Food and Beverage Final

7/23/2019 Food and Beverage Final

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Food and BeveragePrepared by: Sherry Banton, Raysa Barcelon ,Jerome Benipayo,



FOOD PROCESSING

Food processing is the transformation of raw ingredients, bchemical means into food, or of food into other forms. Foocombines raw food ingredients to produce marketable foodcan be easily prepared and served by the consumer.

Commercial food processing is defined as that branch of manu

starts with raw animal, vegetable, or marine materials and trainto intermediate foodstuffs or edible products through the alabor, machinery, energy, and scientific knowledge.



BRIEF HISTORY OF FOOD PROCESSING

•Some of the earliest forms of food processing resulted in dry foThese references to various types of commodities date to verand the use of thermal energy from the sun to evaporate waproduct and establish a stable and safe dry product

• The use of high temperature to produce safe food products d1790s in France. Napoleon Bonaparte offered a prize to scien

develop preserved foods for the armies of France. This offer leresearch of Nicholas Appert and the commercial sterilization



BRIEF HISTORY OF FOOD PROCESSING

•The history of chilled and/or refrigerated foods dates to very ewell. The first references are to the use of natural ice used to pproducts for extended periods of time.

• A patent for use of a commercial refrigeration process for fishregistered in 1842.

•

In the 1860s, Louis Pasteur, working with beer and wine, develprocess of pasteurization.



TOP 5 FOOD PROCESSING INDUSTRIES IN THE PHILIPPINES

• Nestle Philippines Incorporated;

• San Miguel Foods Incorporated;

• Universal Robina Corporation;

• Jollibee Foods Corporation;

• Monde Nissin Corporation



UNIT OPERATIONS IN FOOD PROCESSING



All the unit operations applied in food processing c

divided into:

Fluid Flow Processes

Mechanical Processes

Heat Transfer Processes

Mass Transfer Processes



FLUID FLOW PROCESSES

Fluid transportation - moving a fluid product from one point to anvarying degrees of turbulence. Transport of fluids is achieved eitherflow or through the use of pumps.

Gravity flow - flow is laminar and is transferred from the fluid to the

between the adjacent layers. Adjacent molecules don’t mix.



FLUID FLOW PROCESSES

Centrifugal pump uses a rotating impeller to create acentrifugal force within the pump cavity. The flow iscontrolled by the choice of the impeller diameter androtary speed of the pump drive. The capacity of acentrifugal pump is dependent upon the speed,impeller length and the inlet and outlet diameters.

Positive displacement pump cons

reciprocating or rotating cavity betwlobes or gears and a rotor. Fluidgravity or a difference in pressure, andforms the seals between the rotatingrotating movement of the rotor prodpressure to cause the fluid to flow.



MECHANICAL PROCESSES

Cleaning of Raw Material

Wet Cleaning More effective than dry methods for removing soil from root crops

pesticides residues from soft fruits and vegetables Dustless and causes less damage to foods than dry methods Different combinations of detergents and sterilants at different tempe

flexibility in operation.

Dry Cleaning Used for products that are smaller Have greater mechanical strength and possess a lower moisture conten Surfaces are dry to aid preservation or further drying

The main groups of equipment used for dry cleaning are amagnetic separators and separators based on screening of foods.




Cleaning of Raw Material




Removal of Inedible Parts

Removal of inedible parts from the raw material is anotheroperation in food processing, which needs specially designed equipment. Mmechanical operation but some chemicals and heat are also used. Destonindeboning of meat and poultry, deheading of fish are the examples of meoperations, in which force is used to push out or cut out an inedible pamaterial.

Disintegration

1. To fulfil expectations of the consumer.2. To facilitate further processing.3. To enable separation of parts of the material

with different properties.4. To enable joining of different materials or

parts of the material with special properties.




Sorting and Grading

Sorting

Separation of foods into categoriesof a measurable physical properties

Should be employed as early asensure a uniform product forprocessing

Four main properties used to sort shape, weight and color.

Grading Often used interchangeably wit

strictly means ‘the assessmenquality of a food using a number

Carried out by operators who asimultaneously assess a number o



Heat Transfer Processes

Heating is used to destroy microorganisms to provide for a healthful foodshelf life through the destruction of certain enzymes and to promote a product wacceptable taste odor and appearance.

