Millet Based Wafer Sandwich

Development of Avocado Honey Flavoured

Foxtail-Finger Millet Creamy Wafers Sandwich

ABSTRACT

The main purpose of this study is to develop gluten free and sucrose free wafers sandwich having high nutritional value of essential amino acids and unsaturated fatty acids. Anotherobjective is to introduce an appealing taste of avocado with sweetness of honey in this confectionary snack product. Wafer

Sheet Batter Formulation is done by Foxtail and Finger millet Flour in standardized ratio with small proportion of Dried Avocado powder, Honey and other essential ingredients incorporated within it. As millets contain no gluten, hence they do not provide a stable structure to the product, so this problem

can be solved by using Xanthan Gums. Avocado - Honey flavored cream filling is prepared by blending of Avocado puree and Honey with readymade cream of High Fat content along with small amount of Gelatin as thickening agent. This prepared cream is sandwiched between the two baked and cooled wafer sheets which must be stored in refrigerated conditions for better rheological properties and better shelf life. The developed product will be subjected for nutritional, textural, rheological, microbial and sensory analysis taking wafer of simple refinedwheat flour as a control.

Keywords: Foxtail millet, Finger millet Flour, Xanthan gum, Dried Avocado Powder, Honey, Heavy Cream, Gelatin etc.

INTRODUCTION

Wafers are thin, crisp and crunchy type porous sheets with thickness 1 to 5.2 mm having light and delicate texture with highly aerated matrix. Primarily, they are prepared from refined wheat flour having high gluten content. These are cereal based low moisture baked special snack product in range 1 to 2 % enjoyed by a consumer due to their unique sensorial properties. Many consume them to relieve their boredom or for an acceptable treat during stressful times. These are liked and appealing by people for their level of crispiness and its retention over shelf life. The top selling confectionary products are made up of wafers due to their ability to perfectly combine with cream fillings and coatings consumed as

ice cream cones, sandwiches etc.

Global Market Outlook of Wafer:

The global wafer market is set for a valuation of US$ 107 billion in 2023. Worldwide sales of wafer cream products are estimated to increase to a market value of US$ 160 billion by 2033-end, increasing at a CAGR of 4.1% through 2033. Demand for wafer is increasing due to the rise in craving for convenient foods as well as snacks that can be carried easily, this robust the growth opportunities in the market. In addition, the long shelf life of these products is also estimated to contribute to their sales. Increasing popularity of wafer is also attributed to their diversified flavour chains along with rising preferences among adults and kids. Cream-filled wafers are the most popular type. The growing population of gluten-intolerant people is also resulting in a rising demand for gluten-free snacking options.

Introduction to Raw materials:

Millets have No Gluten, rich source of phytochemicals, dietary fiber and also provide a good nutritional health benefits. Millets provide nutritional well being in daily diet and also helps in control of disorders like diabetesmellitus, hyperlipidemia and obesity (Veena, 2003). Different studiesrevealed that daily intake of millets into diet can increase the immunity against several diseases. (Mckeown. 2002). The 2 to 7% dietary fiber in millets can help to prevent various gastrointestinal problems. Millets also provide prebiotics to gut microflora. The low Glycemic Index of millet makes them to digest and absorb slowly, hence there is slow release of glucose in blood stream cause longer satiety and prevent diabetes. 

The grain of foxtail millet is small, ovoid around 2mm long, pale yellow to orange red in colour. The protein content is higher among all millets upto 12.3 % (Icar, Hyderabad). Fiber (as glucan 42.6%) provide low GI is beneficial for prevention of diabetes and other cardiovascular diseases. (K Hariprasanna, 2016).

Finger millet, also known as ragi, is a good source of nutrient especially Calcium and other minerals and fiber. The protein is nearly 7 to 8 % in which 44.7 % is essential amino acids (Mbithi, 2002). The crude fat

content is 1.3 to 1.8 % with high PUFAs (Antony. 1996). The major fatty acids in finger millet are : Oleic followed by palmitic and lonoleic acid. The fatty acid profile shows that saturated fatty acid account for 25.6 % while unsaturated fatty acid account for 74.4 % of total fatty acid (Sridharand Lakshminarayana, 1994). These millets also have high amount of nutrition inhibitors and toxic factors such as tannins and phytic acid which bind minerals like iron and phosphorus respectively to them. Their content can be reduced by soaking, roasting, boiling, malting and by using different combinations of these methods. (Rao, 1994)

Avocado is primarily used in ripe form rich in monounsaturated fatty acid, health promoting phytosterols and phenolic antioxidants. Avocado can be dried or freeze dried to covert it in powder form contain high fat content make it an excellent energy source. It contains Vitamin C and E and persist Antioxidant properties if freeze dried. Rich in Omega Fatty Acids hence, protects our Heart.

Honey has Low GI than sugar due to presence of high amount of Fructose and less amount of glucose making it more sweeter in small quantity. It can also provide instant energy with Anti Bacterial and Anti

Fungal Properties.

