Food Processing.pdf

Learning Objectives
After completing this chapter the learner will be able to:
z
z understand what is food processing and technology, its history,
development and present status
z
z explain the significance and basic concepts of the subject
z
z be aware of the skills required to be a professional food technologist
z
z be aware of the career opportunities available and educational
qualifications required for specific careers in the industry
z
z know the scope for self employment as small, medium or large scale
entrepreneurs.
Introduction
Fooditemsarebeingprocessedforvariousreasons.Sincetimesimmemorial,
grains have been dried after harvest to increase their shelf life. Initially,
foods were processed primarily to improve digestibility, palatability and
to ensure a continuous supply. In India pickles, murabbas and papads
are examples of preserved products made from certain vegetables/ fruits/
grains. With passage of time, improved transportation, communication
and increasing industrialisation, the needs of consumers have become
Food Processing
And Technology
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Chapter
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more diverse and there is now increasing demand for ‘fresh’ and ‘organic’
foods, ‘safer and healthier’ foods and foods with adequate shelf life.
Consumers expect better-quality foods with retention of nutrients, many a
time having specific functional properties and taste/texture/consistency,
while being shelf-stable and easy to package, store and transport. This has
served as a stimulus to scientists to develop methods and techniques to
process foods in a manner that the food products will meet the requirements
and demands of the consumers. All of us eat readymade foods. These range
from biscuits, bread, pickles/papads to foods such as ready-to-eat curries,
meal items, snacks, etc. Such foods are manufactured using a variety of
processes and technologies. For some, simple traditional methods are still
used while newer processes and technologies are employed to produce
processed foods in bulk.
Significance: India has progressed from an agro-deficit to an agro-
surplus country creating need for storage and processing of agricultural
and horticultural produce. Indian food industry has thus emerged as
a major producer of processed foods and ranks fifth in terms of size,
contributing nearly 6 per cent of GDP. Besides, changes in lifestyle,
increasing mobility and globalisation have increased the demands for
various types of products, making the research for newer technologies
necessary. It is well known that simple diets based largely on staple foods
such as cereals are often deficient in certain nutrients leading to their
deficiency disorders. Therefore, food fortification is done by adding the
nutrient that is lacking in the food stuffs or condiments to ensure that
minimum dietary requirements are met. Some examples are iodised salt,
folic acid added to flour, vitamin A and D added to milk and oils/fats. In
fact, FSSAI has laid down standards for fortification of staple food like salt,
wheat flour, milk and oats. Increasing prevalence of diseases like heart
disease and diabetes and concern about wellness, has made it necessary
for scientists to alter the nutrient content of foods, for example reducing
the Calorie content of processed foods in several ways such as using
artificial sweeteners. Likewise fat from ice creams is replaced by specially
treated proteins which give ice cream the smooth texture associated with
fat but the energy value is reduced. Also, consumer perceptions about
food have changed. The demand for foods free of chemicals, pesticides
and preservatives, yet having a longer shelf life and retaining their natural
flavour and appearance, is rapidly increasing. All this has increased the
importance of food processing and technology as a discipline and there is
a huge demand for food technologists.
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Basic Concepts
Food Science: It is a distinct field involving the application of basic
sciences such as chemistry and physics, culinary arts, agronomics and
microbiology. It is a broad discipline concerned with all the technical
aspects of food, beginning with harvesting or slaughtering and ending
with cooking and consumption. Food Scientists have to use the knowledge
of biology, physical sciences and engineering to study the composition
of foods, changes that occur at various stages from harvest through
different processes and storage, causes of their spoilage and the principles
underlying food processing. Food scientists deal with physico-chemical
aspects of food, thus helping us to understand the nature and properties
of food.
Food Processing: It is the set of methods and techniques used to transform
raw ingredients into finished and semi-finished products. Food processing
requires good quality raw materials from either plant and/or animal
source to be converted into attractive, marketable and often long shelf-life
food products.
Food Technology: Technology is the science and application of scientific,
as well as socio-economic knowledge and legal rules for production.
