UNIT 1: INTRODUCTION TO FOOD PROCESSING

LESSON: 1: The Food Processing Industry Personnel

Food processing is concerned with converting raw agricultural products for consumption.

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

CAREER OPPORTUNITIES:
1. FOOD PRODUCTION WORKER- Receiving food items and ensuring appropriate storage
2. PACKAGING STAFF/PACKER- Assembling containers and packaging
3. QUALITY CONTROL STAFF- Inspecting, testing or measuring raw materials

TOPIC 2: Professional Work Habits of a Food Processing Worker

DO’s:
1. Participate in workplace meetings and discussions.
2. Complete relevant work-related documents.
3. Identify role and responsibility within team.
4. Set and meet work priorities.

LESSON 2: The Food Processing Plant

TOPIC 1: The Food Processing Facility
A food processing facility is a facility where food for human consumption is:
 Manufactured;
 Packaged;
 Labeled; and
 Stored.

UNIT 2: Fundamentals of Food Processing

LESSON 1: Principles of Food Processing

Food is processed for several reasons:

 Add value to raw agricultural products
 To extend shelf-life
 To improve the nutritional value of products
 To create new food products
 Create new food products

SALTING involves introducing salt into the flesh of fish or meat.

CURING is another method of food processing that involves the application of salt and other ingredients.
(Salting is an example of curing)
Common products of curing in:

 Cludepork
 Chicken
 Beet
 Carabeet
 Tocino
 Longganisa
 Ham
 Bacon
OSMOSIS is the movement of water or other solvent from a region of low solute concentration.
SMOKING involves exposing fish or meat to smoke from burning wood.
There are two ways of smoking:
1. COLD SMOKING is usually done at 20 1o 37 degrees Celsius Cold-smoked products retain
about 90% of their moisture so they have to be refrigerated.
2. HOT SMOKING is done at temperatures up to 63 to 80 degrees Celslus.
adds flavor while cooking the product.
DANGER ZONE- range of temperature wherein food-borne bacteria can grow to unsafe levels.

TOPIC 2: Fermentation and Pickling

Fermentation has three different types:
1. Lactic Acid fermentation- is the anaerobic microbial breakdown yields energy
2. Alcoholic fermentation- is the anaerobic microbial breakdown of sugar into alcohol and carbon
dioxide due to the addition of yeast.
3. Acetic acid fermentation- ethanol undergoes oxidation to produce vinegar.

TOPIC 3: Sugar Concentration

The secret to their preservation is in the concentration of three key ingredients:
1. Sugar- has the same osmotic effect as salt that reduces the amount of free water in food
2. Pectin- soluble gelatinous polysaccharide
3. Acid- pertains to the level of acid in fruits
TOPIC 4: Drying and Dehydration
Drying and dehydration involve taking out moisture content from food. prevent the growth of bacteria,
yeasts, and mold.
DRYING-refers to a simple method of moisture removal like sun-drying
ex.: Daing and Tuyo.
DEHYDRATION- Controls the temperature, time, and humidity.
ex.: Dried Mango. Tamarind.

TOPIC 5: Thermal application

Thermal application is the application of heat to ensure microbial destruction.
Two methods:
1. PASTEURIZATION – also referred to as partial sterilization. 100*C or less
ex.: done to milk, and fruit juices.
2. PRESSURIZATION- kills microorgnisms by subjecting it to intense pressure aand heat.
ex.: Canning
LESSON 2: Food Safety and Sanitation
TOPIC 1: Food Spoilage
FOOD SPOILGE is any change in food which renders it unfit for eating.
FOOD - especially high protein food is easy to contaminate.
ACIDITY- highly acidic food prohibits the growth of bacteria while weakly acidic (4.6 to 7.0)
TIME- Highly-perishable foods such as meat, poultry, fish, and dairy. (more than 4hrs-risk of spoilage)
TEMPERTAURE- Microorganisms can grow to unsafe levels at a temperature of 4.4 to 60-degree celsius.
OXYGEN- sustains respiratory activities among several microorganisms.
MOISTURE- The higher the moisture content of food the more it is prone to microbial contamination
WATER- The growth of microorganisms is significantly attributed to the availability of water
Common Cuses of outbreaks of Food-Borne Illnesses:

1. Failure to properly refrigerate food.

2. Failure to thoroughly heat and cook food.
3. Poor personal Hygiene.
4. Food prepared day before they served.
5. Raw.

TOPIC 2: HACCP
Republic Act. 10611- ensure the safety of all food processing and product packaging activities
Hazard Analyses at Critical Control Points (HACCP)- refers to a food safety management system which
identifies, evaluates and controls hazards
Food Safety Hazards is any biological, chemical, or physical agent in food with the potential to cause
adverse effects on health.
Examples:
 Biological: bacteria, viruses, parasites, molds
 Chemical: pesticides, processing chemicals, drug residue, allergens
 Physical: bones, pits, glass, metal, hair

