wood,
plastic, stone tiles are desirable.
b) Fruits (especially after cutting), salt and
other materials should not be exposed to dirt.
c) All ingredients should be free from dirt
and iron contamination. Alum and salt is
a good source of iron.
d) Water should not be very hard, as its
mineral may affect texture and color shade of Tuti Fruitee.
ii)
Pieces
should be properly cut, and check cut material frequently. If they are having seeds, peels or off cut
pieces, take corrective actions. If
pieces are not sharp cut, check blades.
iii)
Cooking
and cooling should be properly done to avoid unnecessary carmalisation of
sugar.
iv)
The
premises should be maintained clean and free of flies. Use bleaching powder and regularly use
insecticide (Nuvan). Prepared goods
should not be unnecessarily exposed to atmosphere to minimize contamination
from air, microorganism and insects.
8)
Costing:
It is based on present prices, However actual cost of
material is to be considered at the time of calculation.
(A)
Papaya
pieces in brine: Usual recovery of cubes from papaya is 50% to 60%.
Therefore, cost of 100-Kg papaya cubes is:
200 Kilo Raw Papaya @ Rs. 2.50/kilo = 500.00
8
Kilo salt refined @ Rs. 2.50/Kilo = 20.00
Total = 520.00
Raw Material Cost of pieces/Kilo = Rs. 5.20
Raw material Cost of Tuti Fruitee
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Raw Material
|
Price/kg
|
70 brix
|
55 brix
|
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Quantity
|
Value (Rs.)
|
Quantity
|
Value (Rs.)
|
|
Papaya Cubes
|
5.20
|
87 Kg
|
452.40
|
100 Kg
|
520.00
|
|
Sugar
|
16.00
|
72 Kg
|
1152.00
|
56 Kg
|
896.00
|
|
Colors
|
400.00
|
20 gms
|
8.00
|
20 gms
|
8.00
|
|
Sodium Benzoate
|
60.00
|
20 gms
|
1.20
|
100 gms
|
6.00
|
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Citric Acid
|
80.00
|
100 gms
|
8.00
|
100 gms
|
8.00
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Potash Alum
|
30.00
|
300 gms
|
9.00
|
350 gms
|
10.50
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Total raw material cost
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1630.60
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|
1448.50
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Labor
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|
|
150.00
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|
150.00
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Fuel
|
|
|
200.00
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|
150.00
|
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Power etc.
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|
|
50.00
|
|
50.00
|
|
Packing cost
|
|
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200.00
|
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200.00
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Total cost
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2230.60
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1998.50
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Say for a proper Tuti Fruitee it is aprox. 22/ Kilo
and a low brix Tuti Fruitee it is 20/kilo
Of course, actual cost will have to be worked out at
the time of production. The above is only as guideline
9. The machines:
The major machines are:
1. Peelers: It should be made of S.S., and
minimum 1 meter diameter. However
initially one can manage with hand peeling.
2. Balance: A 300 Kilo platform balance is
ideal. Avery loose weight models are
sturdy and economical
3. Slicer and cuber: They may be separate or
combined.
4. Sieve: Helps in getting uniform sized
pieces.
5. Cooking: For small capacity, diesel bhatti
and aluminum bhigona are good. For large
production, Boiler and S.S.pans are ideal.
6. Cooling: Aluminum top tables are good.
7. Lot of vessels are needed for storing of
sugared cubes, syrups etc.
8. Knives, ladles etc.
9. Brining tank cemented or HDPE drums for
storage of brined papaya.
10. Filling tables, sealing machine, balances,
carton strapping machines etc.
10. Quality Control
For checking Brix:
Refrectometer
Brix
Hydrometer, Measuring Cylinder 500 ml.,
Aluminum
dishes
Surgical
cotton and malmal clothe to dry refrectometer.
For brine strength Baume
Hydrometer, 0-20
Measuring
Cylinder 500 ml.
pH Initially
pH paper 2.5-4.5 range or pH meter
Balance A
balance of 1 kilo weight to check weigh packed material and for analysis purpose.
Stove,
Bhigona, glass jars etc.
11. Conclusion :
Tuti Fruitee is a product that is simple to make. Although it is a fruit preserve, but due to
its small size and large surface its processing is faster than normal preserve
like Petha, anwala etc. We have given a process which if adopted will make a
good product in a simple way.
5.3.19
