Professional Documents
Culture Documents
FPPKG Lec 4 Fruit Processing AY19-20 S
FPPKG Lec 4 Fruit Processing AY19-20 S
FPPKG Lec 4 Fruit Processing AY19-20 S
FRUIT
PROCESSING
2
Specific Learning Outcomes
Classify the various types of fruits
Describe the upstream processing of fruits
Outline the unit operations and processing parameters for the
canning of fruits
Define commercial sterility
Explain the factors that affect heat transfer in a retort process
Calculate F0 value and its application in thermal processing
Name the different types of fruit-based products
Evaluate the processing technology used for the production of
different fruit-based products
- Fruit jam - Dried fruits - Fruit juices and concentrates
3
What’s a fruit?
■ In botany, a fruit is the seed-bearing structure in
flowering plants (also known as angiosperms)
formed from the ovary after flowering.
4
Classification of fruits
Fruits may be classified by:
Botanical relationships
Geographical relationships
Culinary use
5
Classification of fruits
Botanical relationships
o Pome fruits (apple, pear)
6
Classification of fruits
Geographical relationships
o Tropical fruits (banana, durian, mango, pineapple)
7
Classification of fruits
Similarities in fruit type
o Berry fruits
(blueberry, boysenberry, raspberry, strawberry)
8
Classification of fruits
Culinary use
o Salad vegetable fruits
(capsicum, cucumber, egg plant, tomato, zucchini)
9
Maturity & Ripening
Maturity
o The stage of development of the fruit on the parent
plant
10
Maturity & Ripening
Ripening
o Can occur on or off the plant
11
Maturity & Ripening
Climacteric fruits
o Have a period of rapid ripening
12
Climacteric Fruit Ripening
and Climacteric Rise
13
Maturity & Ripening
Non-climacteric fruits
o Do not undergo rapid ripening phase
14
Fruit Processing
Fruits are eaten fresh, processed into canned, dried,
frozen, baked products, or converted into juice or jam
15
Fruit Processing
Raw materials
o Must be the right variety, sound, ripe, free from
blemishes and disease
16
Types of Local Bananas: Varieties
Cooking and
eating.
Favoured by Eating and
Most the cooking;
common in For curries For kueh Indian quick
supermarket and chips community maturation
Cavendish Plantains Kepok Kerala Lemak manis
19
Fruit Processing
Dry Cleaning
Produces a dry cleaned surface
Relatively inexpensive
20
Fruit Processing
Wet Cleaning
Effective in removing adhering soil
21
Fruit Processing
Sorting by size
Product size is a critical factor in the control of the
filling operation, and final product appearance
Weight sorting
Dimensional sorting
22
Titan Farms new packing line can sort by color, defect, weight, and
dimension. (Photo credit: Webb’s Photography)
http://www.growingproduce.com/fruits/stone-fruit/technology-helping-to-
bring-that-fresh-picked-peach-to-consumers/
23
Cleaning and Sorting Machine
https://www.youtube.com/watch?v=vOSTje10Vss
(1 min: cleaning and classifying machine)
https://www.youtube.com/watch?v=YAUeQHghUUs
(3 mins: cleaning and packaging of apples)
24
Fruit Processing
Peeling
o Hand peeling
o Mechanical
o Chemical
o Flame peeling
https://www.youtube.com/watch?v=c_pw2dJHQRI
Peeling of pineapple, melon and papaya (7 mins) 25
Fruit Processing
Mechanical peeling
o Cutting knives
Fruit impaled and rotated against a knife that follows
the contour of the fruit
o Abrasion
Surface of product ground away by rubbing against
carborundum surface
26
Fruit Processing
Chemical peeling
o Uses hot caustic solution to soften the skin
https://www.youtube.com/watch?v=t4kbxHJ8X9E
(chemical and steam peeler,2 mins)
27
Fruit Processing
Thermal shock (steam) peeling
o Uses steam to thermally shock the superficial layers
of the product to be peeled
28
Fruit Processing
Flame peeling
o Product surface heated by infrared rays and by a row
of gas burners
https://www.youtube.com/watch?v=EpOEY1rTdSo (1 min)
29
Fruit Processing
Size reduction
o To obtain particles that can easily be packed into the
containers for canning
30
Fruit Processing
Blanching
o Modification of tissue structure
Increases the flexibility of the product
31
Fruit Processing
Reduction of microbial and chemical contamination
o Depends on the blanching method used, time and
temperature
Enzyme inactivation
o Preserves colour of fruits containing anthocyanin
pigments by inactivating polyphenol oxidase
