Processing Technologies For Value Added

Value-Added Food Products Potential Processing Technologies for ValueAdded Fruit & Vegetable Products Yanyun Zhao Dept. of Food Science & Technology Oregon State University

• ValueValue-added food products are raw or prepreprocessed commodities whose value has been increased through the addition of ingredients or processes that make them more attractive to the buyer and/or more readily usable by the consumer.

The New Food Entremanuer Conference, April 11-2, 2005

Adding Value to Your Products

Food Processing Technologies Physical Methods

Product ideas Processing technologies Package design Marketing and advertising

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High temperatures (canning) Low temperatures (freezing) Remove of water (drying) High hydrostatic pressure Use of ionizing radiation

Chemical Methods – Use of sugar (jams, jellies) – Fermentation and salting (natural fermentation) – Treatment with acids (addition of vinegar)

ShortShort-term Processing Methods – Refrigeration – Cold storage and packaging with modified or controlled atmosphere – Chemical treatments

Freezing Fruits and Vegetables Freezing is a quick and convenient way to preserve fruits and vegetables. The extreme cold slows the growth of microorganisms and the chemical changes that affect quality or cause spoilage. Correctly frozen foods maintain excellent color, flavor, texture, and food value.

Freezing Methods Air freezing – airair-blast freezer ((-30~30~-45oC, air velocity 10~15m/sec)

Indirect contact freezing – food placed on cold plates, trays, belts, separated from refrigerant

Immersion freezing – immersion in cold air - fluidized bed – immersion with cryogenic liquid (liquid N2 & CO2) boiling temp. of liquid N2 is -196oC, CO2 is -79oC

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Air-blast Freezer

Tray Freezer

Spiral Freezer

Immerse Freezer The product is exposed to a liquid refrigerant that is undergoing phase change as the freezing process occurs. The common refrigerants used for immersion freezers -nitrogen, carbon dioxide, and FreonFreon-must be approved for food product contact. Very rapid freezing is achieved, resulting in superior product quality when rate of ice crystal formation influences quality. Overall process efficiency is influenced by recover expensive refrigerant as the freezing process is complete.

Quality Control of Frozen Fruits and Vegetables Rapid freezing (>4 (>4oC/min) to have small small regular ice crystals Maintain low and stable storage temp. (– (–18 ~ – 23oC) to prevent re - crystallization, high drip loss, etc. Prevention of freezing burn during storage – appropriate packaging materials and prevent temp. fluctuation during storage Blanching before freezing of some fruits and vegetables to inactivate natural enzymes for preventing discoloration and quality loss

Fluidized Bed Freezer A modified version of an IQF system. Very high convective heat transfer coefficients. Product pieces must be relatively small to establish and maintain a fluidized bed. The limits to use of the process are based on efficiency: energy requirements necessary to maintain the fluidized condition. The primary product parameter influencing energy required for fluidization is size or mass of the product.

Indirect Contact Freezer - Plate Freezer

Application (Market) of Frozen Fruits and Vegetables As end products for direct consumer usage Ingredients in ice cream, frozen yogurt, fresh and frozen baked goods and other frozen dairy and nonnon-dairy products

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Drying Fruits and Vegetables Drying is the oldest method of preserving food by removing water from food (reducing water activity). Advantages include: -Make product safe -Convenience -Increase shelf life -Reduce weight

Drying Methods Sun (raisins) Belt oven (vegetable pieces, crackers, cookies) Roller or drum (mashed potatoes) Spray (coffee, infant formula) Freeze (coffee, strawberries) Osmosis (infusion)

Batch and Continuous Air Drying

Drum Drying

Freeze Drying

Freeze Drying

• Water removal by sublimation • Under vacuum (27 - 133 Pa)

Components in freeze drier – FreezeFreeze-dryer – Heater – Vacuum pump

Best nutrient quality Best product quality (shape; rehydration) rehydration) Most expensive Good control

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Infused Dried Fruits and Vegetables Place solid food, whole or in pieces, in sugars or salts aqueous solutions of high osmotic pressure At least two major simultaneous countercurrent flows – water flow out of the food into the solution – transfer of solute from the solution into the food

Major advantages

Process Control in Osmotic Dehydration Pre - treatments – blanching, SO2 Temperature control; Type of sugar or salt Agitation Final drying

– Soft texture – Enhanced flavor and taste – Energy saving and others

Application (Market) of Dried Fruits and Vegetables Dried fruits as snack Fruits - salads, brownies, muffins, cookies, breads, bagels, cereals, rice dishes, entrees, etc. Vegetables - dry soups, breads, bagels, stuffing and rice mixes, pasta dishes, boxed dinner kits, etc.

pH Scale and Classification of Foods According to Their Acidity

Canning Canning can be a safe and economical way to preserve quality food. Canning practices remove oxygen; destroy enzymes; kill and prevent the growth of undesirable bacteria, yeasts, and molds; and help form a high vacuum in cans.

