PROCESS FOOD PRODUCTS

Food Processing
Processing of foods is a segment of manufacturing industry that transforms animal,
plant, and marine materials into intermediate or finished value-added food products
that are safer to eat. This requires the application of labour, energy, machinery, and
scientific knowledge to a step (unit operation) or a series of steps (process) in
achieving the desired transformation.
Aims of food processing:
Extending the period during which food remains wholesome (microbial and
biochemical) – closely linked to food preservation.
Providing (supplementing)nutrients required for health (e.g.fortification, restoration
and substitution).
Providing variety and convenience in diet (e.g. flavour,texture, colour,
differentrecipes/meals etc
Adding value (i.e. for producers and shareholders)
Categories
Primary Food Processing:Raw products from harvest or slaughter into food
ingredients (e.g. vegetables cleaned, sorted, and packaged)
Ready for direct consumption or ready for use in other food products Its easier to be
transported and sold.

Secondary Food Processing:Follows on from primary processingFood material

and ingredients into foods (e.g.tomatoes peeled, chopped, and then tinned).
Ensures quality and shelf-life of foods.
Ensures that seasonable products can be available allyear-round

Tertiary food processing: Processed and ultra-processed foods.

Ready to eat and heat-and-serve foods (e.g. ketchup, jam, juices, and pickles)

Convenience foods (e.g. ready meals)

Food Processes
6 different unit operations
Heat transfer
- Conduction
- Convection
- Radiation
Fluid flow
- Centrifugal
- Positive displacement 
Mass transfer
Mixing 
Size adjustment
- Reduction
- Enlargement 
Separation
- Solid from solid
- Solid from liquid
- Liquid from liquid

Many foods need to be processed to preserve them:Many of the methods used in

food processing also lead to food preservation.
This is undertaken with the purpose of…
- Shelf-life extension (food lasts longer)
- Increase food quality
- Increase food safety
- Increase nutritional value
- Prevention of food waste

Categories of processed foods:

1. Unprocessed or minimally processed foods:The edible parts of plants or animals
(e.g. seeds, leaves, muscle, offal, eggs, and milk)They just remove the inedible parts
Can be dried, crushed, roasted, boiled, refrigerated, vacuum-packaging are designed
to preserve natural foods – allowing them to be more suitable for storage, make them
safer and more edible to consume. Usually prepared/cooked at home or in
restaurants in combination with processed culinary ingredients as dishes or meals

2. Processed culinary ingredients:Such as oils, butter, sugars, and saltsDerived

from group 1 foods or from nature by processes that include pressing, refining,
grinding, milling, and drying Make durable products that are suitable for the use in
the kitchen to prepare, season, and cook group 1 foods to make them varied and
enjoyable E.g. stews, soups, salads, breads, drinks, and desserts Not meant to be
consumed by themselves – used in combination with group 1 foods

3. Processed foods:Such as canned vegetables/fruits, cheeses, and freshly made

bread. Made essentially by adding salt, oil, or sugar – or other substances from group
2 to group 1 foods. Processes include preservation or cooking methods e.g. breads,
cheese, and non-alcoholic fermentation,
Most processed foods have 2/3 ingredients and are modified versions of group 1 foods
Edible by themselves but usually consumed with other foods Purpose is to
increase the durability of group 1 foods, or to modify or enhance their sensory
qualities

4. Ultra-processed foods:Such as soft drinks, sweet/savoury packaged snacks,

reconstituted meat products, and pre-prepared frozen dishes – not modified but
formulations made mostly from substances derived from foods/additives – with little,
if any, intact group 1 foodsFormulations include those also used in processed foods
e.g. sugars, oils, fats, or salts Also include other sources of energy and nutrients not
normally used in culinary preparations Some are directly extracted from foods, such
as casein, lactose, whey, and glutenDerived from further processing of food
constituents e.g. hydrogenated/interesterified oils, hydrolysed proteins, soya protein
isolate, maltodextrin, invert sugar and high-fructose corn syrup