32
Fruit Processing
Blanching – adverse effects
o Loss by dissolution
Leaching of water soluble components e.g. vitamins,
sugars, colors
o Vitamin reduction
Thermal degradation of vitamins e.g. ascorbic acid
33
Fruit Processing
Blanching Equipment:
Water blanchers
o Simple in design, robust and least expensive
34
Water blanching
Advantages:
Lower capital costs
Better energy efficiency
Disadvantages:
Loss of water soluble components
Higher cost of water and disposal of effluent
Risk of contamination
35
Fruit Processing
Blanching Equipment:
Steam blanchers
o Steam tunnels using low-pressure steam
Relatively inexpensive and easy to manufacture but
prone to temperature variations
36
Steam blanching
Advantages:
Smaller loss of water soluble components
Smaller volume of waste
Lower disposal charges
Easy to clean and sterilize
Disadvantages:
Limited cleaning of food
Higher capital costs
Uneven blanching
Some mass loss in food
Poor energy efficiency 37
Blanching Water Atmospheric steam Under pressure steam
Products:
Cleaning effect great reduced reduced
Leaching great reduced reduced
Heat transfer v. good good v. good
Treatment uniformity good average v. good
Microbial contamination average weak nil
Fluid:
Temperature uniformity good average good
Water consumption large slight slight
Steam consumption large average slight
Effluent great reduced slight
38
Fruit Canning
Why can fruits?
39
Fruit Canning
Forms available in canned fruits:
Whole – plums, prunes, cherries (pitted)
Halves – peaches, apricots, pears
(pits, stones, core removed)
Quarters – peaches, apricots, pears
Sections – equal pieces obtained by dividing the fruit
into more than four parts (citrus)
Slices – smaller than sections
Pieces – may or may not have uniform size and shape
(cubes, broken slices)
Crushed or ground –apple sauce, purees
40
Pineapple Canning
https://www.youtube.com/watch?v=ZYQW2B_vrfs ( 4 mins)
Source: http://hongkongmarketmaine.com/hong-kong-market-items/fruits-vegetables/
41
Fruit Canning
Packing/Filling
o Place a specified quantity into a container e.g. weight,
number, volume
42
Fruit Canning
Packing media (cover liquids)
o Fill all voids between solid pieces of product
43
Fruit Canning
Packing media (cover liquids)
o Water, sugar syrups, juices commonly used for fruits
46
Fruit Canning
Ways of creating head space vacuum:
o Fill packing media as hot as possible, >80 °C
47
Fruit Canning
Closing/seaming
o Cans are closed by placing the lid on the filled can and
sealing it to the body by the formation of a double seam
o Two operations:
Can end seaming panel rolled together and interlocked
with the can body flange
48
Can Seaming Operation
https://www.youtube.com/watch?v=yMgSGgiUO4A
49
Fruit Canning
Retorting / processing
o Destruction of bacteria and spores by heat
50
Fruit Canning
Factors affecting rate of heat penetration:
1. Type of product – liquid or particulate foods heat faster
due to natural convection currents; solid
foods in which heat is transferred by
conduction heats slower
51
Fruit Canning
Factors affecting rate of heat penetration:
4. Temperature of the retort – higher temperature difference
between food and heating medium
causes faster heat penetration
52
Fruit Canning
Retorts
o Equipped to receive steam and water and has suitable
drain valves and vents
o Cans are loaded into cages and placed into the retort
and completely covered with the heating medium
https://www.youtube.com/watch?v=V2Prpr4GF_I
55
FRUIT
CANNING:
F0
CALCULATION
D value
When bacteria or spores are exposed to heat, they die
at an exponential rate
900
Number of surviving spores / ml
800
700
600
500
400
300
200
100
0
0 10 20 30 40 50
Time (min)
58
1000
100
Number of surviving spores / ml
10
0.1
0 10 20 30 40 50
0.01
D
Time (min)
o D = 14 mins ; D = 7 mins
o D = 14 mins; 2D = 28 mins;
3D = 42 mins; 12 D = 168 mins
60
Recap: Decimal Reduction Time
The time taken for a 10-fold reduction in the number
of microorganisms at a specified temperature
100
10
D
61
62
z value
Temperature range over which decimal reduction time
changes tenfold
za
D mins
100
10
zc
Temperature in 0C
63
z value
Parameter to characterise the relative resistance of
microorganism to temperature
z : thermal resistance
64
Example 1
A particular microorganism has a D121=14 mins and a
z value of 5 °C, what is the D value at 126 °C?
