Department of Science and Technology

INDUSTRIAL TECHNOLOGY DEVELOPMENT INSTITUTE

Food Processing Division
Outline

1. Food Spoilage 6. Pineapple Jam

2. Food Preservation Processing
3. Jams 7. Business Opportunity
4. Pineapple Plan (BOP) Summary
5. Current Good
Manufacturing Practices
FOOD Spoilage &
Preservation
Food Spoilage
Is the process in which food
deteriorates to the point it is
unacceptable for
consumption.

Occurs thru microbiological,

chemical, or physical
changes in the food.
Causes of Food Spoilage

Microorganisms
Produce substances which alter the colour, texture and odour of the
food, making it unfit/unsafe for human consumption.

Enzymes
Substances that are naturally present in food – responsible for the
ripening process of fruits and vegetables or produced by
microorganisms.
Example: Enzymatic browning

Purely Chemical Reactions

Not catalyzed by enzymes.
Example: Rancidity of fats and oils

Insects, Pests, Rodents

Damage food making it more vulnerable to further deterioration.

Physical Changes
Increases the chance of chemical and microbial spoilage.
Examples: Dried food absorbs moisture, bruises or injuries in fruits
and vegetables

Frazier and Westhoff (1988); Petruzzi et al. (2017)

Food
Preservation
Is the process of treating and
handling food to stop or slow down
food spoilage, loss of quality,
edibility, or nutritional value; thus
allow for longer food storage.

Reasons for Preserving Food:

✓ Shelf life extension
✓ Safety
✓ Acceptability
✓ Nutritive value
✓ Availability
✓ Economic value
 Food Preservation Methods
Heat Treatment: Most widely used process for food preservation.

Blanching Pasteurization Sterilization

• Used mainly for vegetables and Mild heat treatment (<100 °C) to destroy Severe heat treatment to achieve
some fruits prior to freezing to pathogens, reduce bacterial load, commercial sterility and shelf life
inactivate enzymes that could inactivate enzymes, and extend shelf life. extension (2 or more years).
deteriorate food during frozen
stage.
• Involves dipping the vegetable in
boiling or near-boiling water for
1-3 minutes.
Rahman, 2007; Vaclavik and Christian, 2008
Food Preservation Methods
Freezing
Refrigeration

• Food is held at colder temperatures than refrigeration

(below 0°C).
• Can extend shelf life of food by years in some cases.
• Foods held at temperatures below 5℃. • In freezing, microorganisms are dormant and there is
• Effective in retarding bacterial growth. no multiplication occurs.
• Often used in conjunction with other
preservation methods (e.g. heating,
controlled atmospheric conditions, packaging
materials).
Vaclavik and Christian, 2008
Food Preservation Methods

Drying Dehydration

Drying/Dehydration reduces moisture and water activity, thus preserving

foods by precluding microbial growth and deteriorative chemical reactions.

Methods: Sun drying, Solar drying, Mechanical drying (Cabinet drying),

Drum drying, Freeze drying, Spray drying

Rahman, 2007; Vaclavik and Christian, 2008

Food Preservation Methods

Added Preservatives
1. Acid
May be naturally present in foods (e.g. citrus fruits, tomatoes).
Combination of heat and acid provides more effective
preservation.
2. Sugar
It reduces the amount of free water available for bacterial
growth.
3. Salt
Predominantly used for dry/wet curing (e.g., curing of bacon,
ham, as brine)
4. Chemicals
• Food grade organic acids, humectants (e.g., sorbitol,
propylene glycol, glycerol, lecithin)
• Subject to FDA approval.
Smith and Stratton, 2007
Pineapple
Jam
Processing
Jams
• Is the product brought to a suitable consistency,
made from the whole fruit, pieces of fruit, the
unconcentrated and/or concentrated fruit pulp
or fruit puree, of one or more kinds of fruit,
which is mixed with foodstuffs with sweetening
properties with or without the addition of
water.
• Total Soluble Solids (TSS): 60-65%*
• Good jams have soft, thick, smooth, and even
consistency.