High Acid Foods Berries, fruit, tomatoes, sauerkraut Only vegetative cells must be destroyed because spores won’t germinate Boiling water bath or hot fill may be used

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Acidified Foods Food with pH above 4.6 may be acidified and then processed as a high acid food Blanch in acidified water Blanch in water, then pack in acidified brine Direct adjustment of batch pH with acid Predetermined amount of acid added to each individual container • Add high acid food to low acid food • • • •

Final EQUILIBRATED pH must be below 4.6 FDA regulated

If you’re really going to use any of these canning processes.....

GO TO BETTER PROCESS CONTROL SCHOOL

High-Pressure Processing Food Novel, nonnon-thermal food processing, pressure is applied uniformly, in all directions Extremely high pressures – Kills vegetative microorganisms – Retains flavors and nutrients – Extends shelf life

Food has higher quality than thermally processed foods and is safe Food is not crushed Product characteristics virtually unchanged

Low Acid Foods pH > 4.6 Toxins produced by some organisms can be lethal Cannot be made commercially sterile in boiling water bath Must be processed under pressure FDA and USDA regulations Requires a Better Process Control School certified supervisor

High Hydrostatic Pressure High hydrostatic pressure is a novel food processing technology where foods are subjected to high isostatic pressure, generally in the range of 100-600 MPa, at or around room temperature.

Commercialization Product: jams & fruit toppings Elimination of yeasts and moulds Producer: MeidiMeidi- ya, a, Japan Market Introduction: 1991

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Commercialization Fresh orange juice, refrigerated Deactivation of pectin methyl esterase ensures cloud stability Reduction of microbial load (yeasts, lactic bacteria) Producer: Ulti, Ulti, PernodPernod-Ricard, Ricard, France, www.pernodwww.pernod-ricard.com Market Introduction: 1995

Commercialization Guacamole, refrigerated Prevention of browning by deactivation of polyphenol oxidase Reduction of bacterial load Producer: Avomex, Avomex, Keller, TX Market Introduction: 1997 New products: chipotle sauce, salsa, pico de gallo

Terms

Jam and Jelly Jam and jelly are gelled or thickened fruit products with a low pH, cooked and preserved with sugars. Products include fruit butters, jellies, preserves, jams and similar products.

Jelly - a mixture of fruit juice and sugar that is clear and firm enough to hold its shape. Jam - made from crushed or chopped fruit. Jam holds its shape, but is less firm than jelly. Conserves - jamjam-like products that may be made from a mixture of fruits. They may also contain nuts, raisins, or coconut. Preserves - made of small, whole fruits or pieces of fruits in a clear, thick, slightly gelled syrup. Marmalades - soft, transparent fruit jellies that contain small pieces of fruit or citrus peel. Fruit butters - made from fruit pulp cooked with sugar until thickened.

Essential Ingredients in Jellies and Jams Fruit or fruit juice Pectin - make fruit juice to gel Acid - for gel formation and flavor Sugar – proper proportions with pectin and acid to make a good gel – prevent the growth of microorganisms – contributes to the taste

Pectin Pectin content in fruits – Highly variable within and among commodities – Some fruits contain sufficient native pectin for gelation, gelation, e.g. plum – Citrus pectin often added to form gel

Pectin grade – Parts of sugar that one part pectin will gel under standard conditions, pH = 3.23.2-3.5; sugar = 7676-70°Brix – Commercial pectin sold as 100 or 150 grade

Pectin types – HighHigh-methoxyl (Rapid(Rapid-set, SlowSlow-set) – LowLow-methoxyl

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Standard Identity and Regulations Fruit jellies - 45 parts by weight of the fruit juice ingredient to each 55 parts of the sweetener solids (45:55). The finished soluble solids content of a jelly is not less than 65%. Fruit preserves and jams – Berries - 47 parts by weight of the fruit component to 55 parts of the sugar – Pomes - 45:55 – Finished product is not less than 65% solids Title 21CFR Part 150 http://www.accessdata.fda.gov/scripts/cdrh/cfdocs/cfCFR /CFRSearch.cfm

