food technology

Food manufacturing equipment:

TOPIC: Food Manufacture Production and processing of food-Q uality and quantity control in the selection of raw materials for food processing Raw Materials: any item that is used to manufacture a food product, doesn’t just include naturally occurring ingredients but synthetic ones too like additives. Raw materials include: ---- Ingredients; fruits, vegetables, milk, flour, meat Processing materials; steam and water Food additives; emulsifiers, preservatives, colours and flavours Packaging materials; cans, bottles, plastic, glass Band 6 responses will refer to processing materials, packaging and food additives in a Q about raw materials opposed to just ingredients. Value added products are raw materials that have been processed in a way to make the product more valuable to the consumer increasing profits Quality control of raw materials: conducting tests to check the standards of raw materials or products before, during or after production Raw material specifications (what they criteria they are tested against:------ Physical characteristics: shape and size Sensory characteristics: how it looks, smells, tastes Chemical characteristics: moisture content or pH levels Biological characteristics: microbial limits Nutritional characteristics: nutritional content Contamination characteristics: limit of bacteria in raw material that make it unsuitable for consumption Inferior batch results in dissatisfied customers and damage to company image. There are 4 steps in the quality control testing process 1. Describing the characteristics of the raw material; what of the above characteristics are suitable for the product manufacture 2. Choosing the sample of the raw material to be tested; how many will they test 3. Testing for each characteristic; specific tests undergone to determine quality 4. Taking action on the result; decision on use of the raw material or rejection Creating the raw material specifications are established through consultation with FSANZ, the team responsible for establishing specifications are research & development, quality assurance and production. Info included in specifications consists of; name and description, food allergens, sensory, physical chemical and microbial info, storage and shipping, shelf life and handling directions.-De scribe processes that transform raw materials into manufactured food products Specific ones I may not remember definition of: Processing technique Description Canning Food products are packed into a can and heated to high temp to kill harmful microorganisms. Pasteurisation Heating and quick cooling of food products to kill microorganisms. Deep-freezing Freezing of a product that forms ice crystals in the food product’s tissue extending shelf life. Sterilisation Canned food products are steamed to kill harmful bacteria. Fermentation Sugar in food products is broken down by microorganisms in a low oxygen environment. Blanching Heating of product with steam or water prior to canning.-R ole of food additives in the manufacturing process Food additives: substances added to raw materials when making a product, used in small amounts for a range of functions, necessary for efficient manufacturing and distribution. Food labels typically display presence of additives. The functions of food additives are to:---- Improve the stability or keeping quality: sorbitol a humectant used in the preservation of dried fruit to reduce moisture level Adapt foods to provide for special dietary needs: artificial sweeteners such as aspartame used in sugar free substitutes like coke zero to market the product to people with diabetes Restore or improve sensory characteristics of processed foods specifically taste and appearance: Beeswax as a glazing agent to coat apples to improve appearance Extend shelf life: sulphur dioxide used as a preservative in sausage meat to limit microbial growth Commonly asked in the HSC. BE sure to know an example for each Additive Description Examples Antioxidant Prolong shelf life by preventing oxidation – fats or oils turning rancid Ascorbic acid in jams and cured meats Preservatives Prevents growth of mold or bacteria Sulphur dioxide in dried fruits, pickles, sausages and juice Colours Restore colour or enhance physical appearance Red 40 used in confectionary Flavouring Restores flavour and odour lost through processing Flavour concentrates added back to fruit juice or soup packets Flavour enhancers Improves existing flavours Monosodium glutamate MSG used in packet noodles Food acids Maintain acidity Citric acid in juice or lollies Artificial sweeteners Substitute for sugar in low KJ foods Aspartame in coke zero Emulsifiers Allows combination of oil and water without separation Lecithin in salad dressing Vitamins and minerals Added to fortify foods if lost in production Addition of vitamin D to margarine Humectant Absorbs moisture, prevents food from drying out. Sorbitol in dried fruits Regulation of food additives and consumer safety: carefully regulated by FSANZ, assesses each food additive, determines what levels at which it can be safely used and consumed. TNC’s with products with banned additives are required to alter recipe if they wish to sell within Australia. FSANZ also requires additives listed on labels. Code numbering has been used to list additives in labelling because it’s easier to spot, can specify things like type of colour etc. Disadvantages: adverse reactions occur in some of the population, food colour and additives negatively impact children, can cumulate and become toxic, can be used to deceive consumer. -C haracteristics of equipment used in different types of production and factors influencing their selection Domestic and industrial equipment often share the same if not similar processes the only difference is scale of operations. Food manufacturing equipment must be strong, hygienic, efficient and durable (SHED). Strong: needs to produce large amounts of food, sturdy to ensure safety for employees and operators. Hygienic: made of stainless steel, easy to clean to prevent cross contamination. Efficient: time delays can impact the amount of food produced, also produces consistent product. Durable: may have to operate 24/7, able to withstand high volumes of production and continuous operation. Factors that influence a company selecting equipment include cost, accessibility and intended use. -P roduction systems used in the manufacture of food, eg small, scale, large scale, manual, automated and computerised Production systems: systems used to manufacture food, systems vary between foods produced and size of the company making them. Automated: when machines handle and control the processing of food from receiving the raw materials to the finished product. Automated systems have pre-set and predetermined specifications for operation including cooking time, chilling time, weight of products, mixing times and speed, temperature control etc. Computerised: located in highly sophisticated manufacturing organisations (TNC’s), similar to automated but operated by computerised sensors that store complex data, batch numbers, dates, times, production conditions etc. HOWEVER, very costly, isn’t necessarily needed within Australia due to lower demand for food products with a smaller population.-De scribe the processing techniques, equipment, storage and distribution systems used in industry and compare with those used domestically-Q uality management considerations in industrial practises to achieve safe foods for public consumption, e.g., hazard analysis and critical control point ( health and safety and hygiene HACCP ); work Quality management systems: a set of policies, processes and procedures required to plan and execute a safe reliable food supply for consumers. Covers all aspects of product development, production, marketing and servicing. Quality assurance: use of management systems to ensure standards in quality are achieved and maintained. Procedures include: o Clear concise final product specification o Procedures for assessing and measuring quality o Clear specifications for all production areas o Sampling and testing of the completed product is undertaken Without proper procedures in place, there is the risk of food poisoning which can impact all sectors of the agri-food chain as well as all companies involved. Educating the importance of food safety to workers paired with accurate records of relevant information and quick responses to any problems reduce this risk and help the company maintain a safe high quality product. Quality control: characteristics are measured, compared to a standard and any differences that occur may be acted upon. HACCP – Hazard Analysis Critical Control Points is a quality assurance and food safety system that identifies potential food hazards and their control points throughout all stages. HACCP is compulsory in some food sectors and recommended in others. The system is used worldwide and viewed highly. Advantages of HACCP: more profit and less waste for businesses, edge over competition, preventative measure, consumer confidence in safety, job security is improved. Disadvantages of HACCP: costly, requires a lot of manpower, not often realistic for smaller companies and restaurants. HACCP principles 1. Assess the hazards – identify hazard and determine risk level, severity of each hazard is rated for its potential to cause harm to the consumer. Catering kitchen knowing raw chicken contains salmonella bacteria, so they prepare and store it separate from other foods. 2. Identify critical control points – determining where a safety issue arises, known as critical control points (CCP), includes all processes where failure of control can compromise food safety. Examples of CCP’s: storage and transport, cooling, chilling or freezing, heating for pasteurisation etc, cleaning and santising, packaging and sealing. 3. Set critical limits – set limits to ensure issues don’t arise. Limits of 0 to -4 degrees for the storage of a product. 4. Monitoring critical control points – implementing a monitoring system to ensure limits are adhered to, quantitative testing measuring aspects such as temperature, acidity, water activity and microbial load to predetermined standards (example of critical limits), qualitative testing by visual inspection of colour, texture. 5. Establish corrective actions – deciding actions to take if critical limits are not adhered to, involve adjusting the process to prevent future failure or wasting current batch. 6. Verification of HACCP procedures – reviewing process, making adjustments, when necessary, regular reviews of procedures, checking records, outside inspector ensures verification 7. Establish record keeping procedures – keep records of hazard identifications and CCP’s, limits and corrective actions, must be retained for 4 years and available for audit, documentation identifies each batch. Good manufacturing practice (GMP): system ensuring food products are consistently produced and controlled according to quality standards. International Organisation for Standardisation (ISO): specifies requirements for a food safety management system. Creates guidelines for food safety management, relevant and suitable for all organisations within the agri-food chain. Work health and Safety: ensures safety of workers, machinery can be dangerous, accidents in the workplace are often caused most by a worker being unskilled at their job, rushed or poorly maintained equipment, in businesses of more than 20 staff, a WHS committee must be formed. Work Health and Safety Act 2011 (NSW) is a legislation that requires safety for workers including safety guards, correct PPE and rotation of workers. SafeWork NSW enforces this legislation and investigates issues such as injury and death in order to make recommendations and implementations.