Food Processing and Food Products Developments
Food Processing
Food Processing is the set of Methods and techniques used to transform raw ingredients into food or to transform food into other forms for consumption by humans or animals either in the home or by the food processing industry. Food processing typically takes clean, harvested crops or slaughtered and butchered animal products and uses these to produce attractive, marketable and often long-life food products. Similar process are used to produce animal feed.
Processed foods are foods that have been changed mechanically or chemically on a domestic or commercial level.
The food processing sector is highly fragmented industry, it widely comprises of the following sub-segments: fruits and vegetables, milk and milk products, beer and alcoholic beverages, meat and poultry, marine products, grain processing, packaged or convenience food and packaged drinks. A huge number of entrepreneurs in this industry are small in terms of their production and operations, and are largely concentrated in the unorganized segment. This segment accounts for more than 70% of the output in terms of volume and 50% in terms of value. Though the organized sector seems comparatively small, it is growing at a much faster pace.
Brief history
Food processing dates back to the prehistoric ages when crude processing incorporated slaughtering, fermenting, sun drying, preserving with salt, and various types of cooking (such as roasting, smoking, steaming, and oven baking) In 1809 Nicolas Appert invented a vacuum bottling technique that would supply food for French troops. This contributed to the development of tinning and then canning by Peter Durand in 1810. Pasteurization, discovered by Louis Pasteur in 1862, was a significant advance in ensuring the micro-biological safety of food.
In the 20th century, food processing developed with advances such as spray drying, juice concentrates, freeze drying and the introduction of artificial sweeteners, coloring agents, and preservatives such as sodium benzoate In the late 20th century products such as dried instant soups, reconstituted fruits and juices, and self cooking meals such as MRE food ration were developed.
Food processing methods
Peeling: Removal of unwanted outer layers, such as potato peeling or the skinning of peaches.
Mincing: Mincing is a cooking technique in which food ingredients are finely divided. The effect is to create a closely bonded mixture of ingredients and a soft or pasty texture. Flavoring ingredients such as garlic, ginger, and fresh herbs may be minced to distribute flavor more evenly in a mixture.
Chopping or slicing: e.g. diced carrots
Emulsification: An emulsion is a mixture of two immiscible (unblendable) liquids, One liquid (the dispersed phase) is dispersed in the other (the continuous phase). Many emulsions are oil/water emulsions, with dietary fats being one common type of oil encountered in everyday life. Examples of emulsions include butter and margarine, milk and cream, and vinaigrettes
Fermentation: Fermentation in food processing typically refers to the conversion of sugar to alcohol using yeast. Fermentation usually implies that the action of the microorganisms is desirable, and the process is used to produce alcoholic beverages such as wine, beer, and cider
Liquefaction: such as to produce fruit juice e.g mango juice,orange juice etc it means to turn something into the liquid state
Baking: Baking is the technique of prolonged cooking of food by dry heat acting by convection, and not by radiation, normally in an oven, but also in hot ashes, or on hot stones. It is primarily used for the preparation of bread, cakes, pastries and pies, tarts, quiches, and cookies. Such items are sometimes referred to as "baked goods," and are sold at a bakery. A person who prepares baked goods as a profession is called a baker
Packaging: Packaging is the science, art and technology of enclosing or protecting products for distribution, storage, sale, and use. Packaging also refers to the process of design, evaluation, and production of packages.
REASONS FOR PROCESSING FOODS
Make them safe to eat.
Save time & energy in the home.
Create new food products.
For healthier food options.
Vary the diet.
Increase shelf-life.
Ensure wide choice all year round.
Allow for fortification.
TYPES OF PROCESSING
Primary processing: Changes a basic foodstuff, to change keeping quality, make it saleable and ready for cooking and eating. E.g. milling wheat, pasteurising milk, making vegetable oil from seeds & nuts.
Secondary processing (convenience foods):Takes a basic processed food and uses it to produce a food product. E.g. making margarine from vegetable oil, making bread, cakes, biscuits from flour, making dairy products from milk, convenience meals.
RANGE OF PROCESSED FOODS
Milk,cheese, yogurt.
Butter, margarine, spreads.
Flour, pasta, rice.
Bread, cakes, biscuits, breakfast cereals.
Convenience foods.