Principles of Preservation Add sugar to increase osmotic pressure to prevent microorganism development (~60% sugar) In food preservation with sugar, water activity can’ can’t be reduced < 0.845- sufficient for bacteria and neosmophile yeast inhibition, but does not prevent mold attack. Other means are used to avoid mold development: – Finished product pasteurization – Use of chemical preservatives

Vegetable Pickling & Fermentation Pickled or Fermented products cure for several weeks. Curing changes the color, flavor, and texture of the product. Lactic acid produced during fermentation helps preserve the product. Developed by Ministry of Agriculture, Fisheries and Food, BC, Canada http://www.agf.gov.bc.ca/busmgmt/budgets/budget_pdf/value_added/VA2.PDF

Principles of Fermentation Breakdown of carbohydrates under anaerobic conditions Allow growth of nonnon-pathogenic microorganisms to produce acid or alcohol Production of foods or ingredients by microbial cultures

Benefits of Fermentation Preservation of the product - acid produced may

prevent spoilage of food. Add, remove or alter existing flavors Alter chemical characteristics of the food – Sugar to ethanol – Ethanol to acetic acid – Sugar to lactic acid Two ways – natural acidification – artificial acidification

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Natural Fermentation A predominant lactic fermentation – Lactic acid bacteria succeed in overcoming the accompanying microorganisms and lactic acid is formed to reach pH < 4.1

Encourage the multiplication of select M.O.’ M.O.’s and their metabolic activities in foods Raw material is put into a brine without previous heating

Combined Acidification Involve as a preliminary processing step a weak lactic fermentation followed by acidification (vinegar addition) Classes of vegetables preserved by natural acidification (fermentation) – Sauerkraut – Cucumber Pickles – Green Olives

Artificial Acidification Addition of organic acids – Acetic – Lactic – Citric – Addition of acid foods

Cucumber Pickles - 3 major categories Brine stock ( fermented) – Genuine Dills – Sweet Gherkins – Dill Chips

Fresh Pack (acidified and pasteurized) – polish dills – Bread and Butter

Refrigerator Pickles ( acidified and refrigerated) – Claussens

Fruit Juice Juice without pulp (clarified or not clarified) Juice with pulp Nature juice – product from one fruit Mixed juices - products from mix of 2 or 3 juices from different fruit species or by adding sugar Developed by Ministry of Agriculture, Fisheries and Food, BC, Canada http://www.agf.gov.bc.ca/busmgmt/budgets/budget_pdf/vegetables/pklgcuke.pdf

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FDA SINGLE STRENGTH JUICE VALUES http://pdlab.com/juicex.htm http://pdlab.com/juicex.htm Juice Type

Brix

Acerola

6.0

Apple

11.5

Apricot

11.7

Banana

22.0

Major Steps for Fruit Juices Without Pulp Washing and sorting Crushing/grinding/disintegration step – Crushing for grapes and berries; – Grinding for apples, pears; – Disintegration for tomatoes, peaches, mangoes, apricots.

Enzyme treatment – optional step to improve improve extraction yield, juice color and finished product taste – Add 22-8% pectolitic enzymes at ~ 50° 50° C for 30 min – For fruit naturally rich in pectic substances, this may result "exhausted" material

Heating – An optional step used for some fruit to facilitate pressing and color fixing; sometimes, protein coagulation takes place.

Blackberry 10.0

Steps for Fruit Juices Without Pulp Pressing to extract juice Juice clarifying – – –

Centrifugation or enzyme treatment. Centrifugation at a speed of 6000 to 6500 RPM. Enzyme – adding pectolitic enzyme in 0.5 to 2 g/l, g/l, last 2 to 6 hr at room temp, or <2 hr at 50° 50°C – Controlled by checking juice viscosity, or is completed with a step called "sticking" by adding 55-8 g/l of food grade gelatin.

Major Steps for Fruit Juices with Pulp Process at industrial scale in two categories of operations: a. Processing for obtaining juices; b. Juice conditioning for preservation.

Pasteurization – Water baths at 75° 75° C until juice reaches 68° 68° C – Rapid pasteurization at about 80° 80° C, over 1010-60 sec., followed by cooling

Processing for Obtaining Juices Berries (strawberry, wild berries, etc.) Washed, sorted, crushed, preheated and then introduced in extractor. To avoid browning and undesirable taste, add 0.05% ascorbic acid.

Stone fruits (apricots, peaches, cherries, etc.) Washing, sorting, submitted to steam in a continuous heater Warm fruit mass is passed through a pulper and then an extractor.