Common unit processes that include heat transfer as a unit operation include:

Pasteurization (heat) - is a process of heating a product attemperature for a controlled period of time to destroy the most hevegetative pathogenic organism. Originally developed for fluid dairythe process is also applied to other fluids, including fruit juices

products. In addition to destruction of microorganisms, pasteurizachieves almost complete destruction of undesirable milk enzymeslipase.

Sterilization (heat) - the primary object of sterilization is to destroy the mresistant pathogenic spore forming organism.



HEAT TRANSFER PROCESSES

Drying (heat) - Three common methods of drying are: (a) sun or tray drying, (b) sand (c) freeze drying.

Sun or Tray Drying Least expensive followed by spray drying and freeze drying Products that are already solid lend themselves to sun or tray drying Dried by exposure to sun or place in trays and dried in a current of warm o

Freeze Drying Used to products that are very heat sensitive

Moisture is removed w/o a phase change (sublimation) Comprised of dryer cabinet; drying chamber with: heating/cooling shelve

door; vacuum pump, condenser, controls and digital readout.

Spray Drying Most common drying method and is applicable to fluid products Bulk density (weight per unit volume is controlled to a large extent by the s

sent to the dryer.



HEAT TRANSFER PROCESSES

Evaporation (heat) - frequently in the food industry a raw material or a potentcontains more water than is required in the final product. When the foodstuff is

easiest method of removing the water, in general, is to apply heat to evaporate

Refrigeration (cold) - This is the process by which heatis removed from a confined place and material for the purpose of maintaining a lower temperature.

Freezing (cold) - Lowering the temperature belowpoint of the product stops microorganisms fromreduces the activity of enzymes. Vegetables andheat treated (blanched) before freezing to elimina



MASS TRANSFER PROCESSES

Extraction - method used to separate asubstance from a mixture or solution.

Distillation - is a separation process,components in a mixture by making use of thsome components vaporize more readily than

vapor is richer in some components, those thvolatile, and so a separation occurs. Indistillation, the vapor is condensed andevaporated when a further separation occgreat purity is required, successive distillatioused. Major uses of distil lation in the food indconcentrating essential oils, flavors andbeverages, and in the deodorization of fats an



OTHER UNIT OPERATIONS USED IN FOOD PROCESSING

Combination

Mixing - to make homogenous blends for dry or liquid ingredients.

Separation - achieved on the basis of density or size and shape.Separations thatdensity differences include the separation of cream from milk, recovery of solids suspensions, and removal of bacterial from fluids.

Cream Separator - separates the milk into lowand high density fluid streams, permitting the

separate collection of cream and skim milk.

Clarification- sediment and microorganismscan be remove centrifugally in a clarifier,which is generally a disc-type centrifugethat employs forces of 5 to 10 thousandtimes gravity and forcing the denser material to the outside.




Size reduction - can be through the use of high shear forces, graters, cutters or sl

Typical equipment for size reduction in meat products and their component p

Grinder which forces pieces of meat out through small openings cona motor, product tray, grinder screw, die

Bacon Slicer - product holder, cutting blade, conveyor belt, slicer arm

Sausage Stuffer - inlet, stuffer body, stuffer drive assembly, product feproduct outlet, product horn

Vertical Chopper - bowl, cutting blade, motor, cover




Forming -used forHamburger patties,

chocolates, jellies, tablets,butter, sausages, varietybreads, margarine bars,cheeses and etc.

Processes:• Compacting• Pressure• Extrusion• Molds• Powders & binding agents• Heat and pressure• Extrusion cooking

Packaging - Machines operate at high speeds and automatically pproducts in a step-wise and automated fashion from forming the conta

container, sealing the container, labeling and stacking it

Controlling - Tools include valves, thermometers, scales, thermostatother instruments to control pressure, temperature, fluid flow, aciditweight, viscosity, humidity, time and specific gravity.



Beverages

A drink, or beverage, is a kind of liquid which is specprepared for human consumption. There are many tfor drinks. They can be divided into various groups s

water, alcohol, non-alcoholic drinks, soft drinks (carbdrinks), fruit or vegetable juices and hot drinks. In adfulfilling a basic need, drinks form part of the culture

society.