Benefits
Toxin removal, preservation and increasing food consistency
Easy marketing and distribution tasks
Increases seasonal availability of many foods
Enables transportation of delicate perishable foods across long distances
Makes many kinds of foods safe to eat by de- activating spoilage and pathogenic micro-organisms
Increases time efficiency and improves taste
Drawbacks
decreases the nutritive value of the food material
results in loss in quantity of the food material
Processed food usually contain hydrogenated oils, trans fatty acids, artificial coloring and too much sugar, which can cause great harm to us over a period of time
Food Preservation
Food Preservation is a process in which food and vegetables are prevented from getting spoilt. The color, test, and nutritive values of food is also preserved. Food products lasts for a long period of time. Shelf life of food product is increased. So, we can defined Food Preservation as: Retaining food over a period of time without being contaminated by pathogenic organisms or chemicals and without losing its colour, texture, flavour and nutritious value. Food Preservation usually involves preventing the growth of bacteria, fungi and other microorganisms, as well as retarding the oxidation of fats which causes rancidity.
Principles of Food Preservation
1. Inhibit the growth and activity of Microorganisms
-Asepsis(to keep out microorganisms)
-Removal of microorganisms
-Stopping the growth and activity of microorganisms (low temperatures, drying or chemicals)
-Destruction of MO(heating or radiation)
2. Protecting against self decomposition of food
-Inhibit the activity of Endogenous Enzyme (Phenolase)
-Delay or inhibit chemical reactions(Non-enzymatic browning)
3. Protection from invasion and spoilage by insects and rodents
4. Protection against losses by mechanical causes
Importance of Food Preservation:
Important and vital in the Food industry due to a number of social, psychological, and health factors
Increases the shelf life of food
Retain the quality of food - colour, texture, flavour & nutritional value
Increases food supply
Adds variety to the food
Decreases wastage of food
Make foods available throughout the year
Food Preservation Methods
Preservation methods vary according to the food items, and quantity of the items to be preserved
Principles of Food preservation can be broadly classified into two types:
1) Bactericidal methods
2) Bacteriostatic methods
Bactericidal methods: Most of the microorganisms are killed Examples are- cooking, canning, pasteurization, sterilization, irradiation etc.
| Bacteriostatic Methods: Based on prevention of multiplication of microorganisms May be achieved by removal of water, use of acids, oils or spices, keeping the foodstuff in low temperature. Methods based on this principles are: Drying,freezing,pickling,salting, andsmoking. |
Techniques of Food Preservation
• Physical • Chemical
Physical
--freezing and canning(rely on killing the microorganisms or at least stopping the their growth for long enough)
--drying, gamma irradiation, exposure to ultraviolet or high intensity white light, ultra high pressure and filtration
Chemical
• Preservatives: Salt, sodium nitrite, spices, vinegar, and alcohol
• Work either as: Direct microbial poisons or, Reducing the pH to a level that prevents the growth of MOS
Chemicals used today are:
1. Nitrates and Nitrites: to preserve meats
2. Sulphites: to prevent the browning of fruits and vegetables, to prevent fungal spoilage
Common food preservation methods:
• Bottling and canning • Pickling • Drying • Salting • Vacuum packing • Cooling and freezing • Waxing • Pasteurization • Boiling • Smoking
Food Irradiation
Introduction: Food irradiation is a physiological process of subjecting food to shortwave radiation, sterilization, disinfestation etc irradiation is considered as appropriate technology to destroy food borne pathogens as compared to heat or chemical preservation Food irradiation is low temperature sterilizing technique as in this case sterilization can be effected at room temperature .Foods are exposed to high energy gamma rays or fast moving electrons. Cobalt-60 or cesium-137 electrons producing machines are the principle sources of ionizing radiations used for food irradiation. It is also known as cold pasteurization as it kills harmful bacteria without heat.
SOURCES OF IRRADIATION
1. Gamma Rays:
✓ Emitted from radioactive element (cobalt 60 / cesium 137).
✓ Excellent penetration power.
2. X-rays:
Produced by reflecting a high energy stream of electrons into food.
High penetration power
Efficiency of conversion from electrons to X rays is less than 10%.
X-ray machines having a maximum energy of 5 MeV.
3. Electron beam :
Stream of high-energy electrons propelled from an electron accelerator into food.
Can not penetrate very far.
Used only for treatment of thin packages of food and free flowing or falling grains.
Accelerated electron machines having a maximum energy of 10 MeV.
IRRADIATION TYPES
1. Radappertization: Not recommended for most foods as high dose (approx. 30 kGy).Equivalent to radiation sterilization.
2. Radurization: Medium dose (1-10 kGy).Enhances keeping quality by reduction of spoilage caused by micro- organisms. Referred as radiation pasteurization.