Pomaces (apples, pears) Washed, sorted, and crushed in a colloid mill; Fruit puré purée is passed through a screw type heating equipment Warm fruit mass is treated in a pulper with a 2 mm screen and then through an extractor

Juice Conditioning for Preservation ƒ Use continuous centrifugal separator to partially eliminate cellulose ƒ Juice is processed to adjust sugar and acid content for viscosity ƒ Sugar (about 88-10%) is added as a syrup ƒ Acidity is adjusted with citric or tartaric acid ƒ Juice is deaerated under vacuum at about 40° C for avoiding oxidative reactions and vitamin C loss ƒ Homogenization to obtain particles with dimensions below 100 ƒ Pasteurization in plate heat exchanger at ~ 130° C, cooled down to ~ 90° C and aseptically packed

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FreshFresh-Cut Fruits and Vegetables

Developed by Ministry of Agriculture, Fisheries and Food, BC, Canada http://www.agf.gov.bc.ca/busmgmt/budgets/budget_pdf/value_added/VA30.PDF

FreshFresh-Cut Fruits and Vegetables Key controls – Preparation (cutting, trimming, sorting, washing, etc.) – Disinfection – Temperature control – Packaging (MAP) – Shelf- life and microbial safety

Modified Atmosphere Packaging Replacement of air with a single gas or mixture of gases No further control over initial composition

Gases: CO2: Anti-microbial agent, inhibit lipid oxidation O2: Maintain fresh bright red meat color Inhibit growth of pathogenic anaerobic bacteria

N2: Inert gas, as a packaging filler Inhibit aerobic bacteria growth

How to Access University Extension Service – Workshops/short courses – Communication – Contracted work

Licensed facility – Incubator kitchen – Co - packs

Kitchen Incubator A sharedshared-use commercial kitchen where caterers, street cart vendors, farmers, and producers of specialty/gourmet food items can prepare their food products in a fully licensed and certified kitchen. Often sponsored by an umbrella nonprofit organization or existing business incubator, provide startstart-up businesses the opportunity to explore food production without the high cost of buying their own equipment or constructing their own building. Usually offer technical assistance in food production as well as general business management skills, networking opportunities among entrepreneurs, and the opportunity to form shared services cooperatives for marketing, distribution, and supply purchasing. http://www.gjincubator.org/incubatorfacility.html http://www.gjincubator.org/incubatorfacility.html

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Kitchen Incubator in OR Incubator Creative Group Cheshire Oregon Association of Minority Entrepreneurs Ctr Portland Oregon Innovation Center Bend Portland Business Accelerator Portland University of Oregon Eugene

Co-Packing Existing food processors to make your product according to your specifications CoCo-packers usually sign a nonnon-disclosure agreement, promising not to copy, disclose, or use your recipe or formula except in your own products. Check “Thomas Food Industry Register” Register” for coco-packers in different states

Resources “Food Processors Handbook” developed by ODA FDA, USDA, and State website on the federal ad state regulations Technologies – University food science Extension website Equipments – “Food Manufacturer” Manufacturer” http://www.foodmanufacturing.com/

Small scale food processing - http://www.ssfp.ca http://www.ssfp.ca//

Kitchen Incubator in WA Applied Process Engineering Laboratory Richland www.apel.org Ellensburg Business Incubator Ellensburg Military Technology Contracts Incubation Center (360) 377377-0191 Bremerton TriTri-Cities Enterprise Center Richland TriTri-County Economic Development District Colville William M Factory Small Business Incubator Tacoma

Find the Right Co-Packer Gather name Check for quality Compatibility – Level of Involvement – Supplies – Ingredients – Volume – Case Amount

Technical manual on small-scale processing of fruits and vegetables FOOD AND AGRICULTURE ORGANIZATION OF THE UNITED NATIONS Gaetano Paltrinieri Senior Food Technology and Agroindustries Officer, FAO Fernando Figuerola Food Science and Technology Expert Loreto Rojas Food Technology Expert FAO REGIONAL OFFICE FOR LATIN AMERICA AND THE CARIBBEAN Santiago, Chile 1997 http://www.fao.org/documents/show_cdr.asp?url_file=/DOCREP/x0209e/x0209e00.htm

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Small-Scale Food Processing: A Directory of Equipment and Methods Edition: 2nd - Author(s): AzamAli, Sue; Ali, Sue Azam; Battcock, Mike; Fellows, Peter; Judge, Emma ISBN: 1853395048 Format: Paperback Pub. Date: 5/1/2003 Publisher: Stylus Pub Llc

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