*CODEX Alimentarius (2009)

 Jams: Common Problems
Jam Problems Prevention
Too stiff • Use the right maturity of fruit/raw material.
• Do not overcook.
Syneresis (Pagtutubig) • Balance acid and sugar.
• Do not store in a place that is too warm.
Discoloration • Use food-grade metals when preparing jams.
• Do not prolong cooking.
• Transfer jams (while hot) in glass
jars/container.
Sugar Crystals • Establish the exact end point of cooking.
• Do not overcook.
• Follow the amount of sugar in the recipe.
Presence of bubbles • Skim foam before filling in jars.
• Pack immediately after cooking to prevent
jams from partial gelling.
Mold and Yeast • Ensure proper handling and storage.
Meimann, L. (2018). Jam and Jelly Problems? Iowa State University Retrieved from
https://blogs.extension.iastate.edu/answerline/2015/07/09/jam-and-jelly-
problems/
 Nutritional Value of Pineapple
Pineapple
• Ananas comosus Merr. of the family
Bromeliaceae.
• An introduced species in the country.
• Herbaceous plant with long, narrow,
stiff leaves usually armed with sharp
spines along each margin except in a
few varieties.
• One of the major tropical fruits in the
country
• 3rd most important crop in terms of
agricultural crop area and value of
production (FAO, 2007).
Pineapple

• It has been suggested (Neild and Boshell, 1976; Py et al., 1987) that
optimal growth temperature lies between 20 to 30°C, and more
specifically at 23 - 24°C. When ambient temperature drops to 10-16 C,
fruit growth is constrained. Plants may stand sub-freezing
temperatures for very short periods. Conversely, exposure to
temperatures well over 30 °C heat damage may occur due to
increased respiration rate and metabolism and impaired nutrient
absorption (FAO, 2005).
PINEAPPLE
QUEEN Common varieties in the Philippines:
Queen (Formosa)
• Sweetest cultivar
• Fruit is small (0.45-0.95 kg), oblong
• With small and deep prominent eyes
• The leaves are spiny
• Golden yellow pulp is crispy and sweet (14-18 °Brix)
• Good for fresh consumption, dried candy

Esguerra NM, Del Rosario AG, Taro T. 2015. Manual on Crop Production in
Upland Areas of Palau. College of Micronesia, Palau Community College
Philippine National Standard (PNS/BAFS 09:2004)
PINEAPPLE
HAWAIIAN Common varieties in the Philippines:
Smooth Cayenne (Hawaiian)
• Matures in 18 months
• Has bigger fruits and cylindrical in shape (2.3-3.6 kg)
• Bigger flat eyes, not prominent
• Small crown
• Long and broad leaves and spineless
• High acid and sugar content (13-19 °Brix)
• Good for canning

Esguerra NM, Del Rosario AG, Taro T. 2015. Manual on Crop Production in
Upland Areas of Palau. College of Micronesia, Palau Community College
Philippine National Standard (PNS/BAFS 09:2004)
 PINEAPPLE
RED SPANISH Common varieties in the Philippines:
Red Spanish (Native Philippine Red)
• Small to medium fruit (0.91-1.4 kg)
• Cone shaped
• Eyes are relatively large
• Has bright red color once ripe
• Medium quality; Pale yellow flesh
• Fruit has no commercial value
• Mature leaves are excellent source for piña fibers

Philippine National Standard (PNS/BAFS 09:2004)

 Top 5 Pineapple Producing Countries in the World
Production
Rank Countries
(tonnes)
1 Costa Rica 3,418,155
2 Philippines 2,730,985
3 Brazil 2,650,479
4 Thailand 2,113,380
5 Indonesia 1,805,506
Source: FAOSTAT (2020)
 Pineapple Production by Region, 2019
Rank Regions Production, metric ton
1 Region 10 (Northern Mindanao) 1,583,704
2 Region 12 (SOCCSKSARGEN) 810,436
3 Region 5 (Bicol Region) 163,274
4 Region 4-A (CALABARZON) 84,249
5 Region 2 (Cagayan Valley) 36,057
Source: Philippine Statistics Authority (PSA)
Current Good Manufacturing Practices (cGMP)
is a quality assurance system aimed at ensuring
that products are consistently manufactured,
packed, repacked, or held to quality standards
appropriate for the intended use.