3. Radicidation: Low dose (<1.0 kGy) - equivalent to pasteurization of milk.
4. Thermo-radiation: Combination of heat and radiation.
Why irradiate food
1. Prevention of foodborne illness: effectively eliminates microbes; Salmonella and E. Coli
2. Preservation: Destroy/ inactivate organisms that cause spoilage and decomposition.
3. Control of insects: Destroys insects e.g imported fruits.
4. Delay of sprouting and ripening: Lengthen the longevity of products e.g: potatoes.
5. Sterilization: Useful for patients in the hospital especially with impaired immunity.
MODE OF ACTION:
The food is exposed to ionising radiation either from gamma rays or a high-energy electron beam or powerful x-rays. Gamma rays and x-rays are a form of radiation that shares some characteristics with microwave,but with much higher energy and penetration.
The rays pass through the food just like microwaves in a microwave oven, but the food doesn't heat up to any significant extent .electron beams and x-rays are produced using electricity, which can be switched off or on, and they do not require radioactive material.
EFFECTS OF IRRADIATION ON FOOD:
Some foods such as dairy foods and eggs cant be irradiated because it changes in flavour or texture. Fruits, vegetables, grain foods, spices and meat can be irradiated. Irradiation causes minimal changes to the chemical composition of the nutrients, however it can alter the nutrient composition of the food because it reduces the level of some of the B- group vitamins. This loss is similar to those that occur when food is cooked or preserved in more traditional and accepted ways, such as canning or blanching.
Benefits of food by irradiation
Extended shelf life of products
Less food spoilage
Reduced risk of food borne diseases caused by microorganisms such as campylobacter, salmonella, e.coli and Listeria.
Less need of pesticides
Less need for some additives, such as preservatives and antioxidants
Lower risk of importing or exporting insect pests hidden inside the food products.
Reduced need for toxic chemical treatments such as those used to kill bacteria found in some spices.
Reduced sprouting in potatoes, onions and herbs
LIMITATIONS
Irradiation cannot be used for all foods:Dairy Products, Peaches, Nectarines
Fermentation
In food processing, fermentation is the conversion of carbohydrates to alcohol or organic acids using microorganisms- yeasts or bacteria-under anaerobic conditions. Fermentation usually implies that the action of microorganisms is desired. The science of fermentation is known as zymology or zymurgy the process of creating food or changing the properties of food using microbes.
TYPES OF FERMENTATION
Homo Lactic fermentation: The fermentation in which only the lactic acid is produced. There is no any side product formed after the reaction.
Hetero-Lactic Fermentation: The Fermentation in which the lactic acid is produced along with some by products like gases.
There are two types of fermentations
1. Aerobic fermentation
2. Anaerobic fermentation
Aerobic fermentation: Wine, beer and acetic acid vinegar needs oxygen in the primary or first stage of fermentation. For example, preparation of acetic acid vinegar is done by exposing the surface of the vinegar to oxygen as much as possible, which helps in creating healthy, flavorful vinegar with the correct pH.
Anaerobic fermentation: Anaerobic fermentation has been applied to many important industrial fermentations, such as ethanol production by yeasts, lactic acid preservation of foods, anaerobic digestion of organic matters in ruminant cultivation and waste treatment.
Famous fermented foods: kefir.tempeh.natto.kombucha.miso.kimchi,sauerkraut.probiotic yogurt.
Benefits of fermented foods
As a result, fermented foods provide many health benefits such as anti-oxidant, anti- microbial, anti-fungal, anti-inflammatory, anti-diabetic and anti-atherosclerotic activity.
Disadvantages of fermented foods
Another disadvantage is the high sodium levels in many fermented foods. Under some conditions, harmful microbes may also cause undesirable effects from the ingestion of fermented foods in certain conditions, such as mycotoxicosis and botulinism.
Bloating: The most common reaction to fermented foods is a temporary increase in gas and bloating.
Headaches and migraines.
Histamine intolerance.
Food-borne illness.
Infection from probiotics.....
Antibiotic resistance
Processing of dairy foods
Dairy products
Dairy products are commodities which have been produced by primary processing or secondary processing of milk. All mammals produce milk which contains the correct balance of nutrients with which to feed their young. This milk can also be produced and used commercially; for example sheep, goat and cows milk.
MAIN DAIRY FOODS
BUTTER
YOGHURT
CHEESE
FROMAGE FRAIS
CREAM
ICE CREAM
Steps of food processing
Thermization (Lewis and Heppell, 2000)
57-68°C for 15 seconds
only effective if cooled to 4°C after treatment
applied to raw milk that needs to be stored for several days prior to use
purpose: reduce gram-negative psychrotrophic spoilage organisms (enzyme production)
Clarification and Clearing
Clarification: removal of small particles, straw, hair etc. from milk; 2 lb/2,642 gal based on density.
"Bactofugation": Centrifugal separation of microorganisms from milk:
- Bacteria and particularly spores have higher density than milk
- Two-stage centrifugation can reduce spore loads up to >99% Optimal temperature for clarification is 55-60°C
Microfiltration: Microfilter membranes of 1.4 µm or less can lead to reduction of bacteria and spores up to 99.5-99.99%.
