Indian Journal of Natural Sciences oe www insroindia.org.in CONS Vol / Issue 48 / June /2018 International Bimonthly ISSN: 0976-0997 Reotre putea Study on the Economics of Spent Hen Meat Puffed Product Sarvadnya RG", Kokene RD?, Dange Az, Gadekar YP?, Girish PS* and G Venkateshwaralus 'MVSc Scholar, Department of Livestock Products Technology, Bombay Veterinary College, Mumbai, Inclia 2Department of Livestock Products Technology, Bombay Veterinary College, Mumbai, India. 2Principle Scientist, Central Sheep and Wool Research Institute, Avikanager, Rajasthan, India. ‘Principle Scientist, National Research Centre an Meat, Chengicherla, Hyderabad, Telangana, India. ‘Dean, Central Institute of Fisheries Education, Mumbai, India. Received: 11 Mar 2018 Revised: 13 Apr 2018 Accepted: 25 May 2018 “Address for correspondence Sarvadnya RG MVSe Scholar, Department of Livestock Products Technology, Bombay Veterinary College, Mumbai. India, Email: sarvadnyargegmail.com «the terms ofthe Creative Commons Attribution License ©OSS sls on Open Accs urate asrioued und ripution, and reproduction in any medium, provided the GERRI (CC-BY-NC-ND 50) which permits unrestricted use, ‘original work is properly cited. Al rights reserves Animal protein is one of the most important food products essential for normal growth of human body.Incorporation of waste protein (Spent Hen) of poultry industry and thus reducing the cost of production of Value added Spent Hen Meat Puffed Product was main motto of the following study (Abdul Latif,2007).The study explains in detail about economic statistics (MOA, 2009) of production since from the incorporation of spend hen meat and other ingredients required for the production of Spent hen meat puffed product to its final use (Shaaban Abdel,2004). The present study was aimed at economic study of value added Hot Extruded puffed product by incorporation of spent hen meat emulsion in the flour in various proportions. Spent hen meat emulsion and two flour mixtures (Corn flour and Rice flour) Were admixed in 15:85 (Ti), 20:80 (T:) and 25:75 (12) proportions to obtained emulsion based dough to produce hot extruded puffed product. Hot extruded puffed products thus obtained by twin screw hot extruder were rich in protein because of incorporation of spent hen meat which possessed almost 10-15% protein. Puffed product from flour mixture admixed with spent hen meat emulsion in different proportion can be effectively manufactured by using twin screw hot extruder. Puffed products produced were studied for the economic survey comparing other meat products in the meat industry and also tried to adopt the best possible methodology of production of cheapest form of highly Value added puffed products in meat industry (Mustafa Ibrahim,2003) Key words: Extrusion,Cooking,Puffed, Swollen aie 14012Indian Journal of Natural Sciences oe www tnsroindia.org.in CLHIONS Vol8 / Issue 48 / June /2018 International Bimonthly ISSN: 0976 - 0997 Sarvadnya et al. INTRODUCTION ‘The Meat and Poultry Industry Economic Impact study measures the combined impact of the meat processing, poultry processing, hide and skin production and offal production industries (hereafter meat and poultry products) ‘The industry Is defined to Include not only the production of meat and poultry based products, but meat distribution and retailing. The protein products of animal food contain different amino acids and fals, which are necessary for normal growth of human body, As a result of constant increase In population, the demand (Dhehibi, 2002) Increased for animal protein praducts of various types such as red meat, fish or poultry due to awareness for health and nutrition (Elhawary, 1992). Also, the average per capita Income Is one of the most Important Indicators of the progress or fallure of States. A study of the demand (Deaton, A 1980) of necessities of life requires high degree of importance. It is an admitted fact that the living standards of members of the community and the spending on 2 particular commodity or a certaln group of food items are heavily Influenced by the level of overall spending on the sels of goods and services, Extrusion is a process in