Food Safety Act of 2013 (R.A. 10611)

Bakit higit na mabuti ang magpatupad ng GMP?
• Upang mapanatili ang tiwala at kumpiyansa ng mga mamimili.
• Upang itaguyod at pangalagaan ang karangalan ng kumpanya o
establisyamento bilang tagagawa ng mataas na kalidad na produkto.
• Upang maiwasan ang mga pagsasauli ng mga depektibong produkto,
kahihiyan dulot ng mababang uri ng produkto, at posibleng demanda sanhi
ng pagkalason o pagkakasakit ng mamimili.
• Upang hindi maging matagal at madalas ang pagkaantala ng produksyon.
• Upang hindi mabilis ang pagkasira ng mga kagamitan
• Upang hindi mabinbin o maantala ang pagbawi ng puhunan
 Food Hazards

Physical Biological Chemical

Also called as foreign objects Organisms, or substances
that can cause mild to severe produced by organisms, that
injuries in consumers. pose a threat to human
health (infection,
• Glass intoxication)
• Metal
• Plastic • Bacteria
• Bone • Molds
• Human/Animal hair • Yeast
• Bird’s feather • Virus
• Parasites
• Pests/Insects
Can contaminate food if not
stored properly.
• Food additives
• Insecticides
• Pesticides
• Vet drugs
• Natural toxins
• Chemical cleaning agents
Components of cGMP

Organization Premises Equipment Sanitation and Hygiene Production & Documentation

Process Controls

Sub-contracting of
Quality Audits Warehousing & Production Recall Retention Samples Manufacture
Distribution
 Components of cGMP
Sanitation and Hygiene
• Personnel

Source: FB page of PAFT-Alpha

• Do not handle foods if you are sick
• Always tell your employer when
you are feeling ill.
Components of cGMP
Sanitation and Hygiene
• Hygienic Practices
✓ Handwashing
Raw Materials Equipment/Utensils

Stainless steel casserole

pot or double boiler
Weighing Scale casserole pot
White Refined
Sugar
Pineapple

Laddle
Packaging
Blender
Knife and
chopping board
Stove

Glass jar with lid

Pineapple Jam Processing
Integrity of Shape
1. Sorting
Uniformity
- Process of collating/ classifying items
according to specific criteria Freshness
▪ Quality of raw material = Quality of final project
Ripeness or Maturity
▪ PASS vs REJECT
Juiciness

Flavor
Ripening Chart
Maturity Indices
- External and Internal Fruit characteristics
- External indices includes:
- Fruit surface color
- Extent of fruitlets (eye) flatness
➢ Mature progressively from the bottom part of the fruit to the top
- Fruit size and weight
- Internal indices:
- TSS
➢ <12% (near the base); 10% near the top
- Appearance
Pineapple Jam Processing
2. Washing and Cleaning

This is to remove soil / dirt and chemical

residues from the raw material.

Do not wash fruits

with detergent or Wash
soap. pineapples
thoroughly in
cold running
tap water.
Drain.
Pineapple Jam Processing
3. Sanitizing
- Reduction of microorganisms to level that is
considered safe for consumption
- Methods:
• Thermal
• Use of hot water or steam
• Generally more expensive due to use of heating
equipment
• Chemical
Soak in 100 to 200ppm chlorine solution for 10 minutes.

Preparation of sanitizing solution:

200 ppm – 15 ml chlorine : 1 gallon water

100 ppm – 7.5 ml chlorine : 1 gallon water
Pineapple Jam Processing

4. Peel the fruits and remove

the eyes and core.
PUREE
5. Wash and chop finely or mash
the fruits to create a puree or may
use of a blender.
Pineapple Jam Processing
6. Weigh the fruit and mix well with
refined sugar (1 part fruit: ¾ to 1 part
sugar). If the mixture is too sweet, add
calamansi juice as desired.
7. Cook with constant stirring for 30
minutes or until thick and of the right
consistency. You may check if the jam
is cooked by dropping a teaspoon into
a bowl of water. If the drop forms a
lump, it means the jam is ready.
Pineapple Jam Processing: Packaging
Sterilization of Glass Jars and Lids

Image Source: Herstylecode

Pineapple Jam Processing: Packaging
8. Pack the mixture while still
hot in sterilized glass jar and
seal tightly. Leave at least ¼
inch headspace.

