American Journal of Applied Science and Technology
33
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VOLUME
Vol.05 Issue 05 2025
PAGE NO.
33-38
10.37547/ajast/Volume05Issue05-08
Study of Barley Grain Processing by Steam Pressure and
Ultra-High Frequency Drying
Sanayev Ermat Shermatovich
Tashkent Chemical-Technological Institute, Republic of Uzbekistan, Tashkent
Mirkhodjaeva Dilobar Davronbekovna
Renaissance Educational University, Republic of Uzbekistan, Tashkent
Nizamov Dilshod Baxtiyarovich
Tashkent Chemical-Technological Institute, Republic of Uzbekistan, Tashkent
Received:
16 March 2025;
Accepted:
12 April 2025;
Published:
14 May 2025
Abstract:
In this study, a modern, energy-efficient, and resource-saving technology for the production of early-
ripening cereals from the grain of the local barley variety "Istak" was developed. Analysis of the main nutrients,
vitamins, minerals, and amino acids in the grain showed that the "Istak" variety has high biological value. Compared
to wheat, it is characterized by the predominance of the amino acids trionine, silicon, and niacin. In the
technological process, the grain was subjected to steam treatment at a pressure of 0.3 MPa with subsequent
microwave drying at a frequency of 2.45 GHz and a power of 600 W/kg. Thanks to this, 84.2% of early-maturing
cereals were obtained in the product composition, microbiological safety was ensured, and energy consumption
was reduced by 3 times compared to the traditional method. It has been shown that the energy consumption in
the proposed technology is 0.7 kW/h, which is significantly more efficient than the traditional method. This process
ensures the microbiological safety of the product and allows for the preservation of nutrients. Based on the
research results, the effectiveness of this technological method in processing local barley has been proven, and
thanks to its implementation in practice, the possibility of providing the population with high-quality, energy-rich,
and biologically rich early-ripening products has been created.
Keywords:
Barley grain, instant cereal, "Istak" barley variety, microwave drying, steam processing, nutritional
value, mineral substances, amino acids, energy efficiency, microbiological safety.
Introduction:
The process of rapidly preparing groats from barley
grain is one of the important directions of research
aimed at efficient use of plant resources. From this
point of view, the conducted research on obtaining
special flour and cereals from barley not only
contributes to increasing the efficiency of its
industrial production, but also opens up new
prospects in the field of functional nutrition aimed at
organizing special nutritional diets.
When processing barley grain, it is important to
isolate optimal components for special food rations.
For this purpose, based on the study and analysis of
the chemical composition of barley grain, a number
of substances with functional properties have been
identified. The important properties of the identified
substances for human health have also been
scientifically substantiated.
Barley stems and grains are mainly used for fodder
purposes for livestock. It should be noted that due to
today's ecologically unfavorable climatic conditions,
the decrease or loss of yields of fodder grain crops
grown on irrigated lands requires efficient use of
American Journal of Applied Science and Technology
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American Journal of Applied Science and Technology (ISSN: 2771-2745)
existing raw material sources.
METHODS
The organoleptic indicators of barley flour were
studied based on GOST 26574-85. Its moisture
content was determined by GOST 13586.5-93, and
the protein content by the Kjeldahl method, in
accordance with GOST 10846-91. The oil content was
assessed according to GOST 29033-91 using the
Sokhlet extraction method, and the water content
was assessed according to GOST 9404-88 by drying at
105°C.
The amount of dietary fiber was studied according to
GOST 31675-2012. The total nutritional value (caloric
value) was determined by calculation method based
on 4 kcal per 1 g of protein and carbohydrates, 9 kcal
per 1 g of fat.
RESULTS AND DISCUSSIONS
For the purpose of using barley grain for food
purposes, the autumn grain varieties listed in the
state register: "Noyob" and "Istak" varieties were
studied. As a result, an analysis of the functional
composition of grain, which is important for the
human div, was carried out, and it was
substantiated that the "Istak" variety is the optimal
variety of barley for drought resistance compared to
the "Noyob" variety, and to obtain quick flour and
groats, the physicochemical, technological, and
biochemical properties of this grain variety were
studied.
Table 1
Chemical composition and nutritional value of the "Noyob" and "Istak"
varieties of barley grain (100 g).
Composition
Istak
Rare
Proteins. gr
10,3
9,2
Fats. gr
2,4
2,0
Carbohydrates. gr
56,4
51,2
Water gr.
14,0
14,0
Food fibers. gr
14,5
15,1
Nutritional value. Kcal
288
271
According to the analysis of Table 1, the superior
"Istak" variety of barley in terms of nutritional value
was selected as the optimal variety for the research
object and its nutritional composition was
substantiated.
Barley groats are a difficult-to-flow and brittle
product, steam-pressure treatment is considered
effective, the upper shell of barley grain under steam
pressure becomes soft, elastic, and does not crumble
when pressed on smooth rollers.