Objective of this innovation:

Normally, Wafers of refined flour are not so nutritious for a consumer as it contain no protein, no essential amino and fatty acids and no micronutrients. They have high gluten content which can cause

indigestion and other gastrointestinal problems. They also do not provide a longer feeling of satiety to an individual. Hence there is an attempt to accomplish the above mentioned limitations of wafers and to practice a development of product Wafer Sandwich with value addition using Millets, dried Avocado Powder and Honey.

The main objective to develop this product is to increase the fat and protein content of wafers along with high nutritional filling cream. This is a sweet confectionary snack product have no gluten and no sucrose with sufficient amount of Unsaturated Fatty acid, Essential Amino acids and other micronutrients. This product has many health benefits for both teens and adults such as it prevent Bad cholesterol, Indigestion, Diabetes etc can also be consumed by people having celiac disease. It can also suppress hunger by providing longer satiety to an individualbecause of low GI and high dietary fiber containing millets. Not only has this, but the presence of honey and avocado provided a sufficient amount of energy to the consumer. Along with nutritional qualities, this Sandwich product has Crispy, Crunchy Texture of Wafer sheet and Smooth texture of Cream filling providing a proper balance of sweet creamy, nutty and earthy flavor of millet, avocado and honey to the product. Hence, this will be a delightful product with many nutritional benefits appealing to all age groups.

Methodology

Materials Required For Batter Preparation

The wafer sheet batter is prepared by using Foxtail and Finger millet grains. Other essential ingredients are Dried Avocado Powder, Xanthan Gums to stabilize the structure of wafer sheets, Soya Lecithin used as emulsifying agent, Sodium Bicarbonate as leavening agent, Coconut Oil, Honey for Sweetness, a pinch of Salt and other additives.

Materials Required For Cream Preparation

The cream filling of wafers sandwich is prepared by using a main ingredient Dried avocado powder to make an avocado puree. Other ingredients required are honey, heavy cream with high fat content, gelatin as thickening agent, lime juice and salt.

Procurement of Material

The procurement of materials can be done by online marketing platform IndiaMART which provide the necessities in reasonable amount. Mithran export provides a deal of Foxtail and Finger millet grains in Jhansi -

● Foxtail millet: Rs 68/Kg

● Finger millet (Ragi): Rs 40/Kg

Baghban Foods provide spray dried Avocado powder at Rs 214.5 / 250g

Dabur Honey can be used in product of Rs 111.60 / 250g

Other essential ingredients like readymade cream, xanthan gum, gelatin,

lime, salt etc are also available on IndiaMART.

Pre Processing Steps

The grains are firstly must be thoroughly cleaned, free of stones and other foreign material. These will soak overnight to reduce phytic acid content and then grind to get Foxtail and Finger Millet Flour. The flour can also be roast for some time for further decreasment of antinutritional factors and to achieve better flavor.

Processing

Batter Preparation

The preparation of wafer sheet batter is started by collecting and pre preparing all the ingredients. The batter preparation should be done by planatery Mixer. First of all, mix a small amount of salt and sodium bicarbonate in water so they mix and dissolve uniformly. Now add foxtail and finger millet flour mixture along with dried avocado powder and other ingredients that are honey, coconut oil, xanthan gum and soya lecithin. Add more water simultaneously according to desired consistency of batter. All the raw materials were mixed for 3 to 6 minutes using a planetary mixer at 100 rpm, in order to blend the batter properly and to avoid the formation of lumps. After the addition of all ingredients, mixing is continued which helps in the prevention of dough formation between flour and water (Mert, 2015). Now, the batter is left undisturbed for 10 minutes for proper leavening and aeration.

Wafer Sheet Preparation

The wafer sheets are prepared using a Baking process in oven. According to the study of Dogan (2006), temp above 170 degree C can make product fragile and dark in color hence it must be of approx 165 degree C. The batter is spread as thin sheets on plates after applying any releasing agent. The thickness of wafer is depending upon the amount of batter depositing on the plates. Baking till the moisture left 1 to 2 % ( approx 1.5 to 3 minutes). After processing wafers were cooled to room temperature. The wafer should not have cooled below the dew point because they will gain moisture from the atmosphere. (Sheeba, 2021). After cooling wafers, condition them to stabilize the texture and then cut them in to equal sizes and shapes.

Avocado Honey Cream Preparation

The Avocado Honey Cream Filling is prepared by rehydrating dried avocado powder to form avocado puree using water or milk. Now mix some honey and readymade heavy cream along with small amount of lime juice and gelatine. Blend all the components in a blender. According to Studies of Massy University, Avocado puree in cream cheese with Ascorbic Acid treated with HIGH PRESSURE PROCESSING show Stable Textural and Rheological properties during storage of 4 weeks at 4 C, increasing its shelf Life. Hence, HPP technique can be used, otherwise directly chilled this cream filling in refrigerator.

