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How Appalam manufacture in factory?

Here we are going to explain how to manufacture appalam in mahaganapathi foods step by step process. (appalam and papad manufacturer in Madurai, Tamilnadu, India.) Appalam is a thin crispy round snack from south india. It is typically based on a seasoned dough usually made from pealed black gram flour (Urad dal flour).

It is typically served as an accompaniment to meal. It has many names depending upon the geography these are, it called as Handmade Appalam, Popadam, Appalam, Papadum, Appadam, Puppodum, Pampad Happala, Popadoms, Paparis , Poppadam, Urad Dal Papad, Papad, Poppadom, Pappad, Pappadam, Papads, Poppadum, Papadam, Papadom, Pappadum.

Appalam Making/Manufacturing Process

Manufacturing Process | Mahaganapathi Foods | MGF Madurai | Papad/Appalam Manufacturer Madurai
Total.no.of machines :
3
Production/day :
2MT
Time to get final product :
3 days

Ingredients to make appalam

Raw Materials | Mahaganapathi Foods | MGF Madurai | Papad/Appalam Manufacturer Madurai
  • Urad flour
  • Rice flour
  • Sodium bi carbonate
  • Edible oil
  • Salt
  • Water

Mixing

Make salt and sodium bi carbonate water (SS water)
  • Mix sodium bi carbonate and salt with water and take it in a separate vessel.
Making
  • Now, pour of urad flour in an industrial mixer and add enough ss water, wait for some time to mix it well.
Raw Materials | Mahaganapathi Foods | MGF Madurai | Papad/Appalam Manufacturer Madurai
Raw Materials | Mahaganapathi Foods | MGF Madurai | Papad/Appalam Manufacturer Madurai
Raw Materials | Mahaganapathi Foods | MGF Madurai | Papad/Appalam Manufacturer Madurai

Sheeting Process

Sheeting is one of the most important steps in appalam manufacturing . It makes the dough soft. Also makes the appalam expand while deep frying it. Once we send dough through the sheeting machine, the dough become softer. Now the dough sheet is ready, sent to appalam / papad making machine.

Sheeting Process | Mahaganapathi Foods | MGF Madurai | Papad/Appalam Manufacturer Madurai
Sheeting Process | Mahaganapathi Foods | MGF Madurai | Papad/Appalam Manufacturer Madurai

Appalam/Papad Making machine

These are two important rollers in this machine,
  • Thinning roller
  • Cutting roller
Thinning Roller

The sheets of dough are coated with oil on both sides. This prevents the dough from sticking to the thinning roller. Once the sheet of dough is sent through thinning roller, the thickness of the sheet is reduced from 1 or 1.5 inch to 0.5mm. This will be the final thickness of the appalam.

Thinning Roller | Mahaganapathi Foods | MGF Madurai | Papad/Appalam Manufacturer Madurai
Thinning Roller | Mahaganapathi Foods | MGF Madurai | Papad/Appalam Manufacturer Madurai
Cutting Roller

This sheet of dough will be sent through cutting roller which will cut in a specified dimension (3”, 3.5”, 4”, 4.5”, 5”, 5.5”, 6” inch) and shape. The appalams comming out of the roller will be stacked on top of one another. Powdered rice flour will be coated between each appalams to avoid stickiness in a stack.

Cutting Roller | Mahaganapathi Foods | MGF Madurai | Papad/Appalam Manufacturer Madurai
Cutting Roller | Mahaganapathi Foods | MGF Madurai | Papad/Appalam Manufacturer Madurai

Fermentation

Now, the appalams which are cut in shapes are stored in room temperature for 7 hours for fermentation. This plays a major role in expansion of the appalams while it is deep fried.

Fermentation | Mahaganapathi Foods | MGF Madurai | Papad/Appalam Manufacturer Madurai

Drying

Drying process take two days.

Day:1

Once the fermentation is done, each appalam is dried under direct sunligh for 30min in day 1 process. After that collect all half dried appalams and store it in a rakes.

Day:2

Which is the final process here half dried appalams are dried for 15mins. collect it and store now, we can get our tasty appalams and is ready to pack.

How to make appalam at Home

The same ingredients are taken for preparing hand made appalam. But the process of manufacturing appalam without the machine. We do it in hand using a wooden roti/chapati maker.