which material is pushed through an orifice or a die of given shape. The pushing force is applied using twin-screw extruder. Extrusion pracessing af food materials has became an increasingly important manufacturing methad, and its application has broadened substantlally In the last two decades (Karwe MV., Food extrusion vol. II), The principle of operation is: rawy materials are fed into the extruder barrel and screw(s) pushed toward die and cutter. From transport phenomenon, extrusion pracess can be a combination of several processes such fluid flow, heat and mass transfer, mixing, shearing, particule size reduction, melting, texturizing, caramelizing, shaping and forming of different types of product (Karwe M.V., Food Process Engineering). Depending on the product, one or many of these processes will take place in an extruder Economic development is normally accompanied by improvement in country food supply and gradually eliminates the problem of nutrient deticiency. India is number one in livestock population with poultry population of 613 million, Livestock sector contributes approximately 4% to GDP and 27% to agricultural GDP (Kumar, 2008). In addition to providing nutritional security to the poor, it offers employment to millions of people in rural areas. The world production of various kinds of meat Is 281.6 MT out of which India’s share is 4.19 MT (FAO, 2009). In comparison with other livestock sectors, the poultry industry in India is well organized and progressing towards modernization. The rapid growth of poultry industry during the last four decades has made our country one of the largest producers of broiler. Today poultry is one of the fastest growing segments of the agricultural sector in India and now the world's third largest egg producer and the Titth largest producer of broilers. ‘Among the various classes of poultry birds, broilers are heavier in body weight and contain high fat (Kondalah et al. 1993). The availability of culled and spent hens has also increased many folds with rapid development of poultry layer industry. Spent hens are those birds of poultry industry whose egg laying capacity is over. The meat from spent hen Is generally tough, less tender and poor in functional properties, because of Its Increased collagen content and cross linkages (Balley, 1984) Unfortunately, the toughness prevents spent hens use In whole meat food and reduces the market value in many countries such as Korea, Taiwan, Japan and United state (Sams, 1990,, Nowsad et al, 2000 2 and b., and Lee et al, 2003).As the egg laying capacity of layer bird is absolute, the farmers have to face a problem discarding spent hen. The disposal of layer hens is one of the rain economical and environmental problems of the poultry industry. Egg producer worldwide disposes off 26 billion spent hens usually after they have finished their laying cycle (Singh etal, 2001) Hence, attempt should be made for obtaining better returns by the way of adopting suitable methods for economic Utilization of spent hens. Spent hens are usually slaughtered and used in feed production and concentrated stock preparations, or sold for domestic consumption in soups and stews (Ajayah et al,1992., and Voller- Reasonover et al, 1997). However, a better use of hens at the end of laying cycle, for example in the manufacturing of food products with higher added value, could provide economic profits. Fast food is one of the world's largest growing sector India’s fast food industry grew by 40% and generated a billion dollars in sales by 2005 (MFPI, 2005). In last six years, mE 14013 avalIndian Journal of Natural Sciences oe www. tnsroindia.org.in CONS Vol8 / Issue 48 / June /2018 International Bimonthly ISSN: 0976 - 0997 Sarvadnya et al. ‘foreign invesiment in this sector stood at Rs. 3600 million, which Is about one-fourth of total investment made in this, sector. The snack products, which are mostly available in large amounts in the market (Hamid Mohammed, 1996) are ‘made of cereals, which are high in carbohydrates and fat but low in protein, The snack foods cover a wide range of food products. They are consumed as a light meals or a partial replacement