Lesson 1Forming, mixing, and shaping (equipment options, shear/pressure effects, ingredient addition points)This lesson details forming, mixing, and shaping legume products, reviewing equipment choices, effects of shear and pressure on structure, ingredient addition times, and parameters affecting texture, inclusions, and uniformity.
Ribbon, paddle, and planetary mixersOrder and timing of ingredient additionShear, pressure, and texture developmentForming dies, moulds, and cutting systemsInclusion distribution and segregation controlOnline viscosity and consistency checksLesson 2Surface finishing and flavouring (coating, seasoning adhesion methods, oil uptake control)This lesson describes surface finishing and flavouring for legume products, covering coating types, seasoning adhesion, oil control, equipment, and parameters that affect flavour strength and stability.
Tumbling drums and enrober selectionDry versus slurry seasoning systemsAdhesion aids, binders, and pre-wettingOil application rate and uptake controlSurface temperature and tackiness controlFlavour stability and oxidation managementLesson 3Thermal processing (boiling/steaming, extrusion, or roasting choices and parameters)This lesson focuses on thermal options like boiling, steaming, extrusion, and roasting, including heat transfer, time-temperature profiles, equipment, validation, and effects on texture, flavour, nutrients, and safety.
Boiling and steaming system designRoasting profiles and colour developmentExtrusion barrel zones and screw designTime–temperature and F0 value controlNutrient retention and texture changesThermal process validation and recordsLesson 4Reception, cleaning, sorting and storage of legumes (moisture control, contamination checks)This lesson covers receiving raw legumes, unloading, inspection, cleaning, grading, and storage, stressing moisture handling, contamination prevention, traceability, and quality preservation before processing in Botswana.
Truck unloading and sampling protocolsInitial visual inspection and documentationDry and wet cleaning equipment selectionOptical sorting and defect removalMoisture monitoring and aerated storagePest, dust, and foreign matter controlLesson 5Soaking and hydration/conditioning step (goals, temperature/time, water quality)This lesson explores soaking and hydration for legumes, discussing goals, water ratios, temperature and time, water quality, pH, sanitation, and impacts on texture, cooking, and nutrients.
Hydration objectives and target moistureSoaking temperature and time profilesWater quality, hardness, and pH controlMicrobiological and sanitation managementCountercurrent and batch soaking systemsDraining, dewatering, and carryover controlLesson 6Packaging line operations and headspace control (gas flush, sealing parameters)This lesson examines packaging operations for legume products, including filling, headspace, gas flushing, sealing, leak checks, and how they impact shelf life, safety, and quality.
Packaging material and format selectionVolumetric and gravimetric fillingHeadspace volume and oxygen targetsGas flush composition and flow controlHeat seal temperature, time, and pressureLeak detection and seal integrity testsLesson 7Cooling, in-line quality checks, and metal detection/X-ray controlsThis lesson covers cooling after heating or drying, in-line checks, metal detection, X-ray, limits, rejection, and records to ensure safety and compliance in food production.
Ambient and forced-air cooling designSpiral and tunnel cooler operationIn-line weight and seal integrity checksMetal detector sensitivity and setupX-ray inspection for dense contaminantsReject mechanisms and verification testsLesson 8Drying and moisture reduction (drying methods, target moisture and water activity, temperature and time control)This lesson studies drying for legume products, comparing methods, target moisture and water activity, temperature and time controls, and ways to avoid hardening, quality loss, and microbial growth.
Convective, drum, and fluidized-bed dryersTemperature, humidity, and airflow controlTarget moisture and water activity limitsResidence time and belt speed settingsCase hardening and cracking preventionMoisture uniformity and sampling plans
