FIELD OF THE INVENTION
The present invention relates to wafers (popularly known as papad) and, in
particular, to nutritious cereal/flour based vegetable papad/wafers having food
values of the nutritious contents involving selectively the cereal, flour and vegetables
and importantly having required high shelf life under all climatic conditions of varying
temperature and humidity. Importantly the papad/wafers of the invention would
provide for papad/wafers including vegetable contents having good taste and flavour
which would be simple and cost effective to manufacture in mass scale apart from
meeting the variety of taste and flavour desired by individuals and thereby making
available papad/wafers as a nutritious value added food product for wide scale
consumption as a food article.
BACKGROUND ART
Papad/wafers are well known to be a pre-cooked snacks item and is widely popular
amongst the masses in India and abroad. Usually, such papad/wafers is
manufactured based on powdered cereals such as variety of dais and the process of
manufacture of such dal papad/wafers basically involves subjecting the cereal (dal)
to powdered form and thereafter kneading the same with water and salt to assume
desired consistency and taste. Finally, the mix is obtained in the form of a dough.
The dough is next portioned into multiple ball shaped small forms of the dough which
are finally flat pressed of desired shape and dried to obtain the cereal (dal) based
papad/wafers.

While dal papad/wafers mostly obtained as above of varying taste and flavour has
been available for consumption over the years, variations of such cereal based
papad/wafers of better taste and flavour has been a continuing need in the art.
Importantly, it is found that the processing of such conventional cereal (dal) based
papad/wafers had been problematic in achieving desired consistency in flavour and
taste of the end product since simple mixing and dough forming of the ingredients
were not always sufficient to reach to the product of uniform quality and flavour.
Added to the above while there has been a continuing demand in the art to provide
papad/wafers of various ingredients in particular nutritious food value containing
vegetables and/or non-veg contents, it has been extremely difficult to process such
papad/wafers containing such nutritious contents such as the vegetables and like.
Thus, in spite of the consumer demand for variety of vegetable/non-veg
papad/wafers there has not been products of desired taste and flavour due to
processing problem and resultant costs of such productions. Moreover, in case of
vegetable/non-veg additives, there has been the problem of maintaining the
papad/wafers storage stable with good shelf life since papad/wafers and the like are
required to be stored and are not readily consumed immediately after production.
OBJECTS OF THE INVENTION
It is thus the basic object of the present invention to provide for cereal/flour based
papad/wafers which would enable achieving better and uniform taste and flavour
even while carrying out large scale production of such papad/wafers thereby making
papad/waferss of more consumer acceptable taste and flavour.

Another object of the present invention is directed to provide cereal/flour based
papad/wafers of better appearance and uniform taste and flavour involving nutritious
vegetable and/or non-vegetable contents which would also be storage stable and
have improved shelf life.
A further object of the present invention is directed to cereal/flour based
papad/wafers including vegetable/non-veg contents selected from wide variety of
available vegetable and non-vegetable ingredients which in one hand would favour
achieving desired taste and flavour and on the other hand would be simple and cost
effective to manufacture thereby favouring more wide scale use of papad/wafers as a
nutritious value added food product.
Yet another object of the present invention is directed to provide papad/wafers which
would be favoured to meet the growing and challenging variety of taste of
consumers of papad/wafers with desired food value as a ready and fast consumable
nutritious food product.
Another object of the present invention is directed to the production of nutritious
value added papad/wafers of varying taste and flavour involving cost effective and
readily available vegetable sources maintaining desired food value and shelf life of
such papad/wafers.
A further object of the present invention is directed to an economic and time saving
manner of manufacture of papad/wafers as a vegetarian food product with nutritious
value to add to the variety of available food options to vegetarians and the like.

A further object of the present invention is directed to add value to papad/wafers as
a food product to make it acceptable among varied consumers in the market desiring
to have nutritious and food value maintain papad/wafers which can be consumed by
consumers from all walks of life across all cultures.
SUMMARY OF THE INVENTION
Thus according to the basic aspect of the invention there is provided A process for
the manufacture of flour based vegetable papad/wafers comprising:
providing selectively anyone or more of cereals, flour,-/starch and food gum;
providing selectively vegetables in paste form;
mixing the said anyone or more of the cereals, flour, starch and food gum alongwith
the vegetables paste with selective desired spices in hot water to obtain a dough;

subjecting the dough thus obtained to steam treatment comprising providing the
dough in containers with perforated base which are covered on the top and stem
heating carried out from below such that the steam travels upwards to heat the
dough for achieving the desired consistency;
subjecting the thus steam treated dough to crushing involving a crushing extruder;
and
obtaining the flour based vegetable papad/wafers from portions of said thus crushed
and extruded dough.