for a regular meal. Snack foods could be redesigned to be nutritious, contain ingredients which are attractive to consumers, and meet regulatory requirements (Shukla, 1994). When meat is used in a snack based products it provides some nutritional diet through the products to the consumer. They are many ingenious varlations in the processes used by the Industry, which serve to increase the range of products manufactured. Utllization of spent hen meat In the snack products will increase the palatability and nutritional value of such foods. Extruded putfed snacks are usually made from degermed corn or corn grits, wheat, rice or other cereals. There has been a remarkable growth In the varieties and popularity of such products because they are easily affordable, tasty, easy to make and nutritive, These products are flavoured with cheose, spices, onion, garlic or chilly and broadly fall In the fast food category. The popularity of extrusion technologies has increase in last two decades because of the following reasons: > Extrusion cost operation has lower and higher productivity than other heating and forming processes; > Costs of extrusion operation are lower than other operations like heating and forming processes in food industry; > Faster time processing reduces energy consumption, Blending of flours with meat in place of ather vegetable products have not been tried yet in extrusion process. The present study was thus planned to study the economics of puffed produets from spent hen meat. MATERIALS AND METHODS “The present study on economics of hot extruded puffed product from spent hen meat was done in various phases, The materials used and methadology employed during the study are discussed here under Source of raw materials for the production of spent hen meat puffed product Spent hen meat Approximately 72 weeks old spent hens reared at the Poultry Science Department of Bombay Veterinary College, Parel were procured, slaughtered and dressed according to traditional halal method (Shaaban Abdel,2002). The body {at was removed and deboning of dressed spent hen was done manually removing all tendons and separable ‘connective tissues. Fresh spent hen meat thus obtained was used for further processing immediately. Ingredients mixture The ingredients mixture formula for spent hen meat emulsion shown in Table 1 was formulated on the basis of preliminary trials conducted in the Department of Livestock Products Technology, Bombay Veterinary College Mumbai. Different proportions of ingredients were tried for one kg lat of spent hen meat emulsion in the preliminary trials, Experimental details To standardize spent hen meat emulsion based dough suitable for puffed product preparation “The procedure far emulsion based dough from spent hen meat was standardized after several preliminary trials for ‘one kg lot of spent hen meat emulsion based dough aie 14014 avalIndian Journal of Natural Sciences oe www tnsroindia.org.in CLIONS Vol.8 / Issue 48 / June (2018 International Bimonthly ISSN: 0976-0997 Sarvadnya et al. of spent hen puffed product at (41°C for 12 hrs) wfion Addition of different levels of flours in emulsion th tT Ts (Flour mixture was comprised of 60% Corn flour + 40% Rice flour) Emulsion biked dough Hot extrusion (104°C) muted etc Where: = ‘Ti (15%emulsion 85% flour mixture) ‘Ts (20%emulsion 80% flour mixture) ‘Ts (25%emulsion 7524flour mixture) Extrusion of Puffed product ABTPL laboratory scale twin screw extruder was used in Department of fish processing, Central Institute of Fisheries Education, Mumbai (Fig.1) in the present study. The exirusion cooking was done on a twin screw extruder (BTPL LST EB10), The power of the motor kept ata speed (350 rpm) is 7.6 KW. A full-actorial design (two factors each at three levels and three replicates) was employed. Screw speed was kept constant (350 rpm) during the experiment. Moisture contents of the extrusion feeds were 143, 175, and 21.0%, respectively. The extruder ternperature was set at 104°C where as barrel temperature was maintained 140%. Feed rate of volumetric feeder equipped with twin scrow was set ldgm/min. A 2 mm circular die was used for extrusion. Materials to be