Food-and-beverage-processing.docx

GROUP 10 Magat, Roderick Jr. Padilla, Ely France, E. Pantaleon, Stephen, D. Food and Beverage Processing When wandering the grocery store aisles, it’s easy to forget that for every colorful package that sits on the shelves, a myriad of processes go into preparing the foods inside. Whether it’s cereal, breakfast pastries, cookies or canned peaches, everything must be either steamed, dehydrated, pulverized, pasteurized or otherwise treated to fit into the cans, boxes and cellophane packages.

STANDARDS Because safety is involved, many regulations and standards are in place around the world. Yet there are few specific guidelines and none that are accepted worldwide to manage the quality and purity of the steam that comes into direct contact with the food or processing that food. In the U.S., there are basically three mentions in current regulations: Accepted Practices for a Method of Producing Culinary Steam, the FDA Code of Federal Regulations and a National Organic Standards Board review.

GRADES OF STEAM Several grades of steam are used in food processing and each has its own level of contamination risk. Each also presents its own challenges for the equipment in process control.

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PLANT STEAM

Industrial or plant steam is the lowest grade of steam. It is the starting point for all steam used in food and beverage processing, but it’s the steam that doesn’t come into direct contract with the food or drink product. In other words, it’s used in heat exchangers or used for hot water generation, in boiling pans and other areas. Softened water, reverse osmosis-treated or dealkalized water is generally used for plant steam.

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FILTERED OR CULINARY STEAM

The next level of steam is filtered or culinary steam. Culinary steam is used in applications used to sanitize the processing system. These are called “Clean in Place” (CIP) procedures, and they are employed to ensure the proper level of hygiene in pipes, valves, fittings and related components in the food processing systems themselves.

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CLEAN STEAM

The highest grade of steam is clean steam, and it is typically raised from purified water in a dedicated clean steam generator. This is the area in which the foods or beverages are in direct contact with the steam. To create clean steam, a secondary generator with a controlled feed water system is used. Clean steam requires the use of stainless-steel pipework and components that eliminate the potential for corrosion of steam traps, valves and pipeline equipment. Methods, Processes, And Equipment in Processing Food and Beverages The food and beverage processing sector covers a wide range of products. Many process steps are common to the manufacture activities of different products. Food and beverage processing plants vary in size and location, and are ideally located in close proximity to fresh water resources. Plant operation is often seasonal reflecting the harvesting of the raw materials, however product lines are unaffected by seasonal variations and take place throughout the year. Product processing Food and beverages can be processed as a single operation or in a combination of several operations. The most common processing methods are through heat application and heat removal. The heat application methods include blanching, pasteurization, heat sterilization, evaporation, and dehydration including heat processing by baking or cooking in oils. Heat removal processing includes chilling, controlled or modified storage and packaging (to reduce the rate of respiration), freezing, and freeze-drying. Other preservation and processing methods include the use of sodium chloride and sugar, food additives, and irradiation. Heat application processes 

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Blanching- is a cooking process wherein a food, usually a vegetable or fruit, is scalded in boiling water, removed after a brief, timed interval, and finally plunged into iced water or placed under cold running water (shocking or refreshing) to halt the cooking process. Blanching foods will help reduce quality loss over time. Pasteurization- is the process of heat processing a liquid or a food to kill pathogenic bacteria to make the food safe to eat. The use of pasteurization to kill pathogenic bacteria has helped reduce the transmission of diseases, such as typhoid fever, tuberculosis, scarlet fever, polio, and dysentery. Heat sterilization Dry heat sterilization process is accomplished by conduction; that is where heat is absorbed by the exterior surface of an item and then passed inward to the next layer. Eventually, the entire item reaches the proper temperature needed to achieve sterilization. Moist heat sterilization describes sterilization techniques that utilize hot air that is heavily laden with water vapor and where this moisture plays the most important role in the sterilization. Evaporation- is the partial removal of water from liquid food by boiling. For instance, liquid products can be concentrated from 5% dry solids to 72%, or even higher, depending on the viscosity of the concentrates. Evaporation is used to pre-concentrate food, to increase the

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solid content of food, to change the colour of food and to reduce the water content of a liquid product almost completely, e.g. as in edible oil drying. Dehydration- In food processing , means by which many types of food can be preserved for indefinite periods by extracting the moisture, thereby inhibiting the growth of microorganisms. Dehydration is one of the oldest methods of food preservation and was used by prehistoric peoples in sun-drying seeds. Distillation-is the process of separating the components or substances from a liquid mixture by selective boiling and condensation.