66
How to do it?
z= (T2 – T1) Given:
T2 = 126
log DT1 – log DT2 T1 = 121
z =5
z = (126 – 121) / log 14 – log DT2 DT2 = ?
DT1 = 14 mins
5 = 5 / log (14/DT2)
log (14/DT2) = 1
14/DT2 = 10
67
Try this?
z = (T2 – T1) / log DT1 – log DT2
Given:
T2 = 131 ; T1 = 121 ; z = 10; DT2 = ? ; DT1 = 0.2 mins
68
Thermal Death Time, F
The total time required to accomplish a stated
reduction in a population of vegetative cells or spores
70
Thermal Death Time, F
Typical thermal death time in thermal processing of
shelf-stable foods is F = 12D with the D value for
Clostridium botulinum
o D121 = 0.2 mins
o z = 10 °C
71
Thermal Death Time, F
Thermal destruction of microorganisms takes place
logarithmically
72
Thermal Death Time, F
Spoilage probability
1 N0
F D
r 10
r – total number of containers processed
N0 – initial population of spoilage microorganisms in each container
73
Example 3
Estimate the spoilage probability of a 2.4 mins process at
121 °C when D121 = 0.2 mins and the initial microbial
population is 105 per container.
5 5
1 N0 10 10 7
F D 2.4 0.2 12 10
r 10 10 10
7
r = 10
74
How to do it?
■ F = 12D = 2.4 mins @121 °C
F = ? @140 °C
FR – known thermal death time
FR T T R z
10 TR – known reference temperature
F
2 .4 140 121 10
10 10 19 10
F
F = 1.8 seconds (0.03 mins)
75
• Find F at 131 0C
2.4 131121 10
10 1010 10
F
F = 2.4/10 = 0.24 mins or 14.4 seconds
• Find F at 141 0C
2.4 141121 10
10 10 20 10
F
F = 2.4/100 = 0.024 mins or 1.44 seconds
76
Try this?
■ F = 12D = 2.4 mins @121 °C
F = ? @111 °C
FR T T R z
10
F
2 .4 111 121 10 10 10
10 10
F
F = 24 mins
77
Thermal Death Time, F
For reference purposes, a commonly used thermal
death time is written as F0
Z 10
T F 121
78
What is Fo value?
It is defined as the number of equivalent minutes of
heat processing at temperature 121.1 °C delivered to
a container or unit of product.
79
Thermal Death Time, F
Two processes that involve different times and
different temperatures can be converted to their
equivalent F0 for comparison:
FR T 121
10T TR z F0 FT 10 z
F
80
Process Calculation
A process with different times and different
temperatures can be converted to their equivalent F0
and can be added up to determine the lethal effect or
lethality of the process
Lethal rate 81
82
Process Calculation
Lethal rate – the proportion of the thermal death time
at temperature T to the thermal death time at a
reference temperature TR
83
Table 2. Thermal processing data obtained in a retort
84
F - SPOIL Version 2.5 (September 25, 2013)
For 4 worked examples of the use of this spreadsheet, and for its validation: see from row 205 onward.
NB: If the product in the can is a SOLID, please calculate the spoilage rate twice:
** first use the total initial number of micro-organisms in the can; the resulting number of spoiled cans b1 will be too high;
** next use the initial number of micro-organisms in 1 gram; the resulting number of spoiled cans b2 will be too low.
The correct number of spoiled cans, so the CORRECT SPOILAGE RATE b of the SOLID product then will be: b2 < b < b1.
Micro- D-value of m.o. = 0.2 min. D-value of micro-organism of concern [in min.]