Milk Fat Standardization/Decreaming
Separation of skim milk (about 0.05% fat) and cream (35-40% fat)
Based on the fact that cream has lower density than skim milk
Centrifugal separators are generally used today
Standardization of fat content: Adjustment of fat content of milk or a milk product by addition of cream or skim milk to obtain a given fat content
Homogenization
Definition: Homogenization is a mechanical process where milk is forced through a small passage at high velocity.Treatment of milk or a milk product to insure breakup of fat globules such that no visible cream separation occurs after 48 h at 40°F (4.4°C)
Effects of homogenization:
- No cream line formation due to smaller fat globules
- Whiter color
-More full-bodied flavor, better mouthfeel
Process requirements:
- Homogenization most efficient when fat phase is in a liquid state
- Cream >12% fat cannot be homogenized at normal pressure, high pressure homogenization process is necessary
Pasteurization
Purpose: Inactivation of bacterial pathogens (target organisms Coxiella burnettii) assurance of longer shelf life (inactivation of most spoilage organisms and of many enzymes)
Pasteurization
- Heat treatment of 72°C (161°F) for 15 sec (HTST) or 63°C (145°F) for 30 min (or equivalent)
- does not kill all vegetative bacterial cells or spores (Bacillus spp. and Clostridium spp.)
- Pasteurization temperature is continuously recorded
Heat Treatment (Con't)
Standards for Grade A pasteurized milk and milk products (PMO)
- Temperature: Cooled to 45°F or less - Bacterial counts: <20,000 cfu/ml - Coliform Counts: <10/ml. - Phosphatase: < 1µg/ml. - Antibiotic presence: negative
Ultra pasteurization: Thermal processing at 138°C (280°F) for at least 2 seconds
- UP milk: ultrapasteurized and "non-aseptically" packaged, refrigerated storage
- UHT milk: ultrapasteurized and aseptically packaged, storage at room temperature; avoid recontamination
Standards for Grade A aseptically processed milk (UHT)
- Temperature: none
-Bacterial counts: no growth
- Antibiotic presence: negative
Vitamin Fortification
Preferably after separation
Has to occur before pasteurization
Can be continuous (using a metering pump) or batch addition
Filling/Packaging
Functions of packaging:
- Enable efficient food distribution
- Maintain product hygiene
- Protect nutrients and flavor
- Reduce food spoilage
- Convey product information
Different containers:
- Glass bottles (translucent vs. dark): can be reusable or recyclable
- Plastic containers
- Cartons
- Plastic bags
Processing of confectionary foods
Confectionery: Confectionery is an art of making confections by using sugar and a carbohydrate based binding medium.
The confections is broadly divided into the five categories they are namely,
Flour confection.
Sugar confection.
Chocolate confection.
Milk confection.
Other confectio
Types of confection
Flour Confections : They are cakes, tarts, doughnuts, cookies, sweet pastries, or any similar confection made using flour. They are mainly served in desserts course.
Sugar confection: They are candies, chewing gums, and jellies. The flavor and colour of the confections are due to the main ingredient.They are made at high temperatures around 150°C. The spoilage is low and hence they have longer shelf life without refrigeration.
Chocolate Confections: They use cocoa powder and chocolate syrup as their main ingredient. They need refrigeration during warm weather.
Milk / Dairy confection: They are thick milk cream based/milk powder based confections made by combining various dry fruits, flavors, and colors into them. They are treated as a part of main course. They are best when fresh. Their shelf life is short but can be extended by refrigeration.
Major Ingredients used in confectionery
The major ingredients used in confectionery industry are
• Sugar • Invert Sugar • Glucose Syrup (Corn Syrup) • Dairy Ingredients • Vegetable Fats • Hydrocolloids- Gums & Gelling agents • Emulsifiers • Colours, Flavours • Antioxidants, Acidulants • Salt, Sugar substitutes
Confectionery Production Processes
Plastic forming: The plastic forming operation is widely used in the confectionery industry for converting plastic masses such as boiled sugar or toffee into individual sweets. In this process, the product will be tempered to correct consistency and flavour ingredients incorporated during the kneading process in the case of boiled sugar, cooling drum or cooling conveyor in the case of toffees. The mass is then fed into a batch roller for obtaining the product in the form of a rope. The rope is the fed to a pressurizer followed by sweet former (to give desired shape to final product) and later packaged.
Wet crystallizing: Wet crystallizing is the process of building up a thin coherent coating of sugar crystal on the surface of a sweet. This seals the surface, and when used on products such as fondant creams or marzipan, retards drying out, extending the shelf life from a few days to 6 months or more.
