EXPERIMENT NO.

4
ESTABLISHMENT OF PROCESS AND PRODUCT SPECIFICATIONS

INTRODUCTION

In Quality Management, a large number of documents and certificates related to the

purchased products and raw materials are required. One of the most important product related
documents is the product specification. This document contains a detailed description of the
product, all the requirements related to the production process as well as technical and
functional aspects of the product (Duteil, 2016).

Outline process plans include raw material specifications and quantities, process flow charts
and processing conditions, product quality specifications, process control points and product
testing methods. Final specifications include the raw material specifications, the product
formulation, the process flow chart, the processing conditions in the individual unit operations, a
preliminary HACCP analysis of the process, the testing of the intermediate and the final
products, and the final product qualities. These are based on only preliminary production runs
and can change during the commercialization. The product and process specifications give
excellent information for a feasibility study and for the evaluation of the product before the very
expensive step of commercialization is attempted (Earle, M.E. & Earle, R., 2009).

The general content of a product specification document includes production method,

identification, ingredients, delivery, expiration date, transport and storage, package size,
possible contamination; location; sensory properties like appearance, color, smell, taste,
texture; nutritional values; declaration of allergens; microbiological limits; chemical - physical
properties; dispatch and storage methods; labeling; certificates; quality management methods;
and manuals (Duteil, 2016).

The specification documents is useful on all stages of the production process, on the
suppliers and producer sides as well as on the buying company side which can use this
document as a quality standard required at the delivery.  In some industries such as in the food
industry, the number of protocols and documents required during the production process can
quickly skyrocket to guarantee food safety and a higher food quality. To meet this goal and
standard, the food product and raw material specifications sheets primarily inform about the
ingredients of each product and its condition of production (Duteil, 2016).

This experiment aimed to assess the most suitable requirement for a quality parameter of a
raw material of an intended finished product, to identify the controllable parameters in the
processing of food products, and to determine the quality parameters of product produced
according to established standards.

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METHODOLOGY

Pre-lab Activity Production

Pre-production Storage
Preparation

Figure 1. Schematic Diagram for the Establishment of Process and Product Specifications

Pre-lab Activity

One week prior to the experiment, each group was assigned to decide and to research on
their own specifications for the raw material and final finished product. The ingredients as well
as the process flow were written. A monitoring form applicable for the process and product was
also designed. For this experiment, the researchers decided to produce calamansi juice (refer
to the monitoring form for more details).

Pre-production Preparation

The different parameters that can measure quality for each raw material were identified.
Also, the appropriate quality parameter for each raw material using proper tools was described
and measured (refer to the monitoring form for more details).

Production

The raw materials and utensils were prepared. The process flow was also indicated based
on the process found in the monitoring form as well as the monitoring. The finished product was
packed and stored accordingly with proper labeling of products ensured.

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Storage

After one week of storing the product, the packaging of the product was observed whether
the integrity was maintained as well as the leakages if found. The product was opened and
evaluated accordingly. The product was described according to the identified quality
parameters through sensorial analysis. Then, observations were recorded.

The attached file is the process and product specification for calamansi juice.

PROCESS AND PRODUCT SPECIFICATION FOR CALAMANSI JUICE

Table 1. Raw Material Specifications for Calamansi Juice Processing
Raw Material Quality Parameter Requirement
Color Yellow-green to Yellow-orange
Texture Fairly smooth
Calamansi Firmness Not soft nor flabby
Defects Free from mechanical defects
Diameter 2.0-2.8 cm
Color Clear
Odor Odorless
Distilled Water Taste Tasteless
pH 5.0-7.5
Color Brown
Sweet, free from fermented, musty
Brown Sugar Odor or undesirable odors
Texture No lumping, free flowing crystals

Table 2. Process Specifications for Calamansi Juice Processing

Process Control Parameters Requirement
Washing Water to be used for washing Clean, sanitized
Slicing Area to be sliced Cross-sectional
Seeds Little to no seeds in extract
Extraction Manual extractor Clean, sanitized
Time 15 seconds
Pasteurization Temperature 80°C
Filling Minimum Fill Not less than 90% of container
Cooling Temperature Room Temperature (23°)