Preparation of Wafers Sandwich

The wafer sheets are now entering into the Creaming Machine to form sandwich. The cream filling is spread over the baked wafer sheet and then placing another wafer sheet above. The previous step will be repeated to make sandwich of 2 layers of cream filling and 3 layers of wafer sheets. The sandwich is then stacked gently with Light weight, with sufficient gap Roller. Cut it into desired shape.

Packaging of the Product

The product is packed and stored in refrigerated temperature. The packaging of these products is done with multiple packets while makingtheir consumption easier for individuals at any point. Due to theirhygroscopic nature, they require high moisture barrier packaging otherwise loss their crispiness when moisture content increase to 6 to 7 % (Dogan, Kokein, 2007). Storage must be done in refrigerated condition.

Summarized Flow Sheet of Processing

Limitations

People having Thyroid Problem do not consume Finger Millet. 

Ragi can also cause Kidney Stone due to presence of Oxalic acid. 

Production Cost is high in comparison to other normal Wafers. 

Excessive Consumption can cause Indigestion.

Conclusion

This is the world of demand of snacks, desserts, confectionaries, baked products etc. And wafers play an important role in all these delightful products. These thin porous sheets are used to make cones, cookies, sandwiches etc. But increased lifestyle diseases in an individual prohibit their consumption due to less nutritional qualities, high gluten content, use of refined wheat flour, sugar and hydrogenated fat or butter. Millets are the best solution of these problems related to gluten, indigestion and other lifestyle diseases. Thus, this innovative millet based product containing dried Avocado and Honey, is an attempt to accomplish the various limitations of wafer products and to practice the Value Addition of the product. 

This wafer sandwich is a very nutritious confectionary Snack product, having no gluten and no sucrose with sufficient amount of Unsaturated Fatty acids, Essential Amino acids and other micronutrients, beneficial for both Teens and Adults. It can also be consumed by people having Celiac Disease and does not Increase the chance of Diabetes, Bad Cholesterol, or other cardiovascular diseases. The Low GI and High Fiber content of millet can provide Longer Satiety to an individual with prevention of gastrointestinal related problems. The Crispy, Crunchy Texture of Wafer sheet along with smooth texture of cream filling makes it a more delightful and pleasing wafer sandwich. The product has acombination of Sweet, Nutty and Creamy Flavor. Sweetness of Honey provides a Proper balance to Earthy and Nutty Flavor of Avocado and millet respectively, makes it more Tastier and Appealing. It can be Prepared, Available and Consumed over the seasons due to availability of all raw materials throughout the year. Assuming, the product may store in Refrigerated Condition for up to 2 weeks.

Reference

1. A. Sheeba Rani, C. Divya, V. Hema and R. Vidyalakshmi* Study on Development and Quality Evaluation of Chocolate Coated Millet Wafers, International Journal of Current Microbiology and Applied Sciences, 2319-7706 Volume 10 Number 01 (2021)

2. V. Sruthi1, Prof. Dr. Kavita Waghray2, Ankush Narayan Rathod3 Development of Wafers Incorporated with Pearl Millet Flour & Barnyard Millet Flour, University College of Technology (A) Osmania University, Hyderabad, Telangana, India

3. Selen Mert, Serpil Sahin*, Gulum Sumnu, Development of gluten-free wafer sheet formulations, Department of Food Engineering, Middle East Technical University, 06800, Ankara, Turkey

4. Satpute DB, Londhe GK, More RV and Chadar UA Development and analysis of nutritional rich traditional snack product from foxtail and finger by using whey protein concentrates (WPC), Journal of Pharmcognosy and Phytochemistry, 2022

5. Dogan, H., & Kokini, J. L. (2007). Psychophysical markers for crispness and influence of phase behavior and structure, Journal of Texture Studies.

6. K Haripasanna, Foxtail millet nutritional importance and cultivation aspect, ICAR, Rajendranagar, Hyderabad, Telangana, India, March 2016

7. Pragya Singh1* and Rita Singh Raghuvanshi2, Finger millet for food and nutritional security, Department of Foods and Nutrition,College of Home Science, GBPUAT, Pantnagar, Uttaranchal, India.31 December, 2011

8. Saheeda Mujaffar1*and Tsai-Ann Dipnarine, THE PRODUCTIONOF A DRIED AVOCADO (Persea americana) POWDER,1,2Faculty of Engineering, The University of the West Indies, Trinidad.

9. Yinxuan Hu, Preparation and Characterisation of Avocado Cream Cheeses: Effects of Different Treatments and Ratios of Avocado Puree, Massey University, Auckland, New Zealand.

10. Olga Escuredo a, Montserrat Míguez b, Maria Fernández-González a, M. Carmen Seijo a Nutritional value and antioxidant activity ofhoney, Department Analytical and Food Chemistry, Faculty of Sciences, University of Vigo, As Lagoas, 32004 Ourense, Spain, 2012

11. www.maximizemarketresearch.com

12. www.factmr.com

13. www.indiaMART.com