LESSON: 1: The Food Processing Industry

Personnel
Next: TOPIC 1: The Food Processing Industry Personnel/Staff, Duties, and
Responsibilities ►

Introduction
Food processing is concerned with converting raw agricultural products for consumption. It
is responsible for a range of products found in grocery, and sari-sari stores.

In the Philippines, the food processing industry is part of the manufacturing sector and accounts
for 7.31% share in total Gross Domestic Product (GDP).  Local employment in the food and
beverage industry has gone up to 880,000 in 2013 and is expected to increase as the food
processing industry expands. 

Ninety percent of the industry’s output is consumed domestically. As the population

increases, work in the food processing industry remains relevant.

This lesson will show you the career opportunities in the food processing industry. It will
also teach you the desirable work habits expected of a food processing industry personnel.

TOPIC 1: The Food Processing Industry

Personnel/Staff, Duties, and Responsibilities
Food processing is an activity that refers to the conversion of raw agricultural products
into food or other forms for consumption. It consists of a range of tasks that are
synchronized to meet the needs of the market. As a food processing worker, you must
be familiar with the different roles that a food processing worker may play. This will help
you determine the scope of work and the skills you need to master.

LESSON 2: The Food Processing Plant

Next: TOPIC 1: The Food Processing Facility ►

Introduction
In this lesson, you will familiarize yourself with the key elements of a food processing
facility. You will also learn about the tools, equipment, and utensils that you may find
inside one. 
This lesson will cover the knowledge, skills, and attitude required to operate food
processing tools, equipment, and instruments in the workplace. 

Towards the end of the unit, you will also learn about the difference between cleaning
and sanitizing which are essential in maintaining the cleanliness and sanitation of a food
processing facility.

TOPIC 1: The Food Processing Facility

A food processing facility is a facility where food for human consumption is:

 manufactured; 
 packaged; 
 labeled; and 
 stored.

Each food processing facility is designed differently depending on the cost of

production, type of product, safety, capacity, hygiene, and sanitation. Being familiar with
the key elements of a food processing facility will help you navigate your way in the
workplace. Explore the layout to learn about the key elements of a food processing
facility.

LESSON 1: Principles of Food

Processing
Next: TOPIC 1: Salting, Curing, Smoking ►

Introduction
Food is processed for several reasons – to add value to raw agricultural products, to
extend shelf-life, to create new food products, to improve the nutritional value of
products, to create new food products and more. Food processing has introduced so
many products – from bacon to pickles, canned goods, even candies! In this lesson, you
will learn about five (5) clustered methods of food processing.

Salting involves introducing salt into the flesh of fish or meat. Water moves out of the
meat or fish and is absorbed by the salt. Microbial cells die in the meat from the loss of
water, therefore, preventing spoilage.

Common raw materials for salting include egg, meat, fish and other marine products.
Salting involves introducing salt into the flesh of fish or meat. Water moves out of the
meat or fish and is absorbed by the salt. Microbial cells die in the meat from the loss of
water, therefore, preventing spoilage.

Common raw materials for salting include egg, meat, fish and other marine products.

LESSON 2: Food Safety and Sanitation

Next: TOPIC 1: Food Spoilage ►

Introduction
Imagine opening the refrigerator and you see a jar of your favorite food. You are very excited
and can’t wait to eat it. But as you opened the lid, the rancid smell fills your nostrils and you
scrunch your face and say, “Yuck!” The food is expired. But you just bought it last week, you
say in vain! 

Imagine opening the refrigerator and you see a jar of your favorite food. You are very excited
and can’t wait to eat it. You open the lid, it looks normal. You eat it but feel something is off.
You spend the next 3 hours at the toilet with an upset stomach. 

You’d be upset, right? What happened to the food? Most of the time, these problems arise when
food safety and sanitation are neglected.

In this lesson, you will learn the concepts behind food spoilage and the hazards it poses. This
lesson will also cover a food safety management system designed for eliminating hazards and
controlling risks of food spoilage. Towards the end, you will understand how you can prevent
food spoilage by maintaining personal hygiene and good grooming as a food processing
worker.

TOPIC 1: Food Spoilage

Food spoilage is any change in food which renders it unfit for eating.  It can
be due to contamination or natural decay which are both associated with
the growth of microorganisms. 

