Food Technology Study Notes: Food Manufacture 2    Glossary:

-­‐ Biochemical: natural changes that occur in food

-­‐ Blanching: process of immersing in boiling water

-­‐ Death phase: the point at which bacteria start to die due to lack of food

-­‐ Dehydration: removal of water from the tissues of an organism

-­‐ Fermentation: the process by which alcohol or acid is produced through the action of micro-organisms

-­‐ Filtration: the process of passing a liquid through a filter to remove any solid particles

-­‐ Food additive: any substance added to a food, not normally consumed as a food by itself and not normally used as a

typical ingredient of food

-­‐ Food manufacture: transformation of raw food into different food products

-­‐ Gas vacuum packing:

-­‐ Hazard Analysis Critical Control Point (HACCP): systematic mehod for identifying, monitoring and controlling hazards

-­‐ Headspace: the amount of space left in all cans and other containers to allow for expansion of the product during

heating

-­‐ Lag phase: the time required for bacteria in contaminated food to become adjusted to their new environment

-­‐ Occupational health and safety: legislation and committees set up in the work place to ensure that the working

environment is safe

-­‐ Pasteurisation: process by which milk is sterilised by holding it at a high temperature for a period of time.

-­‐ Production run: quantity of product manufactured in a certain time period

-­‐ Quality assurance: putting processes in place within an organisation to guarantee the standards achieved during

processing; part of the total quality management plan of an organisation

-­‐ Quality control: conducting tests to check the standards of raw materials or products before, during or after

production

-­‐ Sublimation: to change, when heated, from a solid state to a vapour without going through the liquid state

-­‐ Unit operation: a process involved in the transformation of raw materials into manufactured goods e.g. peeling,

freezing, heating

-­‐ Vacuum packing: process used in the canning or bottling of foods, in which the air in the head space is removed and

a vacuum is put in its place.

o DEFINITION: food manufacture- activities that use power driven machines and materials-handling equipment (e.g. forklifts, conveyor belts) to mechanically or chemically transform new materials into food and beverages for human consumption.

o Food manufactures may be multinational companies e.g. Coca Cola Amatil, Pepsi Co. or companies with a smaller profile who produce and sell in a similar way to the larger companies e.g. a local bakery.

o Ultimately their aim is to prepare and market foods that will be safe to eat and that have a reasonable shelf life. o It is important that food is processed efficiently to:

-­‐ create a minimum amount of waste (i.e. more production & cost effective à less expenses) -­‐ prevent deterioration of food quality

• Quality and quantity control in the selection of raw materials for food processing

RAW MATERIALS: o To achieve its aims manufactures need to:

-­‐ Purchase good quality raw materials -­‐ Process them in a well-designed plant with hygienic equipment -­‐ Follow good manufacturing practices

o DEFINITION: raw material – any product that is used in the manufacture of another processed good. o The main raw materials used in processing are:

-­‐ Product ingredients e.g. fruits, vegetables -­‐ Processing materials e.g. steam, water -­‐ Food additives e.g. emulsifiers, starches, colours, flavours -­‐ Packaging materials e.g. cans, bottles, fibreboard containers

o Most raw materials have undergone some form of processing before being delivered to the factory e.g. salt, sugar, eggs, flour etc.

Quality of raw materials: o A large amount of money spent on raw materials, therefore manufactures need to spend time and effort ensuring they are

good quality. o They must meet strict guidelines as contaminated material can spoil and lead to rejection of an entire production run.

Food Technology Study Notes: Food Manufacture 3    o DEFINITION: production run – is the process of taking raw materials and making them into a finished product within a certain

time period (is usually one batch). o Quality control of raw materials is closely monitored by technicians and tested to ensure it meets specified standards e.g.

dried fruit must be free of sticks, stones and other foreign matter or it will be rejected and another supplier found. o If raw material doesn’t meet quality control an inferior product may result à which may lead to a dissatisfied consumer &

damage to a company’s image (link to FPD). o Quantity control is ensuring the correct proportions of ingredients are used to achieve a consistent product e,g. Mcdonalds

only uses 2 suppliers for their produce Setting up raw material specifications: o Quality control laboratories follow criteria and prepare the following for each material:

- A description of raw material e.g. tolerance standards specified for physical characteristics e.g. size, aroma, moisture content – e.g. Kellogg’s corn kernels moisture content

- A sampling method for the material e.g. exact number of samples to be tested to give the required assurance quality - A test for each characteristic e.g. must be able to accurately test to give an accurate result e.g. pH level or moisture

content e.g. certain acidity level of tomatoes and lemons e.g. bacterial testing of dairy products so at safe level. - Action to be taken from results. Different actions include:

1. Accept Raw Materials if within standards 2. Reject Raw Materials if they are not compliant with the set standards e.g. pears are really ripe they send

back 3. Start controlling problems if raw materials appear that they may deteriorate below standards before being

used à contingency plan – use riper pears first or if they are too raw used controlled atmosphere rooms e.g. large batch on trees, storm coming, pick early & store in these rooms.