Heat removal proceseses  

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Chilling- refers to the rapid cooling of a food product from its manufacturing temperature down to refrigerated or cold temperatures, usually from 2 to 4°C. Controlled or modified storage and packaging (to reduce the rate of respiration)Modified Atmosphere Packaging is an optimal blend of pure oxygen, carbon dioxide and nitrogen within a high barrier or permeable package. A finely adjusted and carefully controlled gas blend is developed to meet the specific respiration needs for each packaged food product. Freezing- In the food industry , freezing usually refers to deep freezing, or lowering the temperature of product below -18°C. Freeze-drying- also known as lyophilisation or cryodesiccation , is a low temperature dehydration process which involves freezing the product, lowering pressure, then removing the ice by sublimation . This is in contrast to dehydration by most conventional methods that evaporate water using heat.

Other preservation and processing methods include the use of preservatives, food additives, irradiation etc. Food coloring - added to food to replace colors lost during preparation, or to make food look more attractive. May be natural or artificial, the latter are much cheaper to use. Unfortunately, artificial food colorings, such as Yellow 5 have been linked to behavioral problems in children. Some food colorings approved for use in the US have been banned in Europe and Japan. Flavors - natural and artificial - while natural sounds healthier, this may not always be the case (see poison mushrooms). Flavors are added to foods to enhance their aroma and entice you to buy them and then eat them. Humectants - prevent foods from drying up. Glycerine is an example. Preservatives - prevent food from spoiling due to mold, bacteria and other microorganisms. Three natural preservatives are salt , sugar , and vinegar . But there are many more artificial preservatives in use today, such as nitrates and nitrites found in meats. Home baked bread goes stale after 36 hours, and starts to develop mold within 4 days, but a loaf from the supermarket will keep for more than a week due to propionates which prevent mold.

Food irradiation is the process of exposing food and food packaging to ionizing radiation . Ionizing radiation, such as from gamma rays, x-rays or electron beams, is energy that can be transmitted without direct contact to the source of the energy (radiation ) capable of freeing electrons from their atomic bonds (ionization) in the targeted food. Equipment

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A Accumulation Table Agitator Aspirator

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B Bin Blancher Blender* Blower Boiler* Box Taper Bucket Elevator

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C Can Closer Cap Sorter Capper Carbo Cooler Cartoner Case Sealer & Gluer Case Taper Caser Centrifuge* Chiller Chocolate Equipment Chopper CIP System Coater Coating Pan Compressor* Conveyor* Cooker Cooler Cooling Tower Corker Counter Crimper Cutter

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D De-Duster Depositor Destemmer

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Detector* Dicer Dryer* Dumper Dust Collector*

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E Encruster Evaporator* Expeller Extractor Extructor* Extruder

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F Feeder* Fermenter Filler* Filling Line Filter* Flaker Freezer Fryer

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G Generator Grinder*

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H Heat Exchanger* Homogenizer Hopper

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K Kettle*

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L Labeler* Lab Equipment Lidder Liquifier

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M Metal Detector

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Mill* Mixer*

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O Oven

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P Pasteurizer Peeler Press* Printer Pulper Pump*

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R Refrigeration Ribbon Mixer Roaster

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S Scale* Screen Screw Press Seasoner Seasoning Drum

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Sheeter Silo Slicer Stainless Steel Tank Stuffer

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T Table* Tank* Tenderizer Tunnel

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U Unloader Unscrambler

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V Valve Votator

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W Washer Water Treatment Winery Equipment Wrapper*

RISK The Food & Beverage Industry is one of the most dynamic industries around. Just as in the world of fashion, the food sector too experiences constant evolution. The changing industrial climate makes this industry particularly challenging for manufacturers, suppliers and retailers alike. Risks are aplenty and managers need to ready themselves and their teams to withstand the force of this change. Having a comprehensive risk management system in place will enable manufacturers to recognize risks and counter them effectively. It is important for companies to build physical and intellectual capabilities that can protect them from the risks associated with a dynamic market. The Food & Beverage Industry faces multiple risks, such as:       

Changes in consumer tastes Changes in national and regional statutory regulations Evolving demographic trends Compromised quality of ingredients and materials Contamination and poisoning of ingredients and end products Development of incorrect product design

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Unnecessary and unhealthy practices and processes in place Mismatch in technological capabilities and market requirements Manhandling of product and materials and resulting damage Financial risks associated with various processes and practices Third party risks related to transport agencies, middlemen, financiers, retailers and so on Risks associated with sharing intellectual property Risks associated with product information misrepresentation Consumer safety risks Loss mitigation risks and inability to manage risk