Types of Microorganisms
The growth of microorganisms is significantly attributed to the availability of water. Just
like in humans, water supports the growth of bacteria, yeasts, and molds. You may have
observed that most food processing methods aim to decrease the concentration of free
water by adding sugar or salt or by allowing water to evaporate from the foodstuff. Food
spoilage can also be caused by reactions with oxygen, light, and chemical constituents
of the food. Furthermore, these causes can act together and increase the rate of food
spoilage. When spoiled food is consumed, it can lead to food-borne illnesses.
TOPIC 2: HACCP
Under the Republic Act. 10611, the Department of Health shall ensure the safety of all
food processing and product packaging activities. For this reason, the Food and Drug
Center for Food Regulation and Research enforces HACCP and other risk-based
control measures in food processing. 

Hazard Analyses at Critical Control Points (HACCP) refers to a food safety

management system which identifies, evaluates and controls hazards which are
significant for food safety at critical points during a given stage in the food supply chain.

Food Safety Hazards is any biological, chemical, or physical agent in food with the
potential to cause adverse effects on health.

Examples:

o Biological: bacteria, viruses, parasites, molds

o Chemical: pesticides, processing chemicals, drug residue, allergens
o Physical: bones, pits, glass, metal, hair

Risk is the result of exposure to a hazard.

How to Develop a HACCP Plan

There are five (5) steps that you must first take in order to develop the HACCP Plan.

1. Assemble the HACCP Team. Ideally, the HACCP Team is composed of members
from different departments: Top Management, Purchasing, Food Safety and Quality
Assurance, Production, Maintenance, and Sales.

2. Describe the product. What are the raw materials? What are the product
specifications? What should be the conditions for storage?

3. Specify intended use and target consumers. Who can consume the product? Who
should not?

4. Draw a flow diagram to describe the process steps. Begin with the supplier and take
note of every step that the product undergoes up until distribution.

5. Visit the plant for on-site confirmation of flow diagram.

LESSON 3: Food Manufacturing

Practices
 Next: TOPIC 1: Good Manufacturing Practices (GMP) ►

Introduction
An effective food processing worker possesses knowledge and skills in food processing
techniques. Aside from that, he/she must also be aware of the supervisory aspects of
working in the food processing industry.

In this lesson, you will learn about management practices that aim to (1) meet quality
standards, (2) ensure safety of the workers, (3) maintain cleanliness in the workplace,
and (4) implement proper waste disposal.

LESSON 3: Food Manufacturing

Practices
Next: TOPIC 1: Good Manufacturing Practices (GMP) ►

Introduction
An effective food processing worker possesses knowledge and skills in food processing
techniques. Aside from that, he/she must also be aware of the supervisory aspects of
working in the food processing industry.

In this lesson, you will learn about management practices that aim to (1) meet quality
standards, (2) ensure safety of the workers, (3) maintain cleanliness in the workplace,
and (4) implement proper waste disposal.

TOPIC 2: Occupational Safety and Health

Proper Handling of Cutting Tools
Fire Safety
The following are the measures you can take to ensure fire safety:

 Inspect wires, plugs, gas range, and other equipment on a regular basis.

 Extinguish the fire! Pull pin. Aim at the base. Squeeze handle. Sweep from side
to side.

 Not all fires are the same. Use the right Class of fire extinguisher for every type
of fire.

o Class A - ordinary combustibles such as wood and paper

 o Class B - combustible liquids and gases such as alcohol, LPG, grease
o Class C - electrical fire
o Class D - combustible metals such as aluminum

5S of Good Housekeeping
5S of Good Housekeeping is another management approach for productivity and
quality that focuses on maintaining orderliness and cleanliness in the workplace. It is
derived from the Japanese words: seiri, seiton, seiso, seiketsu, and shitsuke.

Distinguish between what is needed and not needed.

Secure a place for everything and everything should be in its place.

 Clean, and look for ways to keep it clean and organized.

Establish guidelines and monitor.

Commit to a clean and organized workplace. Stick to a cleaning schedule.

TOPIC 4: Cleaning and Sanitizing Equipment, Tools,

and Utensils
Cleaning
Cleaning means to remove unnecessary and unpleasant matter like garbage, food
waste, and grease. Cleaning equipment differs from cleaning tools and utensils.
Equipment is usually bigger and involves electrical wiring.

It is always best to refer to the manufacturer’s instructions when cleaning and sanitizing
equipment. However, there are general rules that must be observed when cleaning
equipment:

1. Make sure that the power is turned off and power cords are unplugged.

2. Gas equipment should be turned off.

3. Proper protective clothing must be worn when cleaning equipment that deals with
chemicals.

4. Ventilation should be provided.

Sanitizing involves the use of a chemical agent to reduce the number of bacteria to

safe levels.