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.
2. Describe the product.
3. Specify intended use and target consumers.
4. Draw a flow diagram to describe the process steps.
5. Visit the plant for on-site confirmation of flow diagram.
Seven Principles of HACCP
Principle 1 - Conduct a Hazard Analysis (HA)- involves listing the steps in the process and identifying.
Principle 2 - Identify the Critical Control Points (CCP)- is a point, step or procedure
Principle 3 - Establish Critical Limits (CL)- is the maximum and/or minimum value
Principle 4- Monitor CCP- monitoring procedures for the measurement of the critical limit
Principle 5 - Establish Corrective Action- refer to it as protocol
Principle 6 – Verification- to validate if the system is in place.
Principle 7 – Recordkeeping- Crucial in providing

When to wash your Hands?

 When entering food handling areas
 Before starting work
 After handling contaminated mate...
 After breaks
 After using toilet facilities
LESSON 3: Food Manufacturing Practices
An effective food processing worker - possesses knowledge and skills in food processing techniques.

Occupational safety can be ensured by eliminating hazards, controlling risks, and by being mindful.
 Personal Protective Equipment
 Proper Handling of Cutting Tools
 Fire Safety
Use the right Class of fire extinguisher for every type of fire.
 Class A - ordinary combustibles such as wood and paper
 Class B - combustible liquids and gases such as alcohol, LPG, grease
 Class C - electrical fire
 Class D - combustible metals such as aluminum

TOPIC 3: 5S of Good Housekeeping

1. SEIRI or SORT- Distinguish between what is needed and not needed.
2. SEITON OR SET IN ORDER- Secure a place for everything and everything should be in its place.
3. SEISO OR SHINE- Clean, and look for ways to keep it clean and organize
4. SEIKETSU OR STANDARDIZE- Establish guidelines and monitor.
5. SHITSUKE OR SUSTAIN- Commit to a clean and organized workplace.

TOPIC 4: Cleaning and Sanitizing Equipment, Tools, and Utensils

4 STEPS IN CLEANING TOOLS AND UTENSILS.
1. Removing loose dirt and food particles.
2. Rinsing with warm potable water.
3. Washing with hot detergent solution
4. Rinsing with clean potable water.

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.
Ex.:
 Used oil
 Contaminated syringe
 Pesticides
 Batteries

Food Recovery Hierarchy

Most preffered----------- Least preffered
1. SOURCE REDUCTION
2. FEED HUNGRY PEOPLE
3. FEED ANIMALS
4. INDUSTRIAL USES
5. COMPOSTING
6. LANDFILL/ INCINERATION

LESSON 4: Dietary Laws

TOPIC 1: Halal Guidelines in Food Processing

Halal Guidelines - This guideline is followed by Muslims or believers of the Islamic religion.

TOPIC 2: Kashrut Guidelines in Food Processing

Kashrut Guidelines- This guideline is followed by Jews or believers of Judaism.
Kosher Food

TOPIC 3: Organic Food Processing

Organic food processing is different from Kosher and Halal as it is not guided by religion
1. NO RTIFICIAL FLAVORS
2. NO ARTIFICIAL COLORS
3. NO ARTIFICIAL IRRADIATION
4. NO ARTIFICIAL PRESERVATIVES (BHA, BHT, SODIUM BENZOATE)
UNIT 3: Basics of Food Processing
LESSON 1: Basic Skills in Preparing Raw Materials

TOPIC 1: Sorting, Grading, and Selecting- Sorting and grading are not mandatory.

CHECKING THE QUALITY

- CHECKING FOR MEAT QUALITY
- CHECKING FOR FISH QUALITY
- CHECKING FOR EGG QUALITY
- CHECKING FOR FRUITS AND VEGETABLES QUALITY

TOPIC 2: Washing and Cleaning

Washing and cleaning are crucial steps.
Washing meat before cooking it is not recommended for two things:
1. cross-contamination may occur.
2. bacteria in the meat can only be killed by cooking it to the right temperature

TOPIC 3: Cutting Techniques

Knife skills are one of the basic requirements in preparing raw materials for food processing.