Table 3. Final Product Specifications for Calamansi Juice Processing

Final Product Quality Parameter Requirement
Color Yellow liquid
Sensorial Properties Flavor Sweet with a hint of sour
Odor Tangy, sour with a hint of sweet
% Headspace 10% headspace

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 pH Not less than 2.0
Physicochemical Properties % Titrable Acidity Not less than 4.50%
Total Soluble Solids 6.0% m/m
Bottle Clear glass or plastic
Packaging and Storage Bottle cap Tight seal
Storage Temperature Room Temperature (23°)

Fruit Receiving Packaging Storage

Cleaning Mixing of
Sorting of Fruit Ingredients

Washing of Juice
Fruit Extraction

Figure 2. Process Flow of Calamansi Juice Processing

Table 4. Monitoring Form for Raw Material for Fresh Calamansi Juice
Raw Material Quality Parameter Observations
Color
Texture
Calamansi Firmness
Defects
Diameter
Color
Odor
Distilled Water Taste
pH
Color
Brown Sugar Odor
Texture

Table 5. Monitoring Form for Processing for Fresh Calamansi Juice

Process Control Parameters Observations
Washing Water to be used for washing
Slicing Area to be sliced

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 Seeds
Extraction Manual extractor
Time
Pasteurization Temperature
Filling Minimum Fill
Cooling Temperature

Table 6. Monitoring Form for Fresh Calamansi Juice

Final Product Quality Parameter Requirement
Color
Sensorial Properties Flavor
Odor
% Headspace
pH
Physicochemical Properties % Titrable Acidity
Total Soluble Solids
Bottle
Packaging and Storage Storage Temperature

Table 7. Monitoring Form for Raw Material for Fresh Calamansi Juice after 1 Days Storage
Raw Material Quality Parameter Observations
Color
Texture
Calamansi Firmness
Defects
Diameter
Color
Odor
Distilled Water Taste
pH
Color
Brown Sugar Odor
Texture

Table 8. Monitoring Form for Processing for Fresh Calamansi Juice after 7 Days Storage
Process Control Parameters Observations
Washing Water to be used for washing
Slicing Area to be sliced
Seeds
Extraction Manual extractor
Time
Pasteurization Temperature
Filling Minimum Fill

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Table 9. Monitoring Form for Fresh Calamansi Juice after 7 Days Storage
Final Product Quality Parameter Requirement
Color
Sensorial Properties Flavor
Odor
% Headspace
pH
Physicochemical Properties % Titrable Acidity
Total Soluble Solids
Bottle
Packaging and Storage Storage Temperature

RESULTS

Table 1. Raw materials specifications for calamansi juice.

Raw Material Quality Parameter Requirement

Color Yellow-green to Yellow-orange
Texture Fairly smooth
Calamansi Firmness Not soft nor flabby
Defects Free from mechanical defects
Diameter 2.0-2.8 cm
Color Clear
Odor Odorless
Distilled Water Taste Tasteless
pH 5.0-7.5
Color Brown
Sweet, free from fermented, musty
Brown Sugar Odor or undesirable odors
Texture No lumping, free flowing crystals

Table 2. Process specifications for calamansi juice.

Process Control Parameters Requirement

Washing Water to be used for washing Clean, sanitized
Slicing Area to be sliced Cross-sectional
Seeds Little to no seeds in extract
Extraction Manual extractor Clean, sanitized
Time 15 seconds
Pasteurization Temperature 80°C
Filling Minimum Fill Not less than 90% of container
Cooling Temperature Room Temperature (23°)

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Table 3. Physico-chemical properties of Calamansi juice.

TSS %TA pH
Day 0
22.17 0.0139 2.46
Week 1
Bottle 1 25.73 0.02997 2.74
Bottle 2 25.07 0.0822 2.76

DISCUSSION
Food of high quality can be produced from raw materials of high quality; therefore, careful
attention must be paid to the cooperation between the producer of raw materials and the
processors.