Sanitizing generally consists of three steps:

1. Soaking tools and utensils in hot, clean, and potable water (75 °C) for at least 2
minutes.

2. Immersing in sanitizing solution for at least one minute.

3. Leaving tools and utensils to air dry in a draining rack.

Preparing a Sanitizing Solution

1 Teaspoon Bleach + 1 Gallon Water

Tips in Cleaning and Sanitizing Tools

1. Pre-cleaning and main cleaning can be combined if there is only light

contamination.
 2. If using a hose to wash equipment, use high-volume, low-pressure hose in order
to prevent splashing and spraying pathogens onto surfaces. 

3. Sanitize items that come into direct contact with food or with the hands of the
food handlers.

4. Sanitizers work best at the correct dilution. Be sure to check the label before
applying them.

5. Always label chemical agents.

6. Store chemical agents and cleaning materials away from where food is being
handled.

7. Be sure to clean and dry the cleaning equipment.

TOPIC 5: Proper Waste Disposal

Chemical Waste Management
Chemical waste is any solid, liquid, gaseous matter that when improperly managed or
disposed of may pose harmful effects on the environment and to the surrounding
community. Examples:

 Used oil

 Contaminated syringe

 Denatured alcohol

 Industrial cleaners

 Pesticides

 Batteries

 Degreasing solvents

How to Dispose of Chemical Waste:

1. Identify the type of chemical waste.

2. Select appropriate container.

3. Label chemical waste. Include chemical name, quantity, the date the waste was
generated, place of origin (what part of the production line, room number),
 assigned personnel. For mixtures, include each chemical along with their weight
or volume.

4. Store in appropriate cabinets and wait for the Pollution Control Officer to collect.

Republic Act 6969

DENR AO 36 s. 2004

Food Recovery Hierarchy

LESSON 4: Dietary Laws
Next: TOPIC 1: Halal Guidelines in Food Processing ►

Introduction
Dietary laws are special laws followed by a community or a group of people that permit
or prohibit certain foods. Dietary laws cover food origin, slaughtering, preparation,
processing, packaging, transportation, storage, and labeling. Studying dietary laws are
valuable in serving export markets. In this lesson, we will discuss three dietary laws that
are widely followed in the food processing industry. 

TOPIC 1: Halal Guidelines in Food Processing

This guideline is followed by Muslims or believers of the Islamic religion. Islamic Law
has a concept of lawful food. The following are the food sources they do not consider
sourcing their food from:
Sources Examples
Animal (a) Pigs and boars.

(b) Dogs, snakes, and monkeys.

(c) Carnivorous animals with claws and fangs such as lions, tigers, bears and other
similar animals.

(d) Birds of prey with claws such as eagles, vultures, and other similar birds.

(e) Pests such as rats, centipedes, scorpions, and other similar animals.

(f) Animals that are forbidden to be killed in Islam i.e., ants, bees and woodpecker
birds.

(g) Animals which are considered repulsive generally like lice, flies, maggots and
 other similar animals.

(h) Animals that live both on land and in water such as frogs, crocodiles, and other
similar animals.

(i) Mules and domestic donkeys.

(j) All poisonous and hazardous aquatic animals.

(k) Any other animals not slaughtered according to Islamic Law.

(l) Blood
Plant Intoxicating and hazardous plants except where the toxin or hazard can be
eliminated during processing
Drink (a) Alcoholic drinks.

(b) All forms of intoxicating and hazardous drinks.

Food All food additives derived from prohibited animals, plants, and drinks.
Additives

To be considered Halal Food, the following conditions must be met:

 Condition #1: does not consist of unlawful food;

 Condition #2: has not been prepared, processed, transported or stored using any
appliance or facility that has made contact with unlawful food
 Condition #3: has not been in direct contact with any food that fails to satisfy the
1st two conditions

However, halal food can be processed in different sections within the same premises
where non-halal foods are processed provided that necessary measures are taken
to prevent any contact between halal and non-halal foods

Halal food can also be prepared, processed, transported or stored using facilities that
have been previously used for non-halal foods provided that proper cleaning
procedures, according to Islamic requirements, have been observed.

Additionally, certain preparations may only be done by a Muslim.

Halal certification is required before food can be marketed as halal food.