Panning: Panning is an operation which has been used by the confectionaries for centuries. In principle it is the application of coating to centres tu tumbling in a revolving pan mounted at about 30°C to the horizontal. The operation consists of adding enough coating medium to cover the centres completely with no surplus and drying this off either with hot air (hard panning), extra sugar (soft panning) or cold air (for chocolate). Coatings may be sugar syrup (hard panning), glucose syrup -fine sugar (soft panning) or chocolate, solutions containing food grade colours, edible gums, etc.
Processing of cereals and grains
Cereals, or grains, are members of the grass family cultivated primarily for their starchy seeds (technically, dry fruits). Wheat, rice, corn (maize), rye, oats, barley, sorghum, and some of the millets are common cereals
MAIN CEREALS: Wheat, Oats, Rice, Maize (Corn), Rye, Barley
Processing of Cereals
• Cereals undergo a number of processing stages between harvest and consumption.
• The first is the preparation of harvested grain for storage.
• The second, which is referred to as primary processing, involves further treatment of the grain to clean it, sort, remove the husk and other inedible fractions from the grains or reduce the size.
• The products from primary processing are still not consumable.
• Primary processing of cereals includes cleaning, grading, hulling, milling, pounding, grinding, tempering, parboiling, soaking, drying, sieving.
Secondary processing
• The third stage (secondary processing) transforms the grains into edible products.
• Secondary processing of cereals (or 'adding value' to cereals) is the utilisation of the primary products (whole grains, flakes or flour) to make more interesting products and add variety to the diet.
• Secondary processing of cereals includes the following processes: fermentation, baking, puffing, flaking, frying and extrusion.
Processing of beverages
A liquid to consume, usually excluding water. This may include tea, coffee, liquor, beer, milk, juice, or soft drinks. Beverage, is a liquid which is specifically prepared for human consumption. In addition to filling a basic human need, beverages form part of the culture of human society.
Health Importance of Beverages
Maintains water content in body and prevent dehydration
alkaloids present stimulate CNS
water assists in digestion, assimilation,excretion of foods, removal of toxic substances regulates body temperature
source of micronutrients (vitamins and minerals) and anti-oxidants (carotenoids,flavonoids)
heart healthy image due to the presence of flavonoids
beneficial microflora present in assist in restoration and improves gastro-intestinal health.
CLASSIFICATION OF BEEVERAGES
Natural and Synthetic
Carbonated and Non-carbonated
Alcoholic and Non-alcoholic
Hot and Cold
Stimulating and Non-stimulating
STIMULATING & NON- STIMULATING BEVERAGES
Consumption of some beverage stimulates the body systems mainly to nervous system and circulatory system. Eg:- caffeine in coffee and tea many phenolic compounds in herbal drinks ethyl alcohol in alcoholic beverages
ALCOHOLIC BEVERAGES
NON-ALCOHOLIC BEVERAGE
A beverage which does not contain any alcohol or it may contain little alcohol. It is healthy for health. it can be classified into three categories.
1. Stimulating. 2. Refreshing. 3. Nourishing
HOT AND COLD BEVERAGES
Classified on the basis of temperature of serving.
Hot beverage: Certain beverages are consumed only hot i.e. temp above 65-70°C. Eg:- tea, coffee, chocolate and milk
Cold beverages: served at chilled temp. Eg:- iced tea and cold coffee
Most of the fruit beverages, dairy drinks, alcoholic drinks and soft drinks are example of cold drinks
NATURAL BEVERAGES
Prepared from naturally derived ingredients including fruit juices or milk or malt, sugar, acid, flavouring and colouring materials. Eg: fruit based, malt and dairy beverages.
SYNTHETIC BEVERAGES
Contain ingredients which are prepared synthetically like flavouring and colouring materials. Primarily developed to offer pleasure to consumers at affordable cost. Eg: soft drinks which contain flavoured sugar syrup as base material that may or may not be carbonated.