extruded (emulsion and flour mixture) were mixed and formed dough and put into feeder hoop to reach the feed for extrusion. The moisture content of the feed analysed for which sampling done before putting to feeder hoop and kept the sample into hot air over for moisture analysis. Extruded product coming out the sieve (die) was collected in clean tray and sampling is done in twa lots and packed in polythene bags among which one for sensory evaluation and another for chemical and microbial analysis. mE 14015 avalIndian Journal of Natural Sciences oe www. tnsroindia.org.in CIJONS Vol.8 / Issue 48 / June /2018 International Bimonthly ISSN: 0976 - 0997 Sarvadnya et al. Economics of the puffed product ‘The economics of the puffed product prepared from spent hen meat was also worked out on the basis of present cost of various ingredients and cost of other processing parameters. Stat ical analysis ‘The data obtained during the experiment were analyzed by Analysis of Variance following standard procedure (Snedecor and Cochran, 1989). RESULTS AND DISCUSSION ‘The present study on Economics of hat extruded puffed product from spent hen meat was performed in varlous phases al the departments of Livestock Products Technology of Bombay Veterinary College and Fish Processing Department, Central Institute Fisheries Education, Varsova, Mumbai. In the initial stages of the experiment stable emulsion from spent he was obtained after altering the process used for emulsion from broiler meat (Omar Ahmed, 2002). The proper dough consistency was determined after several trials on varlous combinations of different types and levels of flours and spent hen meat emulsion to obtain a proper hot extruded puffed product. Various sieve sizes _were also tried in the preliminary stucly and finally 2 mm diameter sleve size was used for extrusion ‘The moisture content of the feed, extrusion temperature and barrel temperature are very Important for the manufacture of puffed products. Accordingly on the basis of preliminary trials the moisture content of the feed was maintained in the range of 14 to 22 percent for different treatments under study.The barrel temperature was maintained at 140°C to obtain the extrusion temperature 104°C. The steps / processes used in the preliminary trials ‘were selected on the basis of suitable dough quality which was giving proper hot extruded puffed product. Thus the three treatments (Ts - 15% emulsion + 85% flour mixture, Tz - 20% emulsion + 80% flour mixture and Ts - 25% emulsion + 75% flour mixture)(Fig 2,34) as discussed above were finalized and were replicated four times. The results obtained are discussed In the present paper. ‘The dough obtained for three different treatments wore extruded through laboratory scale twin screw extruder at extruder temperature 104°C in 350 rpm speed and 2 mm diameter sieve size separately. Spent hen puffed product (SHPP) thus obtained from each treatments were divided into {wo lots, The first lot was used for sensory evaluation and zero day analysis. Second lot was aseptically packaged in polyethylene bags and kept in airtight container to ‘monitor the shelf life at regular interval Economics of SHPP ‘There are varieties of puffed products throughout the world which are famous with their typical manufacturing processes. The puffed products are very famous at the urban level in Indian continents which are manufactured by Using different flours. Incorporation of spent hen meat in different flours used for puffed product making Is one of the thoughts of value addition of spent hen meat. Puffed products are now very famous in a generation of all ages Looking at the popularity ofthis food, it was also decided to work out the economics of the spent hen meat puted product (SHPP) (Fig.8) in the present study. For this purpose cost of spent hen meat emulsion was worked out by considering the existing market prices (Mustafa Ibrahim Abu-Saad, 2003) of different ingredients and the proportion Used for the spent hen meat emulsion as depicted in Table 2 {As depicted in Table 3 a cost of one kg spent hen meat emulsion was estimated as Rs. 63.51 (Moschini, G., 1998) by considering the present cost