Advantageously, in the above process for the manufacture of papad/wafers the said
steam treatment is carried out by providing the dough is containers with perforated
base which are covered on the top and steam heating carried out from below such
that the steam travels upwards to heat the dough for achieving the desired
consistency. Importantly, the said step of steam heating of the mix is carried out
such as to make the dough stretchable and favour obtaining thin light papad/waferss
therefrom.
In accordance with a preferred aspect the process for the manufacture of
papad/wafers comprises mixing using spices/additives selected from baking soda/
chemical salt (khar)/sodium bicarbonate, jeera (white/black),iodized salt, chanar jal
and asafoetide.
According to another aspect in the above process for the manufacture of
papad/wafers the said base ingredient comprise selectively flour and/or cereal (dal)
preferably selected from rice flour, wheat flour, corn flour, arraroots, sagoo,
soyabean powder and dal besan.
According to yet another aspect of the invention in the process for the manufacture
of papad/wafers the said vegetables is selected preferably from carrot, cabbage,
spinach, tomatoes, pudina, greenchillies, garlic, ginger, potato, red chillies preferably
dried ginger, and the like selective vegetables.

In accordance with yet further preferred aspect in the process for the manufacture
of papad/wafers the mixed dough is extruded through an extruder prior to forming
the papad/wafers therefrom.
In the above process for the manufacture of papad/wafers the crushed dough is
further obtained into small portions which are rolled flat to obtain the thin
papad/wafers of desired shape which are finally dried selectively preferably sun dried
or involving drier machine.
According to yet another aspect of the invention there is provided a cereal/flour
based vegetable papad/wafers comprising :
cereals/flour/starch/food gum in an amount of upto 70% by wt.; and
vegetables in an amount of upto 90 % by wt.
It would be thus apparent that the invention would favour converting effectively
nutritious vegetables to produce papad/waferss having very good shelf life under all
climatic variations of temperature and humidity. Advantageously, following the
method of the invention it would be possible to produce on mass scale such
nutritious value added papad/wafers involving cereal/flour as a base ingredients.
Importantly, in the above disclosed process of manufacture of cereal/flour based
vegetable papad/wafers, the step of steaming is selectively carried out which enables
for the first time to process vegetables alongwith the base ingredients of cereal/flour
and thereby add to the nutritious content of papad/wafers. In particular, it has
surprisingly been found by way of the present invention that the rolling out dough of
dal mix with vegetable paste is possible only if the step of steam heating of the

dough containing the vegetable paste is carried out in accordance with the invention.
Earlier attempts to manufacture vegetable papad/wafers by simply mixing to the
cereal (dal) the vegetable could not produce the vegetable papad/wafers maintaining
the taste and characteristics of papad/wafers as a food article. Advantageously, in
the process of the invention, steaming in the processing step allowed to produce
papad/wafers with vegetable mix in thin light form by making it stretchable upto the
desired extent for reaching to the end characteristics of a storage stable
papad/wafers.
Preferably, in accordance with another aspects of the invention, the grains are
shifted and cleared before processing as a commitment to maintain purity. This
imparted high level of nutritional value and purity to the product.
According to another aspect of the invention the same proposes the mixing of the
dough in hot water in stead of water at room temperature since such mixing in hot
water is found to advantageously save time and also helps in reducing the cost of
processing of the dough to reach to the papad/wafers of the invention.
It is thus possible by way of the present invention to produce papad/wafers of
variety of uniform taste and flavour for meeting variety of consumer demands
especially in producing non-veg papad/wafers like prawn and chicken/mutton
papad/wafers, variety of vegetable papad/wafers such as vegetable papad/waferss
including selectively carrot, cabbage, tomato, spinach, pudina, garlic, ginger, green
chilly, soyabean, alu(potato) papad/wafers and like.

The details of the invention its objects and advantages are explained hereunder in
greater details in relation to non-limiting exemplary illustration of a process for
manufacturing vegetable papad/wafers in accordance with the present invention:
Example:
Under this exemplary illustration vegetable papad/wafers in accordance with the
invention was obtained as detailed hereunder:-
For the purpose flour 10 kgs, soda 200 gm, iodized salt 300 gm and water 10 - 18
liters were used alongwith starch 500 gms, arraroot alongwith
Vegetable selected from cabbage, carrot, beans and spinach of 1200 gms were
washed, then boiled and pasted to desired consistency and mixed with said flour,
soda, salt and hot water to achieve dough of desired consistency.
Thereafter the dough was subjected to steam heating wherein the dough was kept
on a perforated container which was steam heated from below to subject the dough
to steam heating. In particular, for the purpose of steam heating the dough is
arranged in special container built for steaming purposes. Thereafter the container s
are covered and steam is provided from below such that it travels upwards thereby
steaming all the layers of the dough arranged in plurality of said perforated
containers. The steaming process is carried out for a defined period to avoid over
cooking. Such steam heating provided for making the dough containing the
vegetables stretchable.