Using steam directly in the groat production
processes in the proposed technology is advisable for
optimizing energy-intensive stages such as bleaching,
shell separation, and grinding.
Therefore, it is not advisable to obtain early-ripening
groats from barley grain from bleached barley, as this
leads to the formation of large quantities of grain and
flour shards, which negatively affects the quality and
cost of the finished product. We aimed to carry out
the processes of processing barley grain grown in
local conditions based on the sequence shown in
Figure 1.
Figure 1. Block diagram of the proposed barley grain processing process
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American Journal of Applied Science and Technology (ISSN: 2771-2745)
The pre-cleaned barley grain was processed in a
vortex moisturizing unit at a steam pressure of 0.3
MPa for 5 minutes to facilitate separation of the husk
and reduce the firing stage time, and then directed to
the firing stage.
After this, it was standardized to obtain grains with
the following parameters. In this case, the barley
grain was given a moisture content of 26% and
simmered for 14 hours.
Then it was processed at a steam pressure of 0.3 MPa
for 10 minutes. The barley grain exiting the
evaporation chamber was dried to a moisture content
of 18%.
After removing up to 10% of barley grain shells with
softened shells that have not lost core strength but
have reduced brittleness (plasticized), the mixture
was directed for crushing on smooth rollers with a
rotation speed ratio of 1:1 and an interval of 0.2 mm.
The resulting grain was dried to a moisture content of
10-11% and standardized by sorting in a control
separator.
The quality indicators of early-ripening barley grain
obtained using the proposed new method were
determined.
Evaporation moistens and heats the grain, plasticizes
the kernel, makes it less brittle, and minimizes
grinding during hulling and grinding. Plasticization of
the nucleus also occurs as a result of some chemical
changes: for example, part of the starch gelatinizes,
forming a small number of dextrins with adhesive
properties.
Drying after evaporation largely dehydrates the outer
membranes, which lose moisture, become more
brittle, and are easier to remove during the
separation
process.
Additionally,
deformation
changes occurring in grain components during
evaporation and drying lead to shell movement.
Furthermore, drying the grain led to a decrease in the
number of adhering shells during grinding.
In the pieces of grain obtained using the proposed
new technological method, the following indicators
were determined: the yield of large-fraction grain
pieces was determined by the amount passed
through a 4.5 mm sieve. The yield of grain and flour
fragments during the production process was
determined by the number of particles that passed
through the sieve on a 3 mm sieve.
In the proposed new method, in the technological
process of obtaining early-ripening groats from the
"Istak" variety of barley grain, the grain was pre-
moistened to a moisture content of 26% and
processed at a steam pressure of 0.3 MPa for 10
minutes, and then the groats were obtained by
pressing to a thickness of 2 mm on a two-shaft
machine. After this, drying was carried out on a
microwave installation with a power of 600 W/kg, a
frequency of 2.45 GHz for 2 minutes to a moisture
content of 10-15%. In the composition of the
obtained product, the proportion of coarse, early-
ripening grains was 84.2%, fine-grained grains - 5.8%,
and shells formed during bleaching - 10%.
When conducting experiments, the total amount of
electricity consumed to obtain 1 kg of early grain was
0.07 kW/h. This indicator demonstrates the energy
efficiency of the technological process and confirms
the optimality of the modern UHF drying method
compared to traditional methods, the results are
presented in Table 2 below.
Table 2.
Selected modes and parameters for the proposed new method of rapidly
preparing groats from the Istak barley variety.
Grain
name
Given
humidity in
GTI %
Steam
pressure and
processing
time,
MPa/min.
UHF 600
W/kg/min
drying
GHz/min
Amount of
separated shell,
%
Quantity of
early grain,
%
Amount of
received
defective grain,
%
Energy
consumption for
obtaining 1 kg of
grain, kW/h
Barley
26
0,3/10
2,45/2
10
84,2
5,8
0,7
According to the analysis of Table 3.1.6, in the
technological process of obtaining early-ripening
groats from barley grain using the traditional method,
the grains were pre-moistened to a moisture content
of 26% and processed at a steam pressure of 0.3 MPa
for 10 minutes, and the groats were formed by
pressing to a thickness of 2 mm on a two-shaft
machine.
After this, an infrared drying of 2.5 μm at 3 kV/h was
carried out, drying to a moisture content of 10-11%
for 10 minutes. In the composition of the obtained
product, the share of large early-ripening panicle was
72.0%, fine-grained panicle - 20%, and shells formed
during bleaching - 8%.
American Journal of Applied Science and Technology
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American Journal of Applied Science and Technology (ISSN: 2771-2745)
When conducting experiments, the total amount of
electricity consumed to obtain 1 kg of early grain was
2 kW/h. This indicator justifies the optimality of the
microwave drying method compared to traditional
methods due to the high energy consumption of the
technological process. Table 3.1.3.