TOPIC 2: Kashrut Guidelines in Food Processing

This guideline is followed by Jews or believers of Judaism. Kashrut has a concept of permitted
and forbidden animals. Permitted animals and those that conform to the laws of Kashrut are
called Kosher foods. The following are the permitted and forbidden food sources:

Permitted Forbidden
meat from animals that “have cloven hooves” meat from animals that only fulfill one
and “chew the cud” condition such as:

(a) Pigs (have cloven hooves but does not chew

cud)

(b) Camel (chews the cud but does not have

cloven hooves)
milk derived from kosher animals (have cloven dairy products that are derived from non-kosher
hooves and chew the cud) sources
goose, duck, chicken, turkey birds of prey such as eagle, owl, vulture, stork
eggs of kosher birds eggs of non-kosher birds and eggs that contain
blood inside the shell
fish with fins and scales such as tuna, salmon, shellfish such as shrimps, crabs, mussels, and
and herring lobsters
all products that grow in the soil – plants, insects and infested plants
bushes, trees
wine produced in a kosher winery (a) hybrid fruits

(b) fruits from trees planted within the last three

years

Kosher Food
B’lios or the concept of absorbed flavors prohibits Kosher foods from:

 Being cooked with an equipment that was used to cook a non-Kosher food at a
temperature above yad soledes bo (120°F)
 Being cooked in the same space where non-Kosher foods are cooked
 Sharing a common wall with another product

Additionally, Kosher food does not allow dairy to be mixed with meat. Therefore, the equipment
used to cook dairy must not be used to cook meat. 

Kosher certification is also required before food can be marketed as Kosher food.

TOPIC 3: Organic Food Processing

Organic food processing is different from Kosher and Halal as it is not guided by religion
but of a lifestyle choice. Organic food is minimally processed and boils down to the
following restrictions:

TOPIC 2: Washing and Cleaning

Washing and Cleaning Meat
If the meat is from an accredited supplier and that proper handling and sanitation are
ensured, washing is no longer necessary. 

Washing meat before cooking it is not recommended for two things. First, cross-
contamination may occur when bacteria in raw meat and poultry juices spread on to
other food, utensils, equipment, or surfaces. Second, bacteria in the meat can only be
killed by cooking it to the right temperature so washing meat is no longer necessary. 

Washing meat for food processing will make mixtures watery and will invite microbial
growth. 

If unsure of the source, wash meat gently under cold running water and strain with a
colander before storing it in the freezer. 

Washing and Cleaning Eggs

If your eggs come from commercial suppliers, washing them is no longer
recommended. This is because washing is already a part of commercial egg
processing. Washing the eggs further will only drive bacteria into the pores of the shell. 

Freshly laid eggs have a natural coating which helps prevent bacteria from getting into
the shell. Washing will only remove this protective layer so it is not recommended. 

However, if you are unsure of the source of the egg, you may remove the dirt and
residue in the eggshells with a dry scouring pad.  

Cutting Techniques
Knife skills are one of the basic requirements in preparing raw materials for food
processing. Knowledge  of appropriate cutting tools , as well as their proper handling,
is required.

Cutting is reducing the size of fibrous material in order to prepare foods for further
processing. 

Some of the basic knife cuts in food processing include:

Mincing

Mincing is mainly done for size reduction and homogenization.

Slicing

Slicing refers to cutting food into broad or flat thin pieces.

Julienne

Julienne refers to cutting thinner and thinner lengthwise strips of food.

Rondelle

Rondelle or rounds refers a type of cut that creates round or oval, flat pieces by
cutting a cylindrical vegetable crosswise.

Filleting

Filleting is a cutting technique for cutting off meat or fish from the bone. 

Trimming

Trimming is the removal of inedible parts or parts with defects and cutting it to a size
appropriate for further processing.

Peeling

Peeling is the removal of the outer covering or skin of a fruit or vegetable. It is

achieved by mechanical cutting or by application of steam, hot water or heated air. In
large-scale operations it is done through abrasion or caustic peeling.

In knife peeling, fruits and vegetables are pressed against stationary or rotating blades
to remove the skin. Knife peeling is used for fruits where the skin can be easily
removed with little damage.

In abrasion peeling, the material is fed onto roller peelers or fed into a rotating bowl
line with carborundum. Abrasion peeling is ideal for root crops although it has higher
product loss than knife peeling.

In caustic peeling, a fruit or vegetable is submerged in a diluted solution of sodium

hydroxide. The skin may be then removed by mechanical scrubbers or high-pressure
water sprays.
LESSON 2: Standard Measurements and
Conversions
Next: TOPIC 1: Standard Measuring Devices and Instruments ►

Introduction
Measuring the weight and volume of ingredients is integral not only in
achieving the desired flavor but also in ensuring the consistency of products
sold to the market. Measuring ingredients also guarantees that the amount of
ingredients in a product is within health standards.