The steam treated dough was next crushed either by hand for small scale production
or by using a crushing extruder for large scale production.
Thereafter the crushed dough was portioned into multiple portions in the form of
balls which were subsequently flattened into circular shape. Such flattening of the
crushed balls can be carried out by pressing machine on a small scale or roller
machine using dies for any shape on large scale production.
Finally, the flattened circular shape papad/wafers were subjected to drying which can
be sun drying for small scale production for involving drier machine for large scale
production. The drying was carried out such that the moisture contents of the
product is maintained upto 14%.
It is thus possible by way of the present invention to provide for cereal/flour based
papad/wafers which would enable achieving better and uniform taste and flavour
even while carrying out large scale production of such papad/wafers thereby making
papad/waferss of more consumer acceptable taste and flavour. Advantageously, the .
invention is directed to provide cereal/flour based papad/wafers of better appearance
and uniform taste and flavour involving nutritious vegetable and/or non-vegetable
contents which would also be storage stable and have improved shelf life.The
present invention would thus add value to papad/wafers as a food product to make
it acceptable among varied consumers in the market desiring to have nutritious and
food value maintain papad/wafers which can be consumed by consumers from all
walks of life across all cultures.

WE CLAIM:
1. A process for the manufacture of flour based vegetable papad/wafers comprising:
providing selectively anyone or more of cereals, flour,-/starch and food gum;
providing selectively vegetables in paste form;
mixing the said anyone or more of the cereals, flour, starch and food gum
alongwith the vegetables paste with selective desired spices in hot water to
obtain a dough;
subjecting the dough thus obtained to steam treatment comprising providing the
dough in containers with perforated base which are covered on the top and stem
heating carried out from below such that the steam travels upwards to heat the
dough for achieving the desired consistency;
subjecting the thus steam treated dough to crushing involving a crushing
extruder; and
obtaining the flour based vegetable papad/wafers from portions of said thus
crushed and extruded dough.
2. A process for the manufacture of papad/wafers as claimed in claim 1 comprising
mixing using spices/additives selected from baking soda, chemical salt (khar),
sodium bicarbonate, jeera (white/black), iodized salt, chanar jal and
spicesasafoetide.
3. A process for the manufacture of papad/wafers as claimed in anyone of claims 1
to 2 wherein said base ingredient comprise selectively flour and/or cereal (dal)
preferably selected from rice flour, wheat flour, corn flour, arraroots, sagoo,
soyabean powder and dal besan.

4. A process for the manufacture of papad/wafers as claimed in anyone of claims 1
to 3 wherein said vegetables comprise upto 30-35 % by wt. and is selected
preferably from carrot, cabbage, spinach, tomatoes, pudina, garlic, potato (alu),
green chillies, red chillies preferably dried, ginger, and the like selective
vegetables.
5. A process for the manufacture of papad/wafers as claimed in anyone of claims 1
to 4 wherein said step of steam heating of the mix is carried out such as to make
the dough stretchable and favour obtaining thin light papad/waferss therefrom
and the crushed dough is obtained into small portions which are rolled flat to
obtain the thin papad/wafers of desired shape which are finally dried selectively
preferably sun dried or involving drier machine.
6. A cereal/flour based vegetable papad/wafers comprising :
cereals/flour/starch/food gum in an amount of upto 70% by wt.; and
vegetables in an amount of upto 90% by wt.
7. A cereal/flour based vegetable papad/wafers as claimed in claim 10 obtained by
the process of anyone of claims 1 to 5.
8. A cereal/flour based vegetable papad/wafers and its process for manufacture
substantially as hereindescribed and illustrated with reference to the
accompanying examples.

ABSTRACT
TITLE: A CEREAL/FLOUR BASED PAPAD WAFERS AND ITS PROCESS FOR
MANUFACTURE.
The invention relates to wafers (papad) and, in particular, to nutritious cereal/flour
based vegetable papad/wafers having food values of the nutritious contents involving
selectively the cereal, flour and vegetables and importantly having required high
shelf life under all climatic conditions of varying temperature and humidity.
Importantly, the papad/wafers of the invention would provide for papad/wafers
including vegetable contents having good taste and flavour which would be simple
and cost effective to manufacture in mass scale apart from meeting the variety of
taste and flavour desired by individuals and thereby making available papad/wafers
as a nutritious value added food product for wide scale consumption as a food
article.