9. Process in boiling water

bath for about 15 minutes.

10. Cool, wipe dry and

store.
Pineapple Jam Processing: Packaging
HEADSPACE Requirement
Headspace: refers to the volume in a
container not occupied by the food and the
packing medium (PNS, 2006)
8. Pack the mixture while still
hot in sterilized glass jar and
seal tightly. Leave at least ¼
inch headspace.
9. Process in boiling water
bath for about 15 minutes.
10. Cool, wipe dry and
store.
Pineapple Jam Processing: Packaging
8. Pack the mixture while still
hot in sterilized glass jar and
seal tightly. Leave at least ¼
inch headspace.

9. Process in boiling water

bath for about 15 minutes.

10. Invert (5-15 minutes),

cool, wipe dry and store.
Pineapple Jam Processing: Packaging
Packaging must serve three purposes:
1. containment of the product;
2. protection of the product;
3. communication of information about the
product (labeling)

Glass container is ideal for packaging sugar concentrated products because:

• No chemical reactions between the container and the contents;
• Non-toxic;
• Clear and transparent, growth of molds can be easily detected;
• Reusable as long as it is washed and sterilized;
• High temperature resistance;
• Impermeable, if properly sealed, gas and liquid cannot contaminate the
contents.
 Pineapple Jam Processing: Packaging
Food labels Storage
- communicate the ingredients and
manufacture details of the product as well as Temperature requirement
catch the attention of the consumer. - Room temperature

• Labels must contain the following: Shelf life:

✓ Brand name;
✓ Product’s name;
✓ Manufacturer’s name;
✓ Place of production;
✓ Ingredients;
✓ Manufacturing and expiration dates;
✓ Net weight or gross weight

Source: Philippine Consumer Act (Republic Act No. 7394)

Common
Quality
Control
Tests for
Jams
Total Soluble Solids
- Expressed as °Brix.
- Measurement of the concentration or
% sugar in the given sample using
Refractometer. 3. Read the
measurement value
where the boundary
line intersects the scale.
2. Close the Daylight
plate.

1. Place sample onto

the prism.
Refractometer: the instrument used to measure the
percent soluble solids, referred to as degree Brix, in
concentration of sugars expressed in terms of number of
grains of sucrose per 100 g of liquid (PNS, 2006)
 Image source: Google images

pH Measurement
- pH is the intensity or degree of
acidity of a food material.*
- pH scale ranges from 0 to 14.
- The lower the pH reading, the
more acidic the food.
- pH requirement to preserve
food: 4.6 or below

*PNS, 2006
 Water activity (aw)
- It is the amount of available water for the
growth of microorganisms.
- Measured using water activity meter.
- aw range for jams: 0.82-0.94*

Water Activity Meter

Water Activity Meter Dishes (Sample Dish)
*Schmidt and Fontana (2007)
Direct Materials

Pineapple
Quantity
15 kg
Cost
555.00 Business
Refined Sugar 5 kg
subtotal
250.00
805.00 Opportunity
Utilities:
Electricity 0.01 kWh 1.60 Plan (BOP)
LPG
Water
1 kg
0.25 m3
subtotal
63.63
15.00
80.23
Summary
Labor: for Pineapple Jam
Manpower (Php 542 per day) 1 542.00 Production
Packaging Materials: Disclaimer:
▪ The numbers provided herein are assumptions made by the
Glass Bottle /Jar @250g 40 pcs 400 ITDI Business Development Section based on available data.
Users of these information are encouraged to conduct due
TOTAL PRODUCTION COST PER DAY 1,827.23 diligence based on their actual resources and knowledge.
▪ Costs are rounded off to the nearest thousands.
Unit Cost per Bottle 32.16 ▪ Administrative and Selling Expenses are not included in the
Selling Price per Bottle 38.59 computation.

Business Opportunity Assessment:

For a one-year operation Investment Cost: Php 717,000.00
RETURN ON INVESTMENT 96%
PAYBACK PERIOD, in YEAR(S) 1.04
Suppliers of Glass Jars
Department of Science and Technology
INDUSTRIAL TECHNOLOGY DEVELOPMENT INSTITUTE
Food Processing Division