The manufacturing process of sprouted toor dal/ arhar dal/ tuvar/ toor dal involves several steps to ensure enhanced nutrition by proper sprouting and quality control. Here’s a detailed description of the process:
1. Cleaning and Sorting: The first step is to clean the toor dal to remove any impurities, dirt, or foreign particles. This is usually done using a combination of sieves and air blowers. After cleaning, the dal is sorted to remove any damaged or discolored grains.
2. Soaking: The sorted toor dal is then transferred to large tubs for soaking. Water is added to the dal, and it is left to soak for a specific duration, usually 6 to 8 hours or overnight. Soaking softens the dal and initiates the germination process.
3. Draining and Rinsing: After the soaking period is complete, the water is drained from the soaked dal using drainage systems or colanders. The soaked dal is then rinsed thoroughly with clean water to remove excess starch and ensure hygiene.
4. Sprouting: The soaked and rinsed toor dal is transferred to sprouting containers. These containers are placed in the specialized sprouting machines. The containers also allows air circulation and prevent overcrowding to promote even sprouting.
The containers are placed in a warm, dark environment, in a sprouting chamber at controlled temperature room. The temperature and humidity are carefully monitored to provide the optimal conditions for germination. During the sprouting process, the dal absorbs water, swells, and germinates.
Once the sprouts have grown, they are carefully harvested. This is done by gently removing the sprouted toor dal from the sprouting containers. Harvesting requires precision to prevent damage to the delicate sprouts.
5. Drying: After harvesting, the sprouted toor dal is dried. Drying helps reduce the moisture content and extends the shelf life of the product. It can be done using natural sunlight, low-temperature drying, or specialized drying machines.
6. Quality Control and Packaging: Before packaging, the sprouted toor dal undergoes thorough quality control checks. This includes inspecting for any impurities, damaged grains, or foreign materials. The sprouted dal is then carefully weighed, packaged in cloth bags.
Throughout the manufacturing process, cleanliness, hygiene, and quality control are of utmost importance to ensure the production of safe and healthy sprouted toor dal products.
Nutritional Values per 100 grams (approximate):
The nutritional values of sprouted and dried toor dal (pigeon pea) and regular (uncooked) toor dal are comparable, but there are some differences due to the sprouting process. Here’s a general comparison of the nutritional values of both types:
Regular (Uncooked) Toor Dal:
- Calories: 343 kcal
- Protein: 22.3 grams
- Carbohydrates: 60.8 grams
- Fiber: 15.3 grams
- Fat: 1.2 grams
- Iron: 2.8 mg
- Calcium: 130 mg
- Magnesium: 150 mg
- Phosphorus: 367 mg
- Potassium: 1305 mg
- Folate (Vitamin B9): 257 mcg
- Vitamin C: 0 mg
Sprouted and Dried Toor Dal:
- Calories: Slightly lower than regular toor dal (due to some losses during sprouting)
- Protein: Slightly higher than regular toor dal (due to increased availability)
- Carbohydrates: Slightly lower than regular toor dal (due to some losses during sprouting)
- Fiber: Slightly higher than regular toor dal (due to sprouting)
- Fat: Slightly lower than regular toor dal (due to some losses during sprouting)
- Iron: Slightly higher than regular toor dal (due to increased availability)
- Calcium: Slightly higher than regular toor dal (due to increased availability)
- Magnesium: Slightly higher than regular toor dal (due to increased availability)
- Phosphorus: Slightly higher than regular toor dal (due to increased availability)
- Potassium: Slightly higher than regular toor dal (due to increased availability)
- Folate (Vitamin B9): Slightly higher than regular toor dal (due to increased availability)
- Vitamin C: Slightly higher than regular toor dal (due to increased availability)
Note: The nutritional values mentioned above are approximate and can vary depending on the specific variety of toor dal and the sprouting duration.
Sprouting toor dal increases the availability of certain nutrients like iron, calcium, magnesium, and folate due to the enzymatic changes that occur during the germination process. Additionally, sprouting may reduce antinutrients such as phytic acid, which can inhibit the absorption of minerals in the body.