TOPIC 4: Storing
STORING- helps preserve the condition of raw materials
STORING MEAT- Carcass meats should be stored at 1 to 3* C.
STORING FISH- should be packed in ice and stored at -1 to 1*C
STORING EGG- store eggs in the refrigerator to maintain its freshness.
STORING FRUITS AND VEGETABLES- Don’t store fruits and vegetables together as fruit produce ethylene
gas which cause food spoilage.
LESSON 2: Standard Measurements and Conversions

TOPIC 2: Measurements and Conversion

Weight ounces (net wt oz) are used in measuring dry food
Volume ounces (net fl oz) are used in measuring fluid substances

LESSON 3: Quality Control Parameters

 Total Soluble Solid- Refers to sugar content in solutions
 wherein sugar is the major component (honey, juice, syrup).
 Temperature- coldness or hotness of an object
 Salinity- concentration of salt in a solution.
 Moisture Content- quantity of water contained
 Water Activity- the amount of “free” or” non-chemical bound” water
 pH meter- concentration of hydrogen
Module 2: Sugar Concentration

UNIT 1: Preparing Raw Materials for Sugar Concentration (IUFRJF)

• Integrity of Shape- absence of physical defects.

• Uniformity- should be uniform in size, form, and color.
• Freshness- harvested right on time
• Ripeness or Maturity- indicated by color and firmness
• Juiciness- Juice content in fruits is directly related to the ripeness of the fruit.
• Flavor- measuring the total soluble solids with a refractometer.
 Preparing Fruit and Other Ingredients for Processing ( WKSM)

Washing and cleaning - helps to remove soil and chemical residues

Knife peeling- fruits and vegetables are pressed against stationary or rotating blades to remove the skin.
Slicing - cutting food into broad.
Mincing - mainly done for size reduction
Pectin is a jelly stabilizer naturally found in fruits. made up mostly of carbon, hydrogen, and oxygen.

UNIT 2: Jams, Jellies, Marmalade and Preserves (JJM)

Jams, jellies, preserves, and marmalades - are all gelled or thickened fruit products
Jams- are thick, sweet spreads

TSS of jam should be between 60% to 65%.

Jellies -are transparent, bright gel TSS of jellies should be 65 oBrix
Boiling- Fruits are boiled in an equivalent amount of water.
Draining-The juice is then drained using a cheesecloth jelly bag.
Marmalades- are soft fruit jellies containing small pieces of fruit or peel.

Two Ways of Preparing Preserves (OS)

1. Open Kettle- Fruits are gradually cooked in syrup to render its softness.
2. Slow Open Kettle- Fruit is boiled in a sugar solution and then left overnight.

Testing for Fruit Acidity

 Ideal PH level for fruits is 2.5 to 3.4

 Ideal PH level is 3.2

Adjusting Sugar and Acid Concentration
Sugar- like salt, works as preservative b drawing
out water.

Rich in Pectin = +1 cup sugar

Moderate Pectin= + ¾ cup sugar
Poor Pectin= ½ cup sugar
UNIT 3: Packaging, Labelling and Storing

TYPES OF Packaging materials (GSWF)

Glass container is ideal for packaging sugar

Sterilization
• Wash jars with hot soapy water.
• Rinse with clean hot water.
• Place the glass jars and lids in a pot.
• Fill the pot with water that is enough to submerge the jars.
• Allow the water to boil for 10 minutes. Monitor closely so that the jars remain submerged.
• You now have sterilized glass containers.

Water bath is done by subjecting a packaged product to boiling water for a period of time.
Food labels communicate the ingredients and manufacture details of the product.

Philippine Consumer Act (Republic Act No. 7394), labels must contain the following:

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

Shelf-Life- Unopened sugar concentrated products can last for 1-2 years in the refrigerator

Module 3: Fermentation and Pickling

UNIT 1: Basic Principles of Fermentation

Fermentation is process by which the living cell is able to obtain energy

‘Ferment’ comes from the Latin word fervere, meaning ‘to boil’.
Zymology- The science of fermentation is called Sugars are converted into lactic acid, acetic acid and
ethanol through fermentation.

These are fermentation end product of some microorganisms: (SSPEC)

 Saccharomyces: ethyl alcohol and carbon dioxide

 Streptococcus and Lactobacillus: lactic acid
 Propionibacterium: propionic acid, acetic acid, and carbon dioxide Escherichia coli: acetic acid,
lactic acid, succinic acid, ethyl alcohol, carbon dioxide, and hydrogen
 Enterobacter: formic acid, ethyl alcohol, 2,3-butanediol, lactic acid, carbon dioxide, and hydrogen
 Clostridium: butyric acid, butyl alcohol, acetone, isopropyl alcohol, carbon dioxide, and hydrogen
Anthropological evidence indicates that people were fermenting beverages in 5000 BC.
making fermented bread in ancient Egypt circa 1500 BC and milk circa 3000 BC.
Louis Pasteur,- The French chemist who is also the “father of fermentation”, founded zymology,
discovered fermentation in 1857.