Food technology uses and exploits knowledge of Food Science and Food
Engineering to produce varied foods. Study of Food Technology gives
in-depth knowledge of science and technology, and develops skills for
selection, storage, preservation, processing, packaging, distribution of safe,
nutritious, wholesome, desirable as well as affordable, convenient foods.
Another significant aspect of food technology is to promote sustainability
to avoid waste and save and utilise all the food produced and ensure safe
and sustainable processing practices.
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Food manufacturing: It is the mass production of food products using
principles of food technology to meet the diverse needs of the growing
population. Food manufacturing is one of the largest manufacturing
industries in the present times.
Development of Food Processing and Technology
Research in the field of Food Technology has been conducted for decades. In
1810, development of the canning process by Nicolas Appert was a decisive
event. Canning had a major impact on food preservation techniques. Later
Louis Pasteur’s research, in 1864, on spoilage of wine and his description
of how to avoid spoilage was an early attempt to put food technology on
a scientific basis. Besides wine spoilage, Pasteur conducted research
on production of alcohol, vinegar, wines, beer and souring of milk. He
developed ‘pasteurisation’- the process of treating milk to destroy disease
producing organisms. Pasteurisation was a significant advance in ensuring
microbiological safety of food.
Food Technology was initially used to serve military needs. In the 20th
century, world wars, exploration of space and the rising demand for varied
products from consumers contributed to the growth of Food Technology.
Products such as instant soup mixes and ready-to-cook items including
meals were developed, specially catering to needs of working women.
Further, food industry was compelled to focus on nutritional concerns.
Food preferences and choices changed and people started incorporating
into their diet food items/preparations from different regions and
countries. The desire to have seasonal foods all year round increased. Food
technologists made efforts to provide both safer and fresher food using
new techniques. In the 21st
century, food technologists are challenged to
produce foods suitable for health and other changing needs of consumers.
Food technology has provided a vast variety of safe and convenient foods.
In developing countries this rapidly expanding and developing field, has
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been helpful in improving food security and has opened avenues for
employment at all levels.
Importance of Food Processing and Preservation
It has already been mentioned that food processing is a branch of
manufacturing wherein raw materials are transformed into intermediate
foodstuffs or edible products through the application of scientific knowledge
and technology. Various processes are used to convert bulky, perishable
and sometimes inedible food materials into more useful, concentrated,
shelf-stable and palatable foods or potable beverages. Changes in the
products often reduce preparation time for the cook. Most of the time,
processing of foods adds value to the resultant product by increasing
storability, portability, palatability and convenience. Professionals in the
food processing need to be knowledgeable about general characteristics
of raw food materials, principles of food preservation, processing factors
which influence quality, packaging, water and waste management, good
manufacturing processes and sanitation procedures. Let us briefly examine
the need, principles, methods and modernisation of food processing.
Foods are subject to physical, chemical and biological deterioration.
Food deterioration is associated with spoilage, development of off-flavors,
deterioration of textures, discoloration and loss of nutritional value in
varying degrees, reducing aesthetic appeal and rendering it unfit/unsafe
for consumption. A number of factors can lead to food deterioration or
spoilage e.g. pests, infestation by insects, inappropriate temperatures
used for processing and/or storage, excessive exposure to light and
other radiations, oxygen, moisture. Food is also contaminated by micro
organisms [bacteria, fungus and moulds) or chemicals such as pesticides.
Food can also be spoiled due to degradation by naturally present enzymes
(a specific class of protein molecules that act as biological catalysts to
accelerate chemical reactions). In addition, physical and chemical changes
in certain constituents of food from plant and animal sources occur soon
after harvesting or slaughtering, altering the food quality.
Therefore food processing and preservation are required to preserve
food in edible and safe form. Methods by which food is preserved from
spoiling after harvesting or slaughtering date back to prehistoric times. The
oldest methods were sun drying, controlled fermentation, salting/pickling,
candying, roasting, smoking, baking and using spices as preservatives.
These tried and tested techniques are still used although, with the advent of
industrial revolution, new methods have been developed. Food processing
incorporates and unifies the general characteristics of different classes
of foods and principles of food science, chemistry, food microbiology,
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nutrition, sensory analysis and statistics including good manufacturing
practices as per regulations.