of all the ingredients required for emulsion formulation. While calculating the cost of mE 14016 avalIndian Journal of Natural Sciences oe www tnsroindia.org.in CLIONS Vol.8 / Issue 48 / June (2018 International Bimonthly ISSN: 0976-0997 Sarvadnyar et al. puffed product (SHPP) apart from cost of emulsion, cost of various processing parameters as depicted in Table were ‘considered. From the Table 4 itis clear that the cost of spent hen puffed praduct (SHPP) after considering all the parameters and after extruding was Rs, 45.65, 48.37 and 51.08 respectively for Ts, Te and Ts The average yield ‘observed in the present study for hot extruded puffed product was 80 percent for all the treatments. The higher cost of Ts followed by Te and T; was because of higher proportion of spent hen meat in the formulations. REFERENCES 1. AOAC. (1995) Official method of analysis. 15% Edition, Association of Analytical Chemists, Washington D. C: USA. 2. Anisworth, P. lbanoglu, $.: Hayes, 6.0.(1997) Influence of process variables on residence time distribution and flow patterns of tarhana in twin-screw extruder. Journal of Food Engineering 1997, 37, 101-108. 3. Anjaneyulu, A. S. RN. Sharma and N. Kondaiah (1988) Effect of salt and phosphate preblending on quality of buffalo meat during frozen storage acceptability of patles. Indian J. 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SAS, Institute Inc, Cary, NC, USA. 34, Mahmoud Ezzat Abdul Latif(2007) an economic study for the production and marketing of red meat in Beni Suef, Arab Republic of Egypt, Department of Agricultural Economics, Faculty of Agriculture, Ain Shams University, 2007 35, Mustafa Ibrahim Abu-Saad: Hassan AbdolMeguid Abdel-Maksoud and Hassan Nabi Iorahim,(2003) “an economic study of the efficiency of the marketing of red meat 2 case study in Menoufiya governo’ Menoufiya for Agricultural Research, Volume XXVIII Issue VI, December, 2008, 36, Qin, J. and J Lawless, 1994. Empirical likelihood and general estimating equations, Ann, Statist, 22: 300-325, te" Allournal Table 1. Ingredients used in formulation for spent hen meat emulsion Ingredients ‘Quantity in ©) ‘Spent hen deboned meat 90.59 ‘Common salt 3 Vegetable ott 6 Sodium nitrite or Sodium polyphosphate o4 ‘Table 2. Composition of dough for hot extruded spent hen puffed product Treatments | oportion ofemulsion | Proportion of our | yy5.4 ot gue : 5 sae n 0 ® ‘aor rou By % i ‘as Tour NOTE: T: (Dough with 15% emulsion), T(Dough with 20%emulsion),T3 (Dough with 25% emulsion) mE 14018 avalIndian Journal of Natural Sciences ed www tnsroindia.org.in CLIONS Vol8 / Issue 48 / June /2018 International Bimonthly ISSN: 0976 - 0997 Sarvadnyar et al. Table 3. Cost of one kg spent hen meat emulsion Sr.No. _| Ingredients ‘Oty (gms) Rate(Rs/kg) | Emulsion cost in Rs/kg 1 Meat 915.9 60 54.95 2 Salt 20 18 (00.36 3 Oil 60 90 05.40 4 Sodium nitrite [0.7 42 00.64 5 STPP 4 540 02.16 ‘Cost of one kg emulsion 651 ‘Tabled. Cost of one kg spent hen meat puffed product (SHPP) Ti tr tr StNo. | Ingredients Gly | Cost | Oly] Cost | Oly] Cost @ | es) | @ | @) | @ | es) Emulsion (Rs./kg)_| 6351 150 | 952 | 200 | 1270 | 260 | 15.87 2__[ Corn flour (Rs/kg) | 20.00 | 810 | 10.20 | 480 | 09.60 | 460 | 09.00 3 Rice flour (Rs/kg) | 20.00 | 340 | 0680 | 320 | 06.40 | 300 | 06.00 Hot extrusion cost 4 (avg. 10 mins. / | Rs.60/hr 10 10 10 batch of one_kg) 5 Yield (%) 30 800 800 800 ‘Actual cost of SHPP_ 6 (Reg) 45.65 48.37 51.08 NOTE: T:- Dough with 15% emulsion, T:-Dough with 20%emulsion, T3- Dough with 25% emulsion Fig 1. Twin screw extruder (Department of Fig.2: Hot extruded puffed product prepared fish processing, Central Institute of Fisheries with 15 % emulsion and 85% flour mixture (T1) Education, Mumbai) - 14019 BEIndian Journal of Natural Sciences ed swww.tnsroindia.org.in ©LJONS VoL8 /Issue 48 / June /2018 International Bimonthly ISSN: 0976-0997 Sarvadnyar et al. Fig.3: Hot extruded puffed product Fig.4: Hot extruded puffed product prepared with 20 % emulsion and 80% flour prepared with 25 % emulsion and 75% mixture (12) flour mixture (T3) Fig.5: A sample of dough prepared for the preparation of hot extruded puffed product (SHPP) aie 14020