Maintain quality checks effectively

This means that you:
a) Follow the health, safety, and hygiene requirements when carrying out quality
checks
maintaining high standards of personal hygiene, ie following hand washing
procedures, keeping cuts covered, not wearing jewellery, and not
coughing/sneezing over food
wearing appropriate personal protective equipment (PPE), ie work
overalls, hats, protective footwear, chain mail, and oven gloves
following hazard analysis and critical control point (HACCP) procedures to
avoid product contamination
maintaining a safe work environment, ie storing tools and equipment
safely, and removing hazards promptly
using tools and equipment safely, and using guards and safety systems
Appropriately.

2) Record correctly the results of quality checks

This may include:
Following business procedures to accurately record the findings of quality
checks, eg HACCP documentation, which may include intake records,
storage temperatures, cooking, cooling and hot-hold records, and batch
numbers. Writing must be legible and easy to read, thus preventing
mistakes
Compare accurately the results of quality checks against quality standards
Intake:
fresh goods are below 8°C, frozen goods are below 18°C, packaging is
intact, products are within date, and no sign of contamination
delivery/unloading
company process/procedure
Storage:
fresh goods are below 5°C, frozen goods are below 18°C, packaging is
intact, products are within date, no sign of contamination, and no signs of
product spoilage
packaged goods
dry goods
liquids
packaging
each product that you intake will have set storage conditions that you
must know for all products and look at labels to ensure that you know how
each has to be stored

3) Record correctly the results of quality checks

This may include:
Following business procedures to accurately record the findings of quality
checks, eg HACCP documentation, which may include intake records,
storage temperatures, cooking, cooling and hot-hold records, and batch
numbers. Writing must be legible and easy to read, thus preventing
Mistakes

Monitor and control food manufacturing process

1. Sensors and data
One of the main ways to monitor and control food manufacturing is to use sensors and
data. Sensors are devices that measure physical or chemical properties of the raw
materials, products, or processes, such as temperature, pressure, pH, moisture, color,
or weight. Data is the information that is collected, stored, analyzed, and displayed by
the sensors or other systems, such as computers, software, or dashboards. Sensors and
data can help you to track and optimize the performance, quality, and safety of your
food manufacturing operations, as well as to identify and prevent problems or
deviations.
2. Standards and regulations
Another key aspect of food manufacturing monitoring and control is to comply with
standards and regulations. Standards are voluntary guidelines or specifications that
define the requirements, characteristics, or best practices for food products, processes,
or systems, such as ISO, HACCP, or GMP. Regulations are mandatory rules or laws
that govern the food industry, such as FDA, USDA, or EU. Standards and regulations
can help you to ensure the quality, safety, and legality of your food products, as well
as to meet the expectations and demands of your customers, suppliers, and authorities.

3. Automation and digitalization

A third key aspect of food manufacturing monitoring and control is to leverage
automation and digitalization. Automation is the use of machines, robots, or software
to perform tasks or processes that are normally done by humans, such as mixing,
filling, packing, or labeling. Digitalization is the use of digital technologies, such as
cloud, IoT, AI, or blockchain, to transform or enhance the way you manage,
communicate, or share information or data in your food manufacturing operations.
Automation and digitalization can help you to improve the efficiency, accuracy, and
flexibility of your food manufacturing processes, as well as to reduce costs, errors,
and risks.

4. Variability and waste

A fourth key aspect of food manufacturing monitoring and control is to cope with
variability and waste. Variability is the degree of difference or change in the raw
materials, products, or processes that can affect the quality, safety, or efficiency of
your food manufacturing operations, such as seasonality, shelf life, or customer
preferences. Waste is the amount of resources or materials that are lost, damaged, or
discarded during your food manufacturing processes, such as energy, water, or food.
Variability and waste can challenge your food manufacturing monitoring and control,
as well as your profitability, sustainability, and competitiveness