Classes of Foods Based on Perishability
Perishable foods are foods that spoil quickly within one or two days
e.g., milk, curds, fish and meat.
Semi perishable foods can last for 1–2 weeks. Examples are fruits
and vegetables. Root crops like onions and potatoes last for 2–4
weeks.
Non-perishable are those foods that generally last for one year e.g.,
grains like rice, wheat, pulses and dals, oilseeds.
Many food processing operations are designed to extend the shelf life
of the food products. The concepts associated with food processing are
reducing/eliminating microbial activity and other factors that influence
food spoilage. The principle micro organisms that cause food spoilage
are bacteria, fungi, yeasts and moulds. Just recollect that you studied in
biology how they grow typically very rapidly under congenial conditions.
Factors influencing microbial growth are nutrient availability, moisture,
pH, oxygen levels and the presence or absence of inhibiting substances e.g.
antibiotics. The activity of enzymes inherently present in foods also depends
on pH and temperature. Oxidative enzymes in fresh fruits and vegetables
continue to use oxygen to metabolise, reducing the shelf life of fruits and
vegetables. So the basic concepts
in food processing methods to
prevent food spoilage are:
1. Application of heat,
2. Removal of water moisture,
3. Lowering of temperature
during storage,
4. Reduction of pH,
5. Controlling the availability
of oxygen.
Did You Know?
z Bacteria prefer protein
rich foods e.g. meat, fish,
poultry, eggs, and dairy
products. These are known
as High Risk Foods.
z Bacteria grow at any
temperature between
5–600
C. This temperature
range is known as the
Danger Zone.
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Processed foods can be classified on the basis of extent and type of
processing as follows:
1. Minimally processed foods: These are processed as little as
possible in order to retain the quality of fresh foods. Generally the
processes used are cleaning, trimming, shelling, cutting, slicing
and storage at low i.e., refrigeration temperatures.
2. Preserved foods: The methods of preservation used do not change
the character of the product substantially e.g., frozen peas and
frozen vegetables, dehydrated peas, dehydrated vegetables,
canned fruits and vegetables.
3. Manufactured foods: In such products, the original characteristics
of the raw products are lost and some basic methods of preservation
are used, often using various ingredients such as salt, sugar,
oil or even chemical preservatives. Examples are pickles, jams,
marmalades, squashes, papads, wadis.
4. Formulated foods: These are products prepared by mixing and
processing of individual ingredients to result in relatively shelf-
stable food products such as bread, biscuits, ice cream, cakes,
kulfi.
5. Food derivatives: In industry, components of foods may be
obtained from the raw product through purification, e.g., sugar
from sugarcane or oil from oil seeds. In some cases, the derivative
or the component may be processed further, e.g., conversion of oil
to vanaspati (the process is called hydrogenation).
6. Functional foods: These are foods that can have a beneficial effect
on human health, e.g., probiotics.
7. Medical foods: These are used in dietary management of diseases,
for example, low sodium salt, lactose–free milk for persons with
lactose intolerance.
ACTIVITY 1
z
z In your region/community, list the foods that are preserved
at home and identify the method and preservatives used for
preservation.
z
z Identify the processed food made using artificial sweeteners that
are available in your area.
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Professionals who are involved in food processing and technology
need to have a wide range of knowledge and skills. Table 5.1 shows
categorisation of food production in three stages and lists the knowledge
and skills required for each:
1. Food as a material
2. Food Product development
3. Recipe development
Table 5.1 Knowledge and Skills needed for Food Processing and
Technology
Food as a material Food Product Development Recipe Development
• Seasonal
availability of food
stuffs
• Nature and
properties of food
• Nutritional content
and its analysis
• Cost of food stuff
• Influence
of chemical
pesticides,time,
moisture,
temperature and
additives
• Assessment of the
quality of raw foods
and ingredients for
quality production
of food
• Food Hygiene and
Food Safety
• Knowledge of
Information
Technology for
contemporary food
production
• Knowledge of food
preparation and cooking
skills for large scale food
production
• Knowledge of product
specifications, and
testing it
• Observing and
measuring Quality
Control as per
specifications
• Assessment by sensory
methods [by testing and
tasting produced foods]
• Industrial practices and
manufacturing systems
and their control
• Labelling and packaging
of marketable product
• Hazard Analysis and
Critical Control point.