organism Tref of m.o. = 121 oC Reference temperature for D of micro-organism [in oC]
concern: Initial number a = 100000 total per can Initial total number of micro-organisms of concern in can
85
1
0.9
Unit Area
0.8
0.7
0.6
Lethal Rate
0.5
0.4
0.3
0.2
0.1
0
10 15 20 25 30 35 40 45 50 55
Time (min)
Figure 3. Plot of lethal rate versus time obtained during retort processing
86
Process Calculation
To verify that a thermal process has achieved the
required F0
87
Fruit-based Products
Other processed fruit-based products include:
Fruit preserves e.g. jams, glazed fruits
Dried fruits
88
Fruit Preserve and Jams
U.S. Federal Standards
A preserve is minimally 45 parts prepared fruit with 55
parts of sugar and is concentrated to 65 % or higher
solids
21 CFR 150.160
89
Singapore Food Regulations
90
Fruit Preserve and Jams
Manufacture of Jams
o Four main ingredients, namely:
Fruit: Fresh, concentrated, frozen and/or canned
Pectin
Nutritive carbohydrate sweeteners, Sugars
Acids
Mixing
Boiling
Holding
Filling
Holding and
Dispatch
92
Fruit Preserve and Jams
Preprocessing – Upstream fruit processing that include
harvesting, sorting/washing/cleaning,
peeling and slicing/cutting
94
Plate Evaporation Process
96
Plate Evaporation Process
2nd trimming stage of de-sulphiting may be required if
sulphited fruit pulp are used
The hot mix is then fed into the plate evaporator which
is held under vacuum
o Involves rising and falling film-type evaporator where
the temperature of evaporation is about
60 to 65 ºC
For some soft fruit, especially strawberries, preservation is
done with a mix of 6 % SO2 solution and calcium bisulphite
solution (containing also 6 % SO2).
97
Plate Evaporation Process
Concentrated jam and resulting vapour is then
discharged through a rectangle port to a snail shell
separator where the jam is separated from the vapour
98
Vacuum Batch Process
100
Vacuum Batch Process
Upon mixing of the ingredients, the premix is drawn
under vacuum into a vacuum cooking vessel
o Low-speed scraper agitator is installed in the cooking
vessel
101
Vacuum Batch Process
After evaporation, post-process pasteurisation is done
for jams of a wide rage of total solids with or without
preservatives
102
Fruit Preserve and Jams
High-pressure treated fruit preserve and jam
Provide fresh fruit jam that is of superior colour and
flavour
Processed using high pressure (4000 to 6000 kg/cm2)
Prevent over heating of product that help in preventing
nutritional lost e.g. Vitamin C
However, refrigeration of jam is required due to
presence of residual enzymes
103
Fruit Drying
Fruits are characterized by:
Very high moisture content
High temperature sensitivity
High susceptibility to microbial attack
o Apples Recalled for Potential Listeria Contamination
http://www.foodsafetynews.com/2012/08/apples-recalled-for-
potential-listeria-contamination/
High sugar content
Presence of skin
Watch a video on fruits drying in a factory
https://www.youtube.com/watch?v=paDdBQYdjLU
104
https://www2.ca.uky.edu/enri/pubs/enri129.pdf 105
Fruit Drying
Due to these, drying of fruits needs to be a very slow
process and it requires gentle drying conditions
106
Fruit Drying
Fruit may be dried as:
o Whole: e.g. grapes, berries, apricots
o Leather or as powder
o Moisture content
107
Fruit Drying
Fruits
*Spray
*Conveyor Belt Dryer
*Sun/solar Dryer *Drum
Drying *Freezer Dryer Dryer
*Tray Dryer *Solar
*Vacuum Dryer Dryer
108
Fruit Drying
Drying system for fruit include:
Conventional hot-air drying
o Heat needed for drying is provided by convection with hot
air in contact with the product
109
Fruit Drying
Kiln dryer
An oven heated by gas burners in which the product is
placed in slotted trays
Batch process
110
Fruit Drying
111
Fruit Drying
Cabinet dryer
Batch process
113
Fruit Drying
Continuous belt dryer
It consist of an endless (permeable or impermeable)
belt on which the product to be dried is placed and
carried through a counter- or co-current flow of hot air
114
Fruit Drying
Other drying system for fruit include:
Solar drying – use of solar energy
115
Freeze Drying
116
Fruit Juices and Concentrates
Juice production
Process starts with freshly harvest sound fruit
117
Fruit Juices and Concentrates
Juice production
Extraction – By pressing or enzymatic treatment
Decanting
118
Fruit Juices and Concentrates
Juice production
For cloudy juices, clarification may be done
o Coarse filtration or controlled centrifugation process to
remove larger insoluble particles
Packaging
119
Fruit Juices and Concentrates
For juice concentrate production
Juice is fed to an evaporator
o To remove excessive water until the desired
concentration level is obtained
120
Fruit Juices and Concentrates
Fruit (Fresh or thawed)
Cleaning/Washing
Sorting/Culling
121
Fruit Juices and Concentrates
Juice Extraction (Pressing, Decanting)
Concentration
Pasteurization, Cooling (evaporation, reverse osmosis, freeze-
concentration)
o Dried Fruits
123
References
Arthey, D. and Ashurst, P. R. (2001). Fruit Processing:
Nutrition, Products and Quality Management. USA:
ASPEN
124