Brief History Of BeveragesThe original drink was of course water or Adam’s ale as it is sometimes called. Howinvented farming they invented other drinks

Around 10000BC – agricultural revolution, with this came domanimals and the ingenuity for people to use byproducts such

4000BC - in the middle east Sumer people were fermenting ato make fermented pulp which had an intoxicating effect-a

4100 BC - Oldest Winery Found in America

3000 BC - In Egypt beer is popular

Time of Jesus - Jesus turns water into wine

1561 - beer was first sold in glass bottles in Germany

16th century - Beer was not just a drink it was also a food. It covaluable nutrients

- Wine was often flavored with spices

- Coffee was discovered in Ethiopia and it enteredEurope



1657- Tea is first sold in England

1700- gin drinking becomes very popular among the poor

1772- Fizzy drinks were invented by Joseph Priestly,who disto trap carbon dioxide in water and made carbonated w

1884- evaporated milk is patented by John Mayenberg

-first milk bottle was invented in New Yok state

1886- John Pemberton, a pharmacist in Atlanta, invented the first cola drink

1889- Instant coffee was invented by New Zealander Dav

1903-Decaffeinated coffee was invented by Ludwig Rose

1904- Ovaltine was invented

1908- Thomas Sullivan invented tea bag

1930s- milk cans were replaced with large-on farm storageplastic coated paper milk cartons were invented, which awider distribution of fresh milk

1935- canned beer was first sold in USA



Types Of Beverages

The large number of beverages may be classified as shown:



Uses and Health Benefits

Maintaining body balance by preventing deh

Fruit juices provide a supply of vitamins and m

Tea and coffee, they are calorie-free beveragbrimming with antioxidants, flavonoids and otbiologically active substances that may be go

health.

Milk key source of calcium and vitamin D



Alcoholic Beverages - marinate meat

- Loosen Rusty Bolts

- Boil Shrimp

- Soothe Tired Feet

- Cure Insomnia

- Calm an Upset Stomach

- Skin Softener

- Boost brainpower - Lower your risk of cardiovas

disease

- Decrease chances of devedementia



BEVERAGE PROCESSING

Beverage production utilizes various raw materials. Thesmaterials are the basic materials needed to manufactuincluding your beverage. Raw materials used for the prbeverages includes ingredients such as water, sugar, juvariety of materials used for packaging and labelling likplastic and paper.

It involves the combination of procedures and processto change raw materials into beverage stuffs. It also vadepending on which beverage is being made. Bottlingdiffer in the types of bottling lines they operate and theproducts they can run.



Production of Fruit Juices

Fruit juices are essentially products extracted ffruits such as orange, mango, pineapple, grapFruit juices, after extraction, are generally presdifferent forms such as single strength pure juicsquashes, cordials and fermented fruit juiceconcentrate. Juices serve as non-alcoholic be

drinks for thirst quenching and for supplying vi



Fruit Juice Production Flow Chart



Unit Operation in Fruit Juices Pro

Selection and Weighing of Fresh Fruits

Wholesome and fresh fruits are selected and w

Washing

The selected fruits are washed in a trough usinwater.

Peeling

The fruits are peeled manually.

Juice Extraction

The juice is extracted using an extractor. Pulpefor pineapples and other fleshing fruits



Juice Formulation

This is the addition of other ingredients like: sugar, preservativto obtain the right formulation.

Mixing

The juice is mixed in a tank using a homogenizer (mixer), in oachieve a blending of the formulated juice.

Bottling

The mixed juice is bottled and corked, either manually or wibottle filling machine, depending on the scale of operationTetra pak packages can also be used.

PasteurizingThe bottled juice is pasteurized at a predetermined temperahour using a pasteurizer. If Tetra brik or pak is to be used for pthe juice, bulk pasteurization would be done before the pac

Cooling and Packaging

The pasteurized juice is allowed to cool and then arranged cartons and sealed.



Soft Drink Concentrate Manufac

The making of the concentrate is the first step in th

production of a carbonated soft drink. At the beg

the industry, in the nineteenth century, both conc

soft drink were manufactured in the same facility.

the concentrate was sold to the consumers, who w

their own soft drinks. As the carbonated soft drink

grown, the concentrate and the soft drink manufa

have become specialized. Today, a concentratemanufacturing plant sells its product to various bo

companies.



