Q.1 How would you describe the market potential for the processing of Chilli-based products and the opportunities for Chilli processing at a micro food processing level?

India is the largest producer, consumer and exporter of chilli in the world. Chilli contributes 31% of the total spice export from India with an economic share of Rs. 8429.92 Crore (Spice Board, 2021).

Asia Pacific is expected to witness significant growth in the market due to the geographical concentration of chilli-producing countries. India followed by China, Pakistan and Bangladesh nearly contributes 55% of the total world chilli production. Further, the raw material abundance and ease of labor availability are some of the factors driving regional growth. North America is anticipated to witness substantial growth in the market owing to the rise in cross-culture food trends. Moreover, the increase in consumer preference towards spicy and Asian cuisines coupled with their growing experimentation with various spices and flavors in food is expected to drive market growth in the region. Europe is projected to exhibit considerable growth in the upcoming years due to the changing taste preference of consumers. The growing consumer interest in authentic and new chilli flavors has driven its market. Further, Germany, Spain and UK are the largest chilli powder-consuming countries, which have supported their regional market growth.

Opportunities/Scope for Chilli processing:

Chilli with stem, chilli without stem, crushed dried red chilli flakes, dried red chilli powder, chilli paste, chilli chutney, chilli seeds and chilli oil (oleoresin) are the various processed products of chillies. The clean and dried chillies with stem obtained after primary processing is used as the raw material for the production of all the products.

1. Chilli without stem:

Stems of the clean dry chillies are cut either manually using a knife or mechanically in a chilli stem cutting machine (Fig. 2.1). The chilli stems cutting machine consists of a rotary hollow cylindrical drum with holes on the outer surface. The dry chillies when fed through the hopper, flow into the drum. As the chillies flow inside the drum, the rotation of the drum makes the stem enter into the holes. The stems projecting through the holes are cut using a blade. The dried chillies without stem flow out through the other end of the drum. The output capacity of the machine depends on the retention time of chillies in the drum and the rotary speed of the drum. The stem-cutting efficiency varies in the range of 90-95% at the optimum operating conditions. Chillies without stems are used for making chilli powder, paste, chutney and flakes.

2. Crushed dried red chilli flakes:

The clean dry chillies are first roasted for 1-2 minutes till they turn into slightly brown colour and give off an aroma. Usually roasting is done in a thick-bottomed pan on low flame or in various types of ovens. The roasted chillies are cooled to room temperature. The chillies are then ground in spice grinder or a small hammer mill to get coarse flakes (Fig. 2.2). The size of flakes obtained depends on the duration of grinding. The flakes are blown into the cyclone separator and collected. The chilli flakes are packed in printed flexible pouches, pouch in mono-carton boxes, high density polyethylene and Saran/Cello/Saran poly laminate pouches, and composite, plastic and glass jars. The chilli flakes are widely used in the preparation of snacks, seasoning of pizzas and casseroles, and sometimes used for garnishing of 10-30 mesh size.

3. Dried red chilli powder:

The stems of the clean dry chillies are cut using the chilli stem cutting machine or using a knife. The use of stem-cutting machines generally reduces time and labour costs. The process of milling is commonly also known as the grinding process. A hammer mill is commonly used for grinding. Either the crushed material is passed 2-3 times through the small hammer mills with centrifugal blowers, cyclone separator and sifting machine along with lump breaker between the hammer mills (Fig. 2.2), or a large hammer mill is used to obtain the fine chilli powder (Fig. 2.3). Electric motor operated kandap machine which works on the principle of the traditional pounding of chillies is used obtain the chilli powder with traditional aroma and quality

4. Byadgi chilli paste:

The clean dry chillies without stems are soaked in hot water for about 30-45 minutes. The softened chillies are blended with vinegar and water to prepare the paste. Hot oil is poured and mixed with the paste. The paste is packed in glass jars or printed flexible pouches (Fig. 2.5). The paste is suitable for consumption within one month if preserved under refrigerated conditions. Chilli paste is used in soups and sandwiches to add extra heat and flavour.

5. Chilli chutney (Ranjka):

The clean dry chillies without stems are soaked in hot water for about 30-45 minutes. The softened chillies are blended with jeera seeds, tamarind, jaggery, salt and crushed garlic to prepare the chutney (Fig. 2.6). Hot oil along with spluttered mustard seeds and asafoetida is poured and mixed with the chutney (Fig. 2.6). The chutney is packed in glass jars. The chutney is suitable for consumption within one month if preserved under refrigerated conditions. Chilli chutney is used in regular breakfast and meals.