{HACCP}
• Expertise in cooking
• Knowledge of nature and
properties of food
• Uses of ingredients,
measuring and weighing
them accurately
• Designing, analysing and
adapting a basic recipe
• Food handling skills
• Food production
following hygiene and
safety norms
• Handling tools and
equipment accurately
• Innovations in product
design and preparation
according to consumer
perceptions
• Use of Information
Technology for
contemporary production
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Preparing for a career
Food industry is involved in processing/manufacture, research and
development (modifying existing food products, developing new products,
researching consumer markets and developing new technologies),
ensuring food safety and monitoring food quality, improving quality
control procedures, costing to ensure profitable production, and regulatory
affairs. They may specialise in a particular branch of food technology such
as beverages, dairy products, meat and poultry, sea food, fats and oils,
stabilisers/preservatives/colours, food grains and additives. A professional
in this area requires knowledge and skills about:
z
z Food science, food chemistry, microbiology, food processing, safety/
quality assurance, good manufacturing practices and nutrition.
z
z Analysis of raw and cooked/manufactured foods for composition,
quality and safety.
z
z Food ingredients, their uses in food preparations and food production
on a large scale.
z
z Product specifications and food product development.
z
z Sensory evaluation and acceptability.
z
z Industrial practices, systems control, distribution channels, consumer
purchase patterns.
z
z Food packaging and labeling.
z
z Ability to use information technology to support product design.
z
z Skills in food preparation and cooking.
z
z Ability to design, analyse, follow a design brief and adapt recipes.
After successful completion of 10+2 or equivalent examination, one
can pursue short term certificate, craft and diploma courses at various
institutes/colleges in different states, as well as at the Central Food
Technological Research Institute [CFTRI], Mysore. Such courses are
suitable for self-employment and for placement in small scale units of food
preservation and processing, and catering establishments. Bachelor’s and
Master’sdegreesandresearchqualificationsprovidethemostcomprehensive
grounding for jobs in the food industry, particularly large scale units, and
for taking up research and training as well as entrepreneurship. Many
universities in India and abroad offer graduate and post graduate degrees
in the food technology. There are institutes offering post graduate courses
in specialised aspects of Food Processing and Technology like National
Institute of Food Technology and Entrepreneurship Management (NIFTEM)
at Sonepat.
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Scope
The demand for processed, packed and convenient food with prolonged
shelf life requires well-trained human resource in the food industry. There
is an encouraging, challenging and rewarding future for professions and
careers in Food Technology and Food Processing industry. As this field
requires the application of science and technology to the processing,
utilisation, preservation, packaging and distribution of food and food
products, it encompasses a diverse range of specialisations.
The work of food technologists is mainly in food industries, quality
control departments, hotels, hospitals, labeling and packaging industries,
breweries/distilleries, soft drink industries, dairy, confectionery, fish and
meat processing, fruit and vegetable processing, processing of grains,
cereals, millets, rice and flour mills, etc. Their expertise is useful in various
departments such as purchase and storage, processing/manufacture,
quality monitoring and management, safety assessment, as well as
research and development. Besides this, entrepreneurship is a highly
rewarding avenue. There are various avenues for employment.
Career avenues
z
z Production Managers
z
z Project Implementation
z
z Marketing and Sales Personnel
z
z Sensory Evaluation
z
z Quality Assurance
z
z Research and Development, Product Development
z
z Project Financing
z
z Project Appraisal
z
z Teaching and Research
z
z Entrepreneurship Development
z
z Consultancy
z
z Technical Marketing of products
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With globalisation, Indian shores have opened up to foreign investments
and technologies. As a result, many foreign companies and multinational
companies are setting up their production, R&D, educational and
outsourcing facilities in our country. Thus there is ample scope for food
technologists/scientists in Indian as well as foreign organisations. Also,
food processing industry provides good opportunity for export of products.
Employment exchanges will also be strengthened and upgraded.