Concentrate plants are constantly optimizing their

through systems automation. As the demand for c

increases, automation has allowed the manufactu

satisfy the demand without expanding the size of

manufacturing plant. Packaging size has increase

in the industry, 1/2-, 1- and 5-gallon containers we

common. Today 40- and 50-gallon drums and eve

trucks with capacities of 3,000 to 4,000 gallons are





Operations in a concentrate manufacturing plant can beinto five basic processes:

1. Treating water-Water is a very important ingredient in

concentrate and it must have excellent quality. Each conplant treats water until it reaches the desired quality and micro-organisms.

2. Receiving raw materials- When the plant receives thcompounding ingredients, inspection, sampling and anathe ingredients in the quality-control department are begmaterials that have passed the tests will be used in the co

manufacturing process. Some of the raw materials are retank trucks and require special handling. Also, packagingreceived, evaluated and analyzed in the same way as thmaterials.



3. Concentrate manufacturing- treated water and liqingredients are pumped into stainless-steel tanks, wheremixed, homogenized and/or extracted in accordancemanufacturing instructions.

4. Concentrate and additives filling- Once the concemanufactured, the filling stage is started. All the producinto the filling room. Filling machines are strictly cleanedsanitized before the filling process starts. Most of the filliare dedicated to specific container sizes. The product pipes and tanks at times during the filling process in ordcontamination.

5. Shipping finished products-The products are divideprepared to be sent to the different bottling companieproducts should be labelled following all government rproducts are going to another country, the product mulabelled in accordance with the other country’s labellirequirements.



Soft Drink Bottling and Canning

In most established markets around the world, soft drink

first among manufactured beverages, surpassing evencoffee in terms of per capita consumption.

Soft drinks are available in almost every conceivable sizflavour and in virtually every channel of retail distributioComplementing this universal availability, much of the category’s growth can be attributed to convenient paconsumers have become increasingly mobile, they haveasier-to-carry packaged goods. With the advent of thcan and, more recently, the resealable plastic bottle, spackaging has become lighter and more portable.



Soft drink bottling or manufactur

Treating water

Water is treated and cleansed to meet exacquality-control standards, usually exceeding thethe local water supply.

Compounding ingredients

Treated water is piped into large, stainless-ste

This is the stage at which various ingredients are and mixed. Diet beverages are mixed with artificnutritive sweeteners such as aspartame or sacchwhereas regularly sweetened drinks typically usesugars like fructose or sucrose. It is during this stagproduction process that food colouring may be

Carbonating product



Carbonating product

In order for carbonation (absorption of carbon dioxideoccur, soft drinks are cooled using large, ammonia-basedsystems. This is what gives carbonated products their efferand texture. CO2 is stored in a liquid state and piped into units as needed. This process can be manipulated to contrequired rate of beverage absorption. Depending upon thsoft drinks may contain from 15 to 75 psi of CO2. Fruit-fladrinks tend to have less carbonation than colas or sparklinOnce carbonated, the product is ready to be dispensedand cans.

Filling product

The filling room usually is separated from the rest of theprotecting open product from any possible contaminantsoperators monitor the equipment for efficiency, adding bcaps to the capping operation as necessary. Empty bottleare transported automatically to the filling machine via buhandling equipment



Packaging

The last stage prior to warehousing and deliveprocess also has become highly automated. various marketplace requirements, bottles or cthe packaging machinery and may be wrappcardboard to form cases or placed into reusatrays or shells. The packaged products then epalletizing machine, which automatically stac

onto pallets. Next, the loaded pallets are movtypically via fork-lift — to a warehouse, where tstored.



WASTE TREATMENT FOR FOOD ANDBEVERAGE PROCESSING

Environmental issues in food and beverprocessing facilities primarily include the

following:

• Solid waste

• Wastewater• Energy consumption

• Emissions to air



Solid Waste

Depending on the raw materials, food and beprocessing activities may generate significant

of organic, putrescible solid waste in the form materials and rejected products from sorting, and other production processes.

Recommended measures to prevent and conwaste generation include the following:

Minimize inventory storage time for raw materreduce losses from putrefaction;

Monitor and optimize process yields, e.g. duringrading or cutting activities, and encourage tproductive employees to train others in efficieprocessing.