Fermentation -It is a "spoilage" process that produced an excellent product

Common Ingredients in Fermentation and Pickling: (SYVSS)

 SUGAR is a soluble carbohydrate converted to alcohol or acid through fermentation.

The 3 Simple Sugars are: (GFG)
a. Glucose - found in human bloodstream sap of plants, fruits.

b. Fructose - found in fruits and vegetables.

c. Galactose - found in dairy products.

 TABLE SUGAR is a disaccharide made up of glucose and fructose.
 YEAST or Saccharomyces cerevisiae is a species of fungus
 VINEGAR is both a product of fermentation and an ingredient of fermented products.
 SALT or sodium chloride (NACI) reduces water activity and enhancesflavor.
 SPICES are used to mask color and odor of fermented and pickled products.
3 Types of Fermentation (AAL)
Alcoholic Fermentation- A breakdown of sugar into alcohol and carbon dioxide

Acetic acid Fermentation- Vinegar is produced by this process.

Lactic Acid Fermentation- only produces 2 units of energy for every glucose molecule.

UNIT 2: Basic Principles of Pickling

Pickling- is preserving foods in vinegar (or other acid).
Chutneys- Ketchups
There are two basic categories of pickles:
1. Pickles preserved in vinegar, a strong acid in which few bacteria can survive.
2. Soaking in a salt brine to encourages the growth of fermentative bacteria that make a food less
vulnerable to bacteria.
MODULE 2
UNIT 1: Preparing Raw Materials for Sugar
Concentration (IUFRJF)

Preparing Fruit and Other Ingredients for

Processing ( WKSM)

UNIT 2: Jams, Jellies, Marmalade and

Preserves (JJM)

Two Ways of Preparing Preserves (OS)

UNIT 3: Packaging, Labelling and Storing

TYPES OF Packaging materials (GSWF)

MODULE 3
UNIT 1: Basic Principles of Fermentation
1. These are fermentation end product of
some microorganisms: (SSPEC)
2. Common Ingredients in Fermentation and
Pickling: (SYVSS)
3. The 3 Simple Sugars are: (GFG)
4. 3 Types of Fermentation (AAL)

UNIT 2: Basic Principles of Pickling

There are two basic categories of pickles: (PS)
MODULE 4 Curing, Salting and Smoking
Food spoilage is any change in food which renders it unfit for eating.
Curing is a method of food processing to preserve meat or fish which involves the application of salt and
other ingredients
Salting is an example of curing.

Four ways of curing:

a. Pumping Pickle is a method of curing that injects the mixture into the meat.

b. Cover Pickle is a method of curing that submerges the meat in the prepared mixture.

c. Dry Curing –The dry cure mixture is then rubbed into the meat by hand.

d. Combination Curing – In combination curing, either dry curing and pumping pickle

Common Ingredients in Processing Food by Curing

1. Salt or sodium chloride (NaCl) is the world’s oldest food preservative.

Salt has several qualities:

1. Enhances flavor;
2. Improves texture;
3. Reduces water activity;
4. Causes microbial cells to undergo osmotic shock and lose water, resulting to retardation of
growth;

2. Sugar is a carbohydrate primarily used in curing for its characteristic flavor.

Sugar can be added to:

1. Counteract the harshness of salt;

2. Provide energy for bacteria that changes nitrate into nitrite;
3. Reduce water activity

3. Water is a tasteless and odorless liquid

4. Curing agents – sodium or potassium nitrate and sodium or potassium nitrite –

Nitrites are effective curing agent

Nitrate is a source of nitrite.

NITRITE FUNCTION
1. Stabilize the color of the lean tissues
2. Contribute to the characteristic flavor of cured meat
3. Inhibit bacteria responsible for spoilage and food poisoning, particularly clostridium botulinum
4. Retards development of rancidity.

 Nitrates are used for meat that undergo longer curing processes.

 Phosphates are the salts of phosphoric acid used in food processing

 Phosphate: Have wide application in the meat processing industry.

  Sodium Ascorbate & Erythorbate: These reductants react with nitric to give nitric oxide,

 Ascorbate: Rapidly reduces met myoglobin to myoglobin

 Potassium Sorbate: Is anti-microbial agent

 Monosodium Glutamate: its effect on cured meat flavor is not widely recognized

 Hydrolyzed Vegetable Protein: emulsion types protein contentycind yield.

 Carrageenan: A naturally occurring carbohydrate extracted from red seaweed.