CARBONATED BEVERAGES
CO2 is dissolved in syrup or water. presence of CO2 creates bubbles upon release of pressure and fizzing in the beverage. referred as Soft Drink. Eg:Cola or lemonade beverages,soda water
Ingredients Used: Water, Sweetener, CO2, Acids, Fruit juices, Flavouring and colouring ingredients, Emulsifiers, stabilizers and clouding agents, Foaming agents
NON-CARBONATED BEVERAGES
Doesnot contain CO2. Eg: hot beverages and alcoholic beverages that do not contain CO2, fruit & vegetable beverages
Some beverage example
BEER
world's 3rd most consumed beverage. prepared by fermenting the wort with yeast to attain alcohol level 4-8%. characterized by effervescence and bitterness.bitterness and aroma in beer is contributed by hops (Humulus lupulus).Two variants of beer: Lager beer - fermented by bottom yeast i.e. Saccharomyces pastorianus at lower temp (7-12C) for longer period. Alebeer manufactured by top fermenting yeast i.e. Saccharomyces cerevisia at relatively higher temperature (18-25C)
WINE
made from variety of fruits such as grapes, peach, plum or apricots.grapes are ma grapes are macerated to release juice which is fermented naturally by wide range of yeast like Saccharomyces spp, Pichia spp., Stellata spp. and certain LAB. wine is aged (months to year) to develop desirable sensory characteristics
Two type of wines: white wine -from green grapes. red wine -from red or blue grapes.
TEA
Beverage consisting of an infusion of the processed and dried leaves of tea plant Camellia sinensis. After water, it is the most widely consumed drink in the world. Types of tea:- black tea, green tea, semi fermented tea, pickled tea, instant tea
COFFEE
Coffee is a brewed drink prepared from roasted coffee beans (Rubiaceae). Caffeine content of coffee is high that lead to development of decaffeinated coffee
Special infant foods and formulas
INFANT FOOD
Infant formula
• Infant formula is a manufactured food designed and marketed for feeding to babies and infants under 12 months of age, usually prepared for bottle-feeding or cup- feeding from powder (mixed with water) or liquid (with or without additional water).
• Manufacturers state that the composition of infant formula is designed to be roughly based on a human mother's milk.
• The most commonly used infant formulas contain purified cow's milk whey and casein as a protein source, a blend of vegetable oils as a fat source, lactose as a carbohydrate source, a vitamin-mineral mix, and other ingredients depending on the manufacturer.
Milk based formulas
• Containing milk components such as casein or whey protein.
• These formulas typically start with cow milk as a base.
• This type of formula is fortified with extra nutritional elements.
Animal or vegetable fat based formulas
• Containing vegetable and/or milk components.
• Formula made with vegetable derived milk or a limited amount of cow's milk derived components.
• Most vegetable derived formulas are soybean based.
Non-milk based formulas
• Containing no milk components.
• These are the formulas for infants who have a strong sensitivity to both cow's and soy milk.
• Formulas are available in three forms: powder, liquid concentrate, and ready-to-feed.
• Powder and liquid concentrate are less expensive but they require mixing/dilution prior to use.
• Ready-to-feed is the most expensive type but requires no mixing before use.
The most commonly used infant formulas contain
Purified cow's milk whey and casein as a protein source.
A blend of vegetable oils as a fat source.
Lactose as a carbohydrate source.
Vitamin-mineral mix.
Microorganisms in food
There are three main sort of microorganisms present in the food, they are as follows :
1. BACTERIA 2. MOLDS 3. YEAST {FUNGI}
While other can be consideration as parasites, protozoan, viruses as well as algae.
BACTERIA
Rod, spiral, spherical, comma shaped with or without flagella. Covered with endospores that protect them from changess in temperature. They divide every 20 mts.
Uses: converts ethyl alcohol to acetic acid. This helps in preparation of vinegar and also idli, dhokla, curing coffee and cocoa beans. Some are used in developing stabilizers for preparation of jelly and ice creams. Diseases caused are sore throat, cholera, syphilis, typhoid, dysentery and food poisoning.
Harmful effects
YEASTS:
Unicellular(single cell).
Grow in foods high jams, bread in sugar and salts
Colour less, white in colour.
Not harmful, mostly useful.
Like A Phalloides
MOULDS:
Multi cellular (many cells)
grow on pickles, cheese.
red, pink, blue, yellow, black,
produce toxins like alfa toxins, Parasitic ringworms.
ALGAE :
Are both unicellular and multi cellular.
Usually green in colour(red also) and found in water.
Usually not pathogenic, but some of them have an unpleasant odours.
Uses: important source of agar. Agar is used as a veg substitute for gelatin in preparation of desserts.
In water purification and sewage treatment plants. They are a source of food to the aquatic animals.
Blue green algae are used as fertilizers.
Alginic acids and its salt are used in ice cream preparation to prevent crystallization and give it smooth texture.
Also used in preparation of cheese.
PARASITES/PROTOZOAN:
Parasites are micro organisms dependent on living organisms for thei growth.
Unicellular and parasitic in nature.
Used as source of food by aquatic animals.
Harmful protozoa cause amoebic dysentery and contaminated water or salad vegetable cause mlalarial fever.
Contaminated meat of pigs (uncooked pork) can infect humans and cause gastrointestinal diseases.
It causes cysts and also muscularspasms.