According to the analysis of Table 3.1.7, the optimal
drying frequency at ultra-high frequency and at 2.45
GHz for 120 seconds was determined, and it was
established that the optimal electrical energy voltage
is 600 watts per 1 kg of product. In this case, the
influence of the established parameters of microwave
drying on nutrients and the microbiological activity of
the product was taken into account.
At the same time, during the steaming process under
0.3 MPa pressure, the temperature in the chamber
reached 140-145°C, which, in turn, leads to almost
complete disinfection of the finished product. The
thermal temperature of the steam supplied over a
short period of time does not significantly affect the
nutrients, as it is carried out in a humid environment.
Optimal parameters of microwave drying are also
substantiated in practical experiments based on the
theoretical data presented above.
Table 3.
Research on the selection of optimal parameters of the microwave drying
method in the production of instant cereals.
Parameters
Example 1
Example 2
Example 3
Microwave frequency. GHz
3,0
2.65
2.45
Power density. W/g
1.5–6
1.5–6
1.5–6
Validity period. sec.
30–120
30–120
30–120
Temperature range. °C
80–120
80–120
80–120
Initial humidity (%)
26
26
26
Actual humidity (%)
4–5
7–8
10–11
Degree of reduction of microbes. 105
times, that is, a decrease of 100,000
times, survived by 0.001%.
> 10
⁵
> 10
⁵
> 10
⁵
Optimal porosity capacity (W/kg)
800
700
600
Porosity of early-ripening barley
(g/cm3)
600–700
550–720
600–650
The chosen microwave drying method for rapidly
cooking grains, unlike other drying methods, also
effectively affects the porous texture and
microbiological activity of the product.
The following table shows the indicators of
microbiological activity.
Table 4
Microbiological indicators of early cereals obtained during the drying process
Sample
Microbiological indicators
Determined forms of microorganisms
KMAFANM
(Mesophilic aerobic and
facultative anaerobic
microorganisms)
COE/gram
coliform bacteria group
COE/gram
Yeast and mold fungi
COE/gram
Fact.
Norm
Fact.
Norm
Fact.
Norm
Grain
moisture
content, up
to 11-12%
Not detected
1×10
⁴
in 1 gram of
product
nothing found
in 1 gram of
product
not allowed
in 1 gram of
product
nothing
found
Yeast
10.
Mold
50.
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American Journal of Applied Science and Technology (ISSN: 2771-2745)
Analysis of Table 4 shows the absence of general
mesophilic aerobic and facultative anaerobic
microorganisms in food products. This indicator is
important
when
assessing
the
degree
of
microbiological contamination of the product.
COE/g (colony-forming unit/gram) is taken as the unit
of measurement. CFU/g indicates how many colonies
of living microorganisms are present in each gram of
the product.
These indicators are the main criteria for determining
the safety, quality, and shelf life of products. When
barley grain was processed at a steam pressure of 0.3
MPa for 10 minutes and dried at an ultra-high
frequency (600 W/2.45 GHz), the highest quality
grains were obtained. Based on the obtained
effective results, a new technology for obtaining
early-ripening barley groats has been developed.
Figure 2. Technological scheme for obtaining quick-prepared groats from barley grain.
1-moistening apparatus, 2-tamps, 3-evaporator, 4-
first-stage microwave drying unit, 5-kapron mesh
conveyor, 6-ventilator, 7-magnetic tap, 8-cooler, 9-
whitening equipment, 10-separator, roller machine,
12-separator, 13-finished product conveyor.
CONCLUSION
As a result of the conducted research, a new,
efficient, and energy-saving technology for obtaining
early-ripening barley grain from the "Istak" barley
variety has been developed. During the research, the
chemical, biochemical, and physico-technological
properties of the barley grain were thoroughly
studied, particularly revealing that this variety is rich
in high nutritional value, valuable functional
substances, vitamins, and minerals.
In the new technology, barley grain was pre-treated
with steam under 0.3 MPa pressure, which ensured
softening of the husk, plasticization of the kernel, and
reduced grinding. After this, the grain was dried in an
SVC (super high-frequency) unit at a power of 600
W/kg at a frequency of 2.45 GHz for 2 minutes. This
method allowed for the extraction of 84.2% of large-
fractional early-ripening grain, 5.8% of small-
fractional grain, and 10% of shell.
Compared to traditional drying methods, the energy
consumption for obtaining 1 kg of grain in the new
method is only 0.07 kW/h, which indicates the high
efficiency of the technological process. Drying fully
ensured the microbial safety of the product and did
not negatively affect the nutrients.
The microbiological analysis results showed the
absence of KMAFANM, BGKP, yeast, and mold fungi.
This is an important factor in ensuring the quality,
safety, and shelf life of products.
Based on the obtained results, a new technological
scheme for producing early-ripening groats from
barley grain has been developed and recommended
for implementation in production. This approach
allows for the production of food products with high
biological value based on local raw materials.
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