In this specific experiment, raw food materials — such as its ingredients, processing aids,
and packaging materials — are the foundation of processed food products; therefore,
regulatory requirements must be met for it to be safe and legal for its intended use and the
specifications should contribute to the functionality and quality of the process and product
(Amsbary, 2013).
Appropriate raw materials must be selected based on functionality. Functionality
encompass multiple requirements based on finished product’s identified characteristics:
binders, thickeners, type of resin for plastic packaging, etc.; organoleptic characteristics: aroma,
color, flavor and texture; product safety characteristics which aids in lowering the pH or water
activity aw, additives such as sugar, salts, esters, and organic acids; lastly, preservatives for the
extension of shelf life, color or flavor retention, and others. In the past, food safety concept was
not critically emphasized. Research and development were two separate activities wherein
teams worked in complete isolation, but as of today convergence of all teams put in their
expertise due to increase access to unique and complex materials, global sourcing handling
methods, customer locations, and regulations. The unified team assess’ if the material has
limitations or may be expensive to handle, and determines if additional measures are necessary
to prevent potential safety issues for the employees and product (Pathshala, n.d.).
Raw food material that contains parasites and other unwanted objects should not be
considered as a source for the production of a developed food by the manufacturer so as to
avoid complications in processing a quality food product. Since the quality of raw materials
used influences the total quality of the finished food product.
A product is said to be of desired quality when it complies with the specification as well as
customer’s requirements and expectations and when it displays basic, performance and
excitement functionalities. Products are being produced by manufacturing processes. Also,

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quality cannot be tested into the product. It is to be built in the product by the manufacturing
process during its manufacturing. One of the main factors which affect the quality of the product
is the quality of the manufacturing process which produces the product. Sound and reliable
processes produce quality products; hence, improving the quality of the manufacturing
processes is a precondition for better product quality at an acceptable cost (Satyendara, 2016).
Attaining of the defined and consistent levels of the product quality levels is achieved by
ensuring that the manufacturing processes remain stable and robust while operating them.
In the production of Calamansi juice, these where the physico-chemical properties that
were observed: Total Soluble Solids (TSS), Titratable Acidity (TA), and the pH of the juice that
was produced. Water was added in the solution so as to make the juice not that very
concentrated and give-off a strong flavor of the acidity. Water used in food production has to
fulfill requirements from the microbiological, biological, physical, chemical, and radiological
points of view, as mentioned earlier. Water serves as a reactant in the system, as in such
hydrophilic reactions as sucrose hydrolysis or lipolisis depending upon its usage (Davídek,
2001).
Having specified the quality parameters of raw materials allowed the product to attain its
acceptance rate just by interpreting individual perception of the ten correspondents to whom
nonetheless did not give a negative review in criticizing the Calamansi juice’s flavor, odor, and
taste which is particularly sensitive to individuals overview (refer to Table B in the Annex section
for credits). The product was also able to survive a week of refrigerated storage which meant
that the whole process were generally hygienic and that the work place was sanitized properly
before conducting the procedures in making the Calamansi juice.
The importance of standardizing the recipes in processing a specific food product, as told
by the United States Department of Agriculture (USDA): a standardized recipe has been found
to produce the same good results and yield every time when the exact procedures are used
with the same type of equipment and the same quantity and quality of ingredients.
The essential ingredients in producing a processed Calamansi juice were more or less
modified by the experimentees, such as the amount of sugar to be added on a 1L distilled water
with 300mL concentrated juice of Calamansi. The amount of sugar was altered based on the
sweetness or sourness prefered by each individual. The downside to this is that when
ingredients are substituted, amounts are altered, or alternate cooking equipment is used, the
recipe will lose its standardization and will need to be adjusted accordingly. Recipes can be
adjusted either manually utilizing arithmetic skills or simply by using common knowledge
(Health Meals, n.d.).
Standardized recipe produces a consistent quality and yield every time when the exact
procedures, equipment, and ingredients are used (UC Davis, n.d.).
Here are some of the benefits of standardized recipes: consistent food quality, predictable
yield, customer satisfaction, consistent nutrient content, food cost control, efficient purchasing
procedures, inventory control, labor cost control, increased employee confidence, reduced
record keeping, and etc. Consistent food quality is the result for ensuring menu items that are
based on standardized recipe in order to offer a consistent quality of food served and prepared
every time. A predictable yield is especially important when food is transported from a
production kitchen to other serving sites. Considered to be first on top of a list of a producer

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when developing a product, standardized recipes provide this consistency which results to
customer satisfaction. Ensuring the nutritional values of food per serving are the results of a
standardized reciper for consistent nutrient content. Standardized recipes provide consistent
and accurate information for food cost control because the same ingredients and quantities of
ingredients per serving are used each time the recipe is produced. And so on and so forth for
each of the benefits on strictly following a standardized recipe (Healthy Meal, n.d.).

