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
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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
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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
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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
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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