Seasoning such as herbs and spices are added to enhance the flavor of meat.
Herbs come from leaves of plants. often consumed in their fresh
Spices can come from the root, stem, bark, seed, fruit, or flower of a plant. are consumed in dried form.
Extenders are optional high-protein sources added to cured meat to reduce cost.
Food-grade colorants are added to cured meat to make it more attractive and appealing.

Categories of Food Colorants

1. Colors derived from plants or animals
a. Carotene from orange and yellow vegetables
b. Beet red from beet plant
c. Carmine from Cochineal insect
2. Colors derived from other natural sources
a. Caramel from sugar
b. Titanium white from Titanium dioxide
3. Artificial colors
a. Tartrazine
b. Ponceau 4R
c. Red 2G
SALTING
Salting involves introducing salt into the flesh of fish or meat to extend its shelf-life.
Water activity refers to the amount of “free” or “non-chemically bound” water
Osmosis is the movement of water or other solvents from a region of low solute concentration
Salt Fermentation: Another kind of salt preservation

Salting method
Dry Salting: Dry salt is rubbed on the fish.
Brine Salting: It is a type of curing that submerges meat or fish in brine solution. In salting, the brine
solution consists of salt and water.
Paste Coating Method is a traditional method of salting egg among Asian countries. Clay from termite
mound is added to salt and water.
COMBINATION/HYBRID METHOD- An initial dry rub followed by immerse 10n in the brine that
subsequently form as water is drawn by the salt from the fish body.

 In Tinapa: preservation being achieved by smoking and chilling.

 In Tuyo: Pickling or immersion in concentrated brine this is done for longer term preservation
 Daing: Is called kench curing
Types of Salt
Solar Salt: Is prepared by evaporating seawater
Rock Salt: Is salt that is mined from rock deposits formed from seas
Purified 99.99% Sodium Chloride: Is processed from solar or mined rack salt to attain the purity.
Calcium & Magnesium Impurities Actually desirable in fish curing as it promotes whiter dries fish.
 Imparts Bitterness: Excess of magnesium and calcium salts.
SMOKING
Smoking: fish or meat is exposed to smoke from burning wood.
3 Traditional Reasons for Smoking Meat
1. PRESERVATION
2. APPEARANCE
3. FLAVOR
Smoked Meat: Is less likely to spoil than unsmoked meat.
There are two ways of smoking:
Hot Smoking is done at temperatures 63 to 104 Degrees Celsius.
Cold Smoking is usually done at temperatures 20 to 30C.
Methods in Smoking Fish
Smoking fish is a major fish processing enterprise in the Philippines.
In hot smoking, fish is exposed to temperatures of 63 - 104°C or higher
In cold smoking, fish is smoked for 1 to 5 days at 26°C or lower.
Cold smoking does not cook the fish
3 Stages of Smoking

 First stage/Drying stage -The smokehouse is heated to 52C/125F. All dampers are opened
 Second stage/During the next eight- hour stage - the dampers are partially closed, increased to
57C/135F
 Third stage/ the smoke is continued throughout the third stage with all dampers closed, house
raised to 82c/180f. hold this temperature until the product temperature reaches 61C/142F.

Materials for Smoking

Wood chippings/shavings – when burnt, it becomes the source of the smoke flavor.
Examples of wood: cherry, alder, pecan, walnut, apple, maple, oak

Equipment for Smoking

Smokehouse – a chamber where meat or fish is exposed to smoke for a duration of hours.
Temperature directly affects fire behavior.
Relative humidity refers to the amount of moisture in the atmosphere.

Common Types of a Smokehouse

Box smoker – looks like a vault.
Smokehouse (outdoor) - Usually made of wood and resembles a big cabinet.
Smoker oil drum - Are improvised smoke chambers.

Meat Curing: Used originally as means of preserving meat during times of plenty to carry over to times of
scarcity.
Cured Meat: it was meant to be shelf stable, so these were heavily salted.

Meat Curing Ingredients

Salt: Basic to all curing mixtures its preservative action is due its effect of lowering water activity
Low Sodium Salt: Is a combination of sodium chloride and potassium chloride 60:40
Sugar: Added to the curing mixture to balance flavor. Also counters the harshness of salt,
Nitrate/Nitrite: Now used as preservatives and an essential in meat curing was first discovered as an
impurity in salt.
Nitrosamines- Compounds which can form when nitrites combine with amines.
AMINES- A natural component resulting from the breakdown of proteins.

 Halophiles: Most significant spoilage microorganisms in salted fish.

 Staphylococcus Aureus: Toxin producing cause of food poisoning