CONCLUSION AND RECOMMENDATIONS

Specifications of the product being developed is important because it ensure the

consumers’ expectations in a product’s fitness for use. The product is said to be of desired
quality when it complies with the specification as well as the customer’s requirements and
expectations, displays basic, performance and excitement functionalities. Moreover, raw and
packaging materials to be used must be inspected and checked thoroughly through conducting
specific quality parameter analysis since the quality of raw materials used influences the total
quality of the finished food product. In addition, it must also be from defects to minimize in order
to provide higher-quality products. Correspondingly, nonconforming raw materials should also
be recorded and investigated to identify and rectify problems. Also, the raw materials should be
purchased to agreed-upon specifications from suppliers capable of achieving the specifications
of the product.
In the production of Calamansi juice, the most suitable analysis such as the total soluble
solids (TSS), titratable acidity (TA), and the pH of the juice was tested to ensure the overall
quality of the product.
It is recommended that the future researchers should follow and observe the process flow
of the product being produced correctly to minimize and avoid future problems in the quality of
the finished product.

REFERENCES

Amsbary, R. (June 12, 2013). Raw Materials: Selection, Specifications, and Certificate of

Analysis. Quality Assurance & Food Quality. Retrieved from

http://www.qualityassurancemag.com/article/aib0613-raw-materials-requirements/ on April

26, 2018

Davídek, J. (August 3, 2001). QUALITY CONTROL OF RAW MATERIALS. FOOD QUALITY

AND STANDARDS – Vol. II - Quality Control of Raw Materials - Jiri Davidek. Institute of

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 Chemical Technology, Prague, Czech Republic. Retrieved from

https://www.eolss.net/sample-chapters/C10/E5-08-03-01.pdf on April 27, 2018

Duteil, B. (2016). Product Specification in the Food Industry: What You Need To Know.
Retrieved on April 8, 2018. Retrieved from http://blog.ecratum.com/product-specification-
in-the-food-industry-what-you-need-to-know
Earle, M.E. & Earle, R. (2009). Product and Process Specifications and Marketing Strategy.
Creating New Foods: The Product Developer’s Guide, The Web Edition, Chapter 5.
Retrieved on April 8, 2018. Retrieved from

http://www.nzifst.org.nz/creatingnewfoods/product_design9.htm

Healty Meals. (n.d.). Standardized Recipes. United States Department of Agriculture (USDA).

Retrieved from

https://healthymeals.fns.usda.gov/sites/default/files/uploads/CDB_StandardizedRecipes.pd

f April 27, 2018

Pathshala, E.G. (n.d.). Quality and Specification of Raw Materials and Finished Products. A

Gateway to All Post Graduate Courses. Retrieved from

http://epgp.inflibnet.ac.in/epgpdata/uploads/epgp_content/food_and_nutrition/02._food_saf

ety_and_quality_control/02._quality_and_specification_of_raw_materials_and_finished_pro

ducts/et/7353_et_et.pdf on April 25, 2018

Satyendara. (October 1, 2016). QUALITY OF PRODUCTS AND PROCESS CONTROL.

