Lecture 3Value Added Processing

Dr. Kassama/Jackson-Davis Professor Food Engineering/Processing

Food Safety

Department of Food & Animal Sciences Alabama A&M University/University of Florida

Postharvest Lecture HOS 5330 Spring 2021

Introduction

What is Value Added???

Introduction

What is Value Added??? The economic enhancement of a product/service Before offering them to customers

Additional features or economic value is effectively the differences between a

product’s prices to consumers and the cost of producing it in several ways, such as adding a brand

Introduction

What is Value??? It is not the result of product development It is not what you are offering to your customers It is what the customers value, or will value now

or in the future it is entirely from the customers perspective

Jack Womack Defines values Right product to the right customers at the

right price and at the right time

Introduction

Knowledge Development Value added activity in product development A significant knowledge based on the

customers: Needs and wants Biggest Frustrations Most significant problems

Introduction

Knowledge Development Customers Behavior Consumer preferences is there an existing problem with a

particular product How do they satisfy a specific need and

want

Introduction

Knowledge Development Customers Environment Their use of the products How could their decision be influenced How are other people relate to their needs

and behaviors Integrate knowledge on the customers and

technical expertise

Value added Processing

Transformation of raw materials or commodities Into a processed product through the

used of: Raw materials Labor Time Technology

Value added Processing

Transformation of raw materials or commodities Purity Authenticity Health claims Sustainability required to add real value to products Consumer willingness to spend a bit more

on the final product

Value added Processing

Horticultural Products Include actions that alters fresh fruits

and vegetables to create a higher value added product for human consumption This includes Canned products Juices Soups Sauces

Value added Processing

Horticultural Products This includes Dehydrated fruits and vegetables

Value added Processing

Processing Transform highly perishable fruits and

vegetables into stable products with longer life Improve the organoleptic properties

Value added Processing

Typical Processing Concepts 1. Short-term Processing Methods Refrigeration Cold storage Superficial chemical treatments Packaging systems involving modification in

atmosphere

Value added Processing

Typical Processing Concepts 2. Preservation Methods by Chemical

Actions Sugars Sulfur dioxide Fermentation Salting and Acidifications

Value added Processing

Typical Processing Concepts 3. Heat and other non-thermal High temperature Low temperature High pressure processing Irradiation

Value Added Processing

Dehydration

Frozen Products

Dehydration

Dried

Dehydration

Dried

Thermal Processing

Thermal processing Understand the thermal processing

concept

Thermal Processing

Thermal processing To make the product safe & shelf-stable Reduce the number of microorganism of public

health concern to a statistically small level Most serious & heat resistant (low acid)

Clostridium botulinum Level: survivor probability 1 in 1012

The same as saying that one of every 1012

containers should not be sterilized by the process Sterilize

• Microbial destruction and sensitivity • Oxygen requirements

• Obligate aerobes • Facultative anaerobes • Obligate anaerobes

• pH • pH ≥ 4.5 Low acid food • pH < 4.5 acid foods

Microbial Sensitivity

• Classification based on oxygen sensitivity

Class Description Examples

Obligatory aerobes Requires oxygen for growth

Molds, micrococcus; Serratia marcescers; Microbacterium tuberculosis

Obligatory anaerobes Requires absence of oxygen for growth

Clostridium botulinum; C. Sporogenes

Facultative anaerobes

Can grow without oxygen

Stephylococcusaureas

Microbial Sensitivity

Thermal Processing

• Microbial destruction and sensitivity

• Temperature

• Thermophylic

• Mesophilic

• Psycrophylic

• Classification based on temperature sensitivity

Temperature Range °C (°F)

High Acid 3.7 < pH <4.5

Low Acid pH ≥ 4.5

Thermophilic 55-35°C(131 -95°F)

B. Coagulans C. Thermosaccharolyticum

Mesophilic 40-10°C (104 – 50°F)

C. Pasteurianum C. Botulinum (A and B)

Phychrophilic (35-5°C)

(95 – 41°F)Pseudomonas C. Botulinum E

Microbial Sensitivity

Pasteurization vs Sterilization

• Pasteurization• Mild heat treatment

• pH < 4.5 acid foods

• Destruction of pathogenic microorganism • Inactivation of enzymes

• Process does not eliminate all vegetative bacteria

Pasteurization vs Sterilization

• Pasteurization• Product refrigerated to control spoilage

• Temporary shelf-life extension

• Temperature applied (55-100 °C) (131-212°F)• Process requires lowering the product

temperature to below 4 °C (39°F) within 2 h after pasteurization

Thermal Process Sterilization

• Sterilization or Appertisation• pH ≥ 4.5 Low acid food

• Application of heat for the purpose of shelf life extension and promotion of safety

• More severe heat treatment

• Long term preservation

• “Commercially sterile”

Thermal Process Sterilization

• Sterilization or Appertisation• Temperature applied at 100-150°C, (212-302 °F)

reference T=121°C (250 °F)

• Association with strong hermetically sealed packaging and stored below 30 °C (86 °F) (usually at room temperature)

• Environment will prevent growth of microbes of public health concern and spoilage type

• Canner and A Simple Vertical Steam Retort

Conventional Thermal Processing

Reduce the chemical changes and decomposition reactionwhich affect odor, flavor, color and nutritive value

Replacement of Conventional Thermal Process High–temperature-Short-time (HTST)

- Sterilization by heat for times ranging from a few seconds to six minutes (100 – 150 °C)

Ultra-Heat-Treated or Ultra-High-Temperature (UHT)- Continuous flow sterilization processes

Temperature range 130-150°C Holding time - two to eight seconds

Aseptic Processing

• Technology• Heat exchangers: Plate type

Food Processing

Pre-sterilization Aseptic Packaging

Aseptic Filling Process

Quality of Products

Orange Juice Processing

Process Flow Chart

Orange Juice Production

Juice HACCP (Discussion)

What do youthink?Is there a Problem withthis plan???

Juice HACCP

• Juice Hazard Critical Control Point• CCP1 biological hazard

• Salmonella species• Critical Limit : the supplies ensures only

orange picked from trees are in the shipment • Corrective action : reject shipment if oranges

are not supplier guaranteed

• CCP 1 Chemical Hazard • Pesticide• Critical Limit the suppliers ensures only FDA

certified pesticides were used

THE PROBLEM

Orange You Happy, Inc.’s processing plant has been experiencing some technical difficulties, making the orange juice products unstable.

Ishikawa Fishbone Cause-and Effect Diagram

Pareto Chart

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apperance off flavor too much pulp not coldenough

too acidic too muchbitterness

very bitter do not like thepackaging

Orange Juice survey Complaints

number of complaints Cumlative Percentage