6. Chilli seeds:

The chilli seeds (Fig. 2.7) can be obtained from the clean dry chillies without stem using chilli de-seeding machine. The machine has the blades and sieves. The blades cut the chilli into pieces and pass them to the vibrating sieves. The chilli seeds pass through the sieves and fall to the bottom. The chilli pulp is sent to the next processing (oleoresin extraction) plant using belt conveyor. The chilli seeds can be directly packed. The chilli seeds are the best source of antioxidants. The consumption of chilli seeds stimulates digestion, lowers cholesterol level and helps in losing weight.

7. Chilli oil (oleoresin):

Oleoresin is obtained by solvent extraction of the pericarp (skin of chilli) or pulp. The oleoresin contains a major pungency principle, capsaicin and colouring principles of capsanthin and capsorubin.

Q.2 Could you please tell us about the support and facilities provided by the Indian Institute of Horticultural Research to micro food processing enterprises?

At ICAR-IIHR, 10 high-yielding varieties/ F1 hybrids suitable for varied processing products are released and IIHR in collaboration with KAPPEC provided the following technologies to micro-enterprises under the PMFME Scheme.

• Arka Jackies (Jack Fruit Cookies)
• Jackfruit Seed and Fruit Powder
• Arka Jackolate
• Arka Avacado Powder

Q.3 What are your thoughts on the scope of value addition in chilli processing?

There is enormous scope for chilli processing. Currently, about 30% of chilli exports are processed products and 70% are in the form of dry chillies. Among the processed products red chilli powder occupies the first position. Other products having huge commercial potential include green chilli powder, green chilli paste, red chilli paste, chilli sauce (red and green), chilli pickles (red and green, as well as small and big), crushed chilli flakes, chilli oleoresin (pungent principle-capsaicin and colour capsanthin and capsorubin), chilli seeds, etc. Almost, 50% of global chilli trade is catered by India. Value-addition for SME's provides an important entry point for development support and business development. Benefits include increased income, employment creation, improved food safety, food security, nutritional benefits and greater consumer confidence.

Q.4 With the immense experience that you have gathered over the period, how do you think the PMFME Scheme would be able to empower micro food processing enterprises?

PMFME Scheme offers an excellent opportunity for chilli processors. Except for oleoresin extraction and its application industries like pharma and cosmetic, most other processed or value-added products can be manufactured at micro and small-scale levels. An industry could be established with an investment of Rs.20 Lakhs and the scheme offers a 35% credit-linked subsidy.

Q.5 What is your advice to aspiring food processing entrepreneurs?

The Government of India has allocated Rs.4,600 crores till 2026 under PM Krishi SAMPADA Yojana for promoting the agro/food processing sector. Similarly, Rs.10,000 crores have been allocated under the PM Formalisation of Micro food processing Enterprises (PMFME) Scheme to support the establishment of new food processing units, upgrade the existing ones with modern machinery, etc. As the agro-food processing sector is showing a growth rate of 9.9% annually, for all aspiring entrepreneurs it is one of the excellent opportunities for generating income and providing livelihoods. While the technology for traditional foods is already available, innovative product/ process development and commercialization are supported through Technology Business Incubators across the sectors with seed funding to test, refine and scale up the innovations. The aspirants should take advantage of the emerging situation and employ them to contribute to employment generation and economic growth.

About the Guest:

Prof. Sanjay Kumar Singh is presently the Director, ICAR- Indian Institute of Horticultural Research, Bengaluru. He was earlier, Prof & Head, Division of Fruits and Horticultural Technology, ICAR-IARI, New Delhi. His research contributions include the development of a commercial protocol for micropropagation and bio-hardening using arbuscular mycorrhizae in horticultural crops like grape, citrus and pomegranate and their rootstocks for growing in saline conditions; micropropagation protocols in mango, guava, papaya, apple, custard apple, rose, carnation, gladiolus, lilium, chrysanthemum, etc. He has developed the in vitro screening procedures for salinity (NaCI) tolerance in grape & citrus and Fusarium tolerance in gladiolus and protocol for in vitro breeding using in-ovulo embryo rescue in seedless grape and mango. He has identified and released four promising seedless grape hybrids (Pusa Aditi, Pusa Trishar, Pusa Swarnika and Pusa Purple Seedless) and two mango varieties (Pusa Deepshikha and Pusa Manohari). Currently, he is working on transcriptomics and functional genomics of mango.

He has published over 200 research papers in international and national journals of repute, 12 books, 4 practical manuals, 49 book chapters, 32 popular articles, 15 extension folders, and over 180 symposia/ seminar papers. He is a member of the International Society of Horticultural Science (Belgium) and life-member of over 30 national scientific societies and academies. He is presently the Vice President and earlier served as the Secretary of the Indian Academy of Horticultural Sciences and was Editor-In-Chief of the Indian Journal of Horticulture from 2014-2019.