Example: Organic Chlorella powder

Food Technology Study Notes: Food Manufacture 4    

• Describe processes that transform raw materials into manufactured food products See mammon blueberry jam production table

Food Technology Study Notes: Food Manufacture 5    

• Production systems used in the manufacture of food, e.g. small scale, large scale, manual, automated, computerised

PROCESSING TECHNIQUES SCALE OF PRODUCTION: Large scale: used with larger production operations e.g. Cadbury and Tip Rop o Such systems are based around a production line set up e.g. continuous processing for inspection of raw materials, through

to processing, storage and distribution. o Generally run 24 hr because it costs money to close & reopen o Equipment is able to cope with large volumes typical of food production o Equipment should fit with machinery to ensure there is no break in the production line o Stainless steel equipment which is inert and will not react with food products or corrode and is able to withstand the high

temperatures used in food processingàcan also be easily sterilised to ensure food safety o Stainless steel is able to withstand high levels of vibrations, no loose parts, which could contaminate foods o Durable and easy to maintain equipmentàprevents delays due to malfunction o Appropriate safeguards and shut down mechanisms are incorporated to ensure worker safety o Advantages: produces larger volumes of a product in shorter timeframe = greater profit after equipment is paid off.

Small scale: used at a domestic level e.g. small kitchen, are smaller in scale and less complex in their operation. o Movement and processing is performed manually or with low grade mechanisation e.g. hand held electric beaters to

make cupcakes

LEVEL OF OPERATION (how mechanised it is & how much technology is being used): Manual operation: involves the operator physically adding food components e.g. rolling biscuits by hand; filling tart cases by hand. o Use semi- or fully-automated processing techniques. o Required where automation would be a disadvantage e.g. visual inspection of fruit quality & size. o More labour intensive, costs are higher (raw materials in smaller batches), decreased efficiency level (don’t have a large

output in small time) & non-consistent product. o Susceptible to human error Automation: machines (e.g. conveyor belts) handle and control processing from raw materials to finished product. (i.e. through processing, packaging, storage, distribution) à CONTINUOUS PRODUCTION! o Automated systems are set to predetermined conditions for operations e.g.

mixing times, cooking dough thickness, speed of conveyor belt to ensure biscuits develop certain level of browning.

o Large volumes can be produce simultaneously in a relatively short period of time à termed high volume or mass production.

o Result in products which better comply with product specifications at a lower cost than manualà24 hr operations machines

o Output is more likely to be higher o Tasks which are dangerous or repetitive , can be undertaken and therefore there is a reduced risk of worker injury which

may occur in manual operations o Automatic shut downs can be installed to ensure that safety margins are maintained

Computerisation: automated processes which are reliant upon sensors which measure variations & provide feedback to process controller (e.g. quality control sensors such as a laser beams goes through a can to measure moisture content).

o Electronic sensor are reliable, accurate & fast response time à however simple ones cannot measure visual and physical quality characteristics e.g. colour, shape.

o Microprocessor or computer control can compare product specifications (stored as data) and directly apply information to automatic control of process.

o They enable large and complex operations to be undertaken due to data being stored and compared to pre-set specifications.

o Also this large amount of data stored enables sales managers to control stock (JIT- whats in, whats been ordered, what needs to be ordered) & compare actual production levels with targets.

o Computer programs are developed to respond to variations in raw materials and conditions during processing & storage e.g. levels of humidity, pH.

o E.g. metal detectors – stop processing automatically if detected. Examples of computerised systems used: e.g. UHT milk

1. CAM: computer aided manufacturing – display monitor provides information on progress and levels of control during manufacturing e.g. prints records of processing conditions & times e.g. 75% through production lines

2. PLC: programmable logic controls – able to program control sequences for a particular application or process e.g. biscuit making – icing before coconut. Are extremely reliable, relatively economical, easily reprogrammed, does not require skilled computer expertise à enables readily modified changes in product formulation & conditions if problem arises.

Advantages of automation/computerisation: o Waste reduction (less products discarded because of less faults) e.g. recycled melted chocolate when making Tim Tam’s,

reusing dough from Sao’s.