This lesson will cover the standard measuring devices and instruments for
weight and volume. It will also discuss the common measurements in food
processing as well as weight and volume conversions.

TOPIC 1: Standard Measuring Devices and

Instruments
Earlier we discussed the devices and instruments that you will find in The Food
Processing Plant. Let’s refresh your memory!
  Measuring glass – a transparent cup with marker lines used to measure
liquid ingredients.1

Measuring cups – set of marked cups used to measure dry ingredients

such as sugar and flour. They are either made of plastic, aluminum, or stainless steel.
Each cup in the set measures a specific amount as indicated on its handle.

Measuring spoons – a set of spoons used to measure small amounts of

ingredients. Each spoon in the set measures a specific amount as indicated on its
handle.
 Weighing scale – used for measuring ingredients as well as for portioning
products for service.

TOPIC 2: Measurements and Conversion

Common Measurements in Food Processing

Measurement Equivalent
Pinch 1/8 tsp
1 tbsp 3 tsp
2 tbsp 1 oz
4 tbsp ¼ cup
8 tbsp ½ cup
12 tbsp ¾ cup
16 tbsp 1 cup
1 cup of liquid ½ pint
2 cups of liquid 1 pint
4 cups of liquid 1 quart/ 1 liter
2 pints of liquid 1 quart
4 quarts 1 gallon
16 ounces 1 pound
1 pound 454 grams

Weight and Volume Conversions

Weight ounces (net wt oz) are used in measuring dry food while volume ounces (net fl
oz) are used in measuring fluid substances and food products. When products are
labeled in grams (g) and milliliters (mL), knowledge of weight and volume conversions
might come in handy.

Weight Conversion

To convert ounces to grams, multiply the number of ounces by 28.35

¼ oz 7g
 ½ oz 14g
1 oz 28g
4 oz (1/4 lb) 113g
8 oz (1/2 lb) 227g
16 oz (1 lb) 454g
24 oz (1 ½ lb) 680g
32 oz (2 lbs) 907g
40 oz (2 ½ lbs) 1.13kg
48 oz (3 lbs) 1.36kg

Volume Conversion

To convert fluid ounces to milliliters, multiply the number (fl oz) by 30

1 tsp (1/6 fl oz) 5 ml

1 tbsp (½ fl oz) 15 ml
2 tbsp (1 fl oz) 30 ml
1 cup (8 fl oz) 240 ml
1 pint (16 fl oz) 480 ml
1 qt (32 fl oz) 960 ml
1 gal (128 fl oz) 3.84 L

Detergents remove dirt and grease but they do not kill bacteria and other
microorganisms. This is why cleaning is followed by sanitizing.

LESSON 3: Quality Control Parameters

Next: TOPIC 1: Total Soluble Solid ►

Introduction
 Quality control parameters are quantitative measures of the physical and chemical
characteristics of processed food. This lesson will discuss what these parameters are
and how to measure them.

1. Total Soluble Solid

2. Temperature

3. Salinity

4. Moisture Content

5. Water Activity

6. pH

LESSON 4: Production Report and

Costing
◄ Previous: IntroductionNext: TOPIC 2: Computing Production Cost ►

TOPIC 1: Making the Production Report

When working for a food processing plant or running a small-scale food processing
business, it is important to make production reports to monitor productivity, cost-
efficiency, and quality. 

Production reports are a good reference for checking the amount of input, rejects,
finished products, as well as quality parameters. Production reports also generate data
about how the business is doing.  

A good production report is a precise production report. 

TOPIC 2: Computing Production Cost

When computing production costs, consider two types of expenses: direct and indirect
costs.

Direct cost pertains to expenses that are directly connected to producing an output.

This includes raw materials, packaging materials, and direct labor. Direct costs can be
further classified as fixed or variable. Fixed direct cost includes labor wages which
remain constant throughout the year. Variable direct cost includes raw materials and
ingredients whose prices vary depending on seasonality and quantity ordered.

Indirect cost pertains to expenses that are not directly connected to an output but is
necessary for maintaining the entire operation. Indirect costs are classified as either
fixed or variable. Fixed indirect costs include rent and equipment. Variable indirect costs
include electricity, water, and gas.

A production period can be a week, month, or quarter during which production activity

is undertaken.  

To compute for total production cost, add direct and indirect costs for an entire
production period.

To determine the production cost per unit of the product, divide the total cost by the
number of units produced within the entire production period.

Cost-Based Pricing