Clean, sort, and grade raw foodstuffs at an ea(e.g. at the farm site), in order to reduce orgaand substandard products at the processing f

Contain solid waste in dry form and consider dthrough composting and / or use for soil amen

Collect and reuse rejected raw materials formanufacturing other products;

Provide leak-proof containers for collected so

liquid waste; Segregating individual by-products from each

from waste to maximize their use and minimize



Wastewater

Industrial Process Wastewater

Effluent streams from food and beverage procehave a high biochemical and chemical oxygen(BOD and COD) resulting from organic wastes ethe wastewater stream, and from the use of cheand detergents in various processes including cl



Process Wastewater Treatment

Techniques for treating industrial process wastewate

sector include grease traps, skimmers or oil water sep

separation of floatable solids; flow and load equaliza

sedimentation for suspended solids reduction using c

biological treatment, typically anaerobic followed b

treatment, for reduction of soluble organic matter (B

biological nutrient removal for reduction in nitrogen a

phosphorus; chlorination of effluent when disinfectio

required; dewatering and disposal of residuals; in som

instances composting or land application of wastewtreatment residuals of acceptable quality may be po

Additional engineering controls may be required to cneutralize nuisance odors.



Energy Consumption

Food and beverage processing activities mayhigh levels of thermal energy consumption in heating, cooling, and refrigeration.

• Implement operational, maintenance andhousekeeping measures

•

Optimize plant processes for energy efficiency• Recover energy from thermal processes wher

i i i



Emissions to Air

The main air pollutants from food and beverageprocessing operations consist of particulate matter and odor. PM may arise from solids handling, solidreduction and drying. Odor may be released by thprocessing steps such as steam peeling, blanching dehydrating and by microbial action in stored solid



Particulate Matter

Recommended techniques to control particulate matter emission

• Cover skips and vessels, and sto

especially outdoors;

• Enclose silos and containers usestorage of powders and fine ma

• Where enclosure is not feasible, windbreaks, sweeping, sprinklingstockpile management techniq

suppress dust ;

• Use closed conveyors equippeto clean transport air prior to rel



Odor

Recommended techniques to prevent and control p

odor emissions include:

•

If the plant is in close proximity to residential areasthe use of wet scrubbers to remove odor emissions

scrubbers are used to remove odors with a high a

water, such as ammonia emitted during the rende

process;

• During the procurement of air emission systems for

units, it is best practice to install integrated systemcombine air cleaning, incineration, and heat reco

• Recirculate exhaust gas from frying and other coo

operations to the burner.



Recommended techniques to prevent and conemissions of odor include:

• Minimize storage duration for solid waste to av

putrefaction;• Operate facilities under partial vacuum to pre

fugitive odor emission;

• Regular inspection of chilling and freezing eqmonitor loss of refrigerants.

W k f A Ch i l E i i



Work of A Chemical Engineer in and Beverages Industry

As consumer demands and desires change, mamust innovate their products to keep up. This oft

changing and improving formulae and process

that the products can be manufactured in a prway while maintaining high quality standards an

consumer satisfaction. In accomplishing this goa

Chemical Engineers play a key role

Chemical engineers work together with chefs foo



Chemical engineers work together with chefs, foo

and nutritionist to come up with ways to prepare a

preserve food efficiently, maximizing nutrients whil

maintaining flavors and textures that consumers w

appealing.

Examine the various steps in manufacturing proce

making recommendations to maximize the efficie

raw materials, equipment and workers.

Responsible for monitoring the environmental safe

sustainability of plant operations,ensuring that was

other byproducts of the manufacturing process ardisposed and cause minimal damage to the surro

environment.



Create packaging material that meet the needs

consumer and manufacturers. New types of plast

coating treatments for paper containers, sealing

compounds and adhesives, and even innovative and sealing mechanism need to be developed.

Also engaged in logistics and transportation sectioefficient ways to store and transport finished prod

the factory to the consumer. This may involve spe

refrigeration systems, designing delivery cartons a

recommending cost efficient materials to make th



FUTURE OF THE FOOD AND BEVERAGE PROCESSING INDUSTRY

Extrusion - The process of extrusion basically includes comprefood to make it a semi-solid mass and then passing it througsmall orifice to enhance the variety of texture, shapes anobtained from basic food stuff. This technique has given the opto increase the variety of designs, shapes and texture of tproducts again and again. Infact this technique of extrusion fvery occasionally cook raw food stuff into finished processed fo



FUTURE OF THE FOOD AND BEVERAGE PROCESSING INDUSTRY

Bioprinting - Bioprinting process centers on the identification of karchitectural and compositional elements of a target tissue, andcreation of a design that can be utilized by a bioprinter to genetissue in the laboratory environment.

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Food and Beverage Final