Food packaging
A combination of art, science and technology that is used in the transportation and selling of foods. Packaging can be defined as a method to protect and contain foods with the aim of minimizing the environmental impact of our consumption.
General requirements of food packaging:
Nontoxic
Prevent contamination from microorganisms & environmental toxicants
Barrier to moisture, oxygen, UV light & odors
Provide resistance to physical damage
Be tamper-resistant or tamper-evident
Easy to open
Have dispensing & resealing features
Be disposed of easily
Meet size, shape & weight requirements
Have appearance, printability features
Have low cost
Be compatible with food
Be transparent
Basic Principles of Food Packaging
• Focus on outcomes, results, deliverables.
• Economic consideration.
• Specify what we expect from the customers, who will participate, types of activities & time required.
Needs of Packaging
Food Engineering
It keeps the product intact and the product remains safe from environmental factors.
It provides aesthetics to the product and attracts customers.
Packaging plays a crucial role in selling the product.
Packaging provides protection to the product from damage.
Packaging provides information and transfer Information such as the origin of the product, its weight, its content and other useful information.
Packaging plays an important role in brand creation, brand awareness and brand development.
It also provides the business the opportunity to rebrand its products.
Packaging provides the edge to business for marketing their products.
Benefits of food packaging
Packaging provides a variety of benefits:.
Barrier protection Packaging provides a barrier to dust, water, humidity and other contaminants that could potentially harm the contents and decrease their shelf life.
Containment Grouping multiple cases, small objects or bulk materials together aids in both manual and automated handling.
Convenience Packages can have features that add convenience in distribution, handling. stacking, display, opening, reclosing, use, dispensing, reuse, recycling, and ease of disposal.
Physical protection Packaged products are protected from damage caused by dropping, shock, vibration, electrostatic discharge, extreme temperature shifts and impacts.
Security - Tamper resistant and tamper evident packaging can reduce the risk of theft, or indicate that damage has occurred during handling.
Sustainability Returnable and reusable packaging can be used repeatedly before it is recycled; some materials are engineered to biodegrade.
Functions of Packaging
Containment | Protection | Preservation | Convenience | Convenient | Communication |
TYPES OF PACKAGING MATERIALS
Metals Aluminium container Aluminium foil
| Paper 1. kraft paper 2. coated paper 3. brown paper for packing and wrapping 4. greaseproof | Plastics 1. Polypropylene 2. Polyvinyl chloride 3. Polystyrene 4. Polyester | Cellulose film Glass laminates |
How Different Foods are Packaged?
Since different foods spoil or deteriorate differently than others, there are certain ways that foods are packaged to give them the longest shelf life possible. We will now go through some of the major categories of foods and discuss their packaging.
Meat Packaging Red Meat: PVC overwrap (Oxygen). Gas flushed in a tray Poultry: Vacuum packaged Frozen turkeys:In a O₂ impermiable bag. Gas atmosphere in a tray Seafood: Frozen as precooked chicken.Frozen.Gas flushed
| Fruits and Vegetables Canned- shelf stable Jars- especially baby food Frozen -in bags in a box Netted fruits Edible coated Gas flushed plastic bags, especially salads |
Cereals and Cereal Products Oat Meal in paperboard Most breakfast cereals in waxed or plastic bags inside a paperboard box. Bread and bakery items are packaged in a plastic bag. Crackers are packaged in waxed or plastic bags within a paperboard box Chips Most chips in a gas filled bag Some chips in paper bags | Dairy Products Originally in glass jugs Later came wax coated paperboard Now, still some wax paperboard but changing over to plastic jugs Cheese, yogurt, cottage cheese etc in plastic containers. Ice cream, butter come in wax coated paperboard or plastic containers.
Beverages Most soft drinks in aluminum cans Some juices sold in plastic jugs Coffee sold in glass jars, plastic jars and metal or plastic cans |
Food products developments
Introduction: Developing new food products for commercial or high street markets is a time consuming and complex process. Even after successful introduction of a new product, recipe or dish, the quality needs to be frequently improved to ensure continued success in an extremely competitive market.
Key areas of new product development
• Producing 'convenience' foods - in response to changing lifestyles.
• Providing products with altered nutritional content - following the increasing public
• interest in nutrition, diet and health, e.g. low fat products.
• Increasing the variety of products available - to provide more choice.
• Producing 'economy' lines - to appeal to people on lower incomes
• Appealing to the 'luxury' market - to attract more affluent customers of those who wish to give an impression of status.
• Maintaining and improving product quality - to retain customer loyalty.
Reasons for developing new product
Technology: Technology that in the favors to develop or to take the risk of new product development
Good Image: Company good image in the Market (in the mind of customer) to take the risk of new product development.