Retrieved from http://ispatguru.com/quality-of-products-and-process-control/ on April 26,

2018

UC Davis Center for Nutrition in Schools. (n.d.). Recipe Standardization Steps. Retrieved from

https://cns.ucdavis.edu/sites/g/files/dgvnsk416/files/inline-

files/recipe_standardization_steps.pdf April 27, 2018

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ANNEX

Table A.1 Raw data for Processed Calamansi Juice Quality Parameters
Day 0
TSS pH %TA Headspace 1 Headspace 2
2.44 @
26.9ºC
1 22.1 10.5 45.325 40.0
2.48 @ 10.5－
26.9ºC 20.4=10.1
2 22.3 44.4 40.35
2.47 @
26.9ºC
3 22.1 20.4－30=9.6 44.45 40.40
Mean Ave.: 22.17 2.46 10.07－0.3 44.725 40.25
VolNaOH: ---- ---- 9.77 ---- ----
---- ---- 0.01389 ---- ----

Table A.2 Raw data for Processed Calamansi Juice Quality Parameters
Refrigerated storage for 1 week
Bottle 1 TSS pH %TA Headspace
1 25.7 2.75 21.7 43.15
2 25.8 2.74 21.6 43.30
3 25.7 2.72 20.8 43.25
Mean Ave.: 25.73 2.74 21.37－0.3 43.23
VolNaOH: ---- ---- 21.07 ----
---- ---- 0.02997 ----
Bottle 2
1 25.0 2.78 20.2 46.0
2 25.1 2.76 18.9 46.30
3 25.1 2.75 19.1 47.35
Mean Ave.: 25.07 2.76 58.2－0.4 46.55
VolNaOH: 0.4 ---- ---- 57.8 ----

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 ---- ---- .08220 ----

Table B.1 Sensory evaluation for Processed Calamansi Juice (Day 0)

Number of Parameters
Correspondents
Color Flavor/Taste Odor
Sweet; sour
aftertaste
1 Golden yellow Sour odor
Clashing of sour & Calamansi odor,
sweet; acidic not strong odor
2 Urine yellow
Not too sour; sour
aftertaste
3 Dark yellow Citrusy odor
Just the right
amount of
sweetness;
4 Dandelion suggestion: add Sweet and not that
more sourness sour odor
Concentrated,
astringent; sour,
5 Urine yellow Hint of sweet smell
but a little sweet
and citrusy
Concentrated; Not strong
bitter aftertaste calamansi scent
6 Urine yellow
Faint calamansi
smell
7 Urine yellow More on sweetness
Sour with a little bit Calamansi odor
sweetness with sweet odor
8 Dark yellow
Calamansi; sweet
odor
9 Yellow-orange Sour & sweet taste
Calamansi-like; not
that strong
10 Dull yellow sour

Table B.2 Sensory evaluation for Processed Calamansi Juice (Refrigerated storage for 1
week)

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 Number of Parameters
Correspondents
Color Flavor/Taste Odor
Not bitter, sweet Sour taste can be
with a tinge of determined, mix
1 Yellow-orange
sourness sweet & sour odor
Sour with a sweet
aftertaste; sweet
2 Dark yellow Honey-like odor
like honey
3 Light yellow Sweet at first; sour Sweet, citrusy
afterwards smell
4 Light yellow Sweet & sour Sweet & sour odor
5 Urine yellow sour citrusy
6 Light yellow Sweet & sour Citrusy (calamansi)
Sour
(concentrated)
7 Pale yellow Slightly sweet odor
Sour (slightly
concentrated)
8 Hazy yellow Citrusy (calamansi)
Balanced
sweetness
9 Hazy bright yellow Sweet odor
10 Pale yellow Extremely sour Fishy

Sample Calculations

Determination of Titratable Acidity

V NAOH×N NAOH×meq. weight of predominant acid

%Titratable Acidity= ×100
Weight of sample ( g )

Where:
VNaOH = volume (ml) of NaOH used in titrating the sample (corrected for the blank)
NNaOH = normality of NaOH used (0.1 eq/L)
Meq. weight = milliequivalent weight of acid (use 0.090 g/meq for lactic acid)

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Predominant acid = citric acid = 0.064 g/meq
Volume of sample per bottle = 450 mL

9 . 77 mL×0 . 1N NaOH ×0 .064 meq . wt . of citric acid

%Titratable Acidity= ×100= . 013895
450 mL

DELGADO, LYNN MARIE (2015-10524)

MAAGMA, MARY ABBYGAIL P. (2015-03913)
SOLAS, ANGELIQUE MARIE (2015-06499)

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