Computation: To maintain or to gain the competitive image in the market.
Change of consumer needs: To brings the changes in the consumer needs
Stages of Product Development
Product development is the process of creating new or modified food products. The aim of product development is to increase sales and maintain a company's competitiveness. The process of product development involves a complex series of stages, requiring the combined talents of many specialists to make it successful. Manufacture of products is controlled throughout to ensure that the original specification is met. The products should fill a gap in the market. In addition, consumers must be tempted to buy the new products in preference to similar products.
Design Brief
This should be established for new products once a concept is developed. It enables a food manufacturer to define consumer market requirements and the price the market will pay for a specific food product. A key component is a manufacturer's mission statement, which sets out goals and policies and provides guidance for new product development.
Steps in the design brief
1. Idea generation and screening
2. Market research
3. Product specifications
4. Feasibility study
5. Production process development
6. Development of a prototype
7. Testing of product prototype
Idea Generation and Screening
• Recording of ideas for a N.F.P.
• Screening the ideas by selecting the best idea by seeing which one fits into the company the best.
2. Market Research
Is an organized way of asking consumers what they want and need and their thoughts on existing products. This can be done through surveys, focus groups or field observations.
Segments are grouped according to:
1. Physical Features e.g. size of the market and demographics or
2. Purchasing behaviour e.g. reasons for buying and influences on buying.
There are two types of research:
1. Primary Research which involves gathering original data from surveys etc
2. Secondary Research which involves investigation what others have found in their primary research
There are two types of sampling methods:
1. Non-Probability which includes Convenience sampling, Volunteer sampling, Judgmental sampling (deliberate)
2. Quota sampling and Probability (picking via numbers and chance) which includes simple random sampling and stratified random sampling.
Once the research is conducted the data must be analyzed.
Qualitative Research
Two techniques are commonly used in qualitative research:
1. in-depth interviews
2. focus groups (sometimes called buying panels)
In both cases an experienced researcher trained in the technique will engage the individual or group in a series of structured discussions to gain insights into subjective aspects of consumer behaviour (perceptions, attitudes, beliefs, values etc). Advertisers can use this technique to gauge consumer reactions to different styles or types of packaging or to help create a consumer profile for a particular market segment. Qualitative research ties to answer 'how' and 'why' questions.
Quantitative research
Quantitative research, is concerned with the collection of data for statistical analysis. This type of research considers objective (factual) information such as the size and composition of markets, demographics and sales figure. Two of the most important data collection methods in the food industry are:
1. Scanning technology: Sales at the checkout are registered using barcodes (formally termed universal product codes [UPCs] which, in conjunction with customer loyalty cards, provide large amounts of consumer purchasing data.
2. Internet use: Provides information relating not only to actual purchases but also browsing behaviour.
Quantitative research tries to answer 'where', 'when' and 'how many' questions.
Product specifications
Is an accurate and comprehensive description of what the manufacturer plans to deliver to a target market (consistency). Lists all the requirements and constraints for production. Also describes packaging dimensions, materials and labelling as well as the storage conditions. Includes a pricing strategy.
Feasibility study
This establishes if the product is profitable. There are two types of feasibility studies:
1. Financial Feasibility: Determines whether the costs of production and the sales forecast will achieve a break- even point.
2. Technical Feasibility: The ability of the company to make the new product using existing resources e.g. availability of ingredients, new processes, costs of ingredients and microbiological safety tests.
Development of a production process
Converting the factory to make the new products - line extension products only need small changes. If the product is new then the equipment and factory layout need to be altered.
Quality Control aims to ensure the highest quality of the product. Quality Assurance is the entire company working together to maintain maximum quality.
Development of a prototype
A prototype is a trial product and extensive experiments are carried out on prototypes to ensure they can stand production. The prototype recipe is converted into commercial batch size.
Packaging must withstand the rigours of processing but be able to fit on the production line as well as provide protection for the product.
Careful screening takes place which includes: sensory evaluations, market tests, packaging tests and storage tests.
Testing the prototype
The new food product needs to be tested to see if it satisfies the A.F.S.C or approved by AQIS.
Packaging tests are also conducted to determine the exact shelf-life, package strength, whether it can handle distribution and other characteristics.
Consumer testing must also be done and if everything is fine then the product is ready for commercialization.
References
1. Handbook of Nutraceuticals and Functional Foods: Robert E.C Wildman
2. Functional Foods: Designer Foods, Pharmafoods, Nutraceuticals: Israel Goldberg
3. Advances in Natural Medicines, Nutraceuticals and Neurocognition: Con Kerry Kenneth Stough, Andrew Scholey
Comments
Post a Comment