Self Employment Avenues: Food processing in India has always been
practised as household or cottage scale activity. Despite lack of basic
training in food processing operations, sweets, papads, murrabas, pickles,
fried snacks, roasted and puffed cereals were prepared and marketed
for local consumption. Now with the growth in agriculture, horticulture
and pisiculture, the production of raw material has improved. Also the
Government is giving incentives and support for enterpreneurs who
want to start their own enterprise by way of providing finances, training,
infrastructure and marketing facilities. Financial support is provided
by many banks, with encouragement for women entrepreneurs. State
Governments also contribute by providing space to those desirous of
obtaining the same. A self employment venture in food technology may be
highly technology-oriented and investment–intensive, or it can be a very
low key technology and low investment unit, e.g., salted peanuts, drinking
water pouches, dehydrated products, pickles, among others.
The Indian food industry with a size of 61 billion US dollars, ranks
5th
in terms of size, contributes nearly 6 per cent of GDP, 13 per cent of
Indian exports and involves 6 per cent of total industrial investment in the
country. Besides, it is estimated to grow at the rate of 20 per cent of which
processed food segment accounts for 25 per cent. Key segments of this
industry are milk and milk products, snack foods, bakery products, fruit
and vegetable products, beverages (alcoholic and non alcoholic), fish and
meat processing, food processing machines and allied equipment. Exports
are rising and this boosts employment avenues.
Key Terms
Food processing, food technology, food preservation, food science, food
spoilage, food product development
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review QuesTions
1. Explain the following terms:(A) Food Science (B) Food Processing (C)
Food Technology (D) Food Manufacturing and (E) Food Spoilage
2. Explain briefly the significance of Food Technology. How has it
affected the life of modern housewives, specially working women?
3. List some of the old methods of food preservation followed at home
giving examples and their viability in present times.
4. Give a brief account of development of food preservation to its
present status.
5. As a prospective food technologist what knowledge and skills does
the industry require you to have?
6. Keeping the concept of health and wellness in mind, explain with
examples how food scientists are trying to enhance the food values
in processed and packaged foods.
7. Explain the following briefly:
• Why do we need to process and preserve food?
• What causes food spoilage and renders it unfit for human
consumption?
• Food spoilage is generally caused by bacteria. What are the four
conditions that bacteria need to grow and multiply?
• What is done in food processing to extend shelf life?
• After the completion of 10+2 examination what is the professional
scope in the field of Food Processing and Technology?
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PracTical 1
Theme: Design, Prepare and Evaluate a Processed Food Product
Tasks: 1. Identify and prepare a product that can be preserved.
2. Evaluate the product for acceptability.
3. Prepare a label.
Purpose
This practical is intended to give the students first hand experience of
planning, preparing, packaging and labeling a processed product which
can be preserved. It will also provide an opportunity to appreciate the
importance of maintaining hygiene throughout the process and to evaluate
the processed product.
Conducting the Practical
Divide the class into groups of 5-6 students each. Each group should do
the practical separately following the steps given below:
1. Identify a product that has long shelf life (that can be preserved and
stored) that you would like to prepare, e.g., pickles, jams, squash,
murabba, papad.
2. Try and make it different from products already available in the
market by using different raw ingredient(s) or consider using artificial
sweetener partly instead of sugar. Make approximately 500 gm of
the product. Try to use locally available fruits and vegetables/ fruit
or vegetable peels e.g., watermelon rind, orange peel or lemon rind/
sweet lime rind, pumpkin seeds, melon seeds, dudhi peel.
3. Make a list of vegetables/fruits, ingredients, preservatives, utensils,
gadgets and medium of heat required, and collect all.
4. List the criteria used in the selection of raw materials, equipment and
accessories.
5. Write the recipe and method of preparation, step-wise, in detail.
6. Identify the packaging material e.g., glass/plastic bottle or polyethylene
pouches or bags.
7. Prepare the product under as hygienic conditions as possible.
8. Do costing in terms of cost of food materials and ingredients, energy
consumed, labour cost and cost of storage and packing material.
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9. Evaluate the product in terms of texture, taste, colour and quality
and write down your observations.
10. Also prepare a label for the product. The label information should
include the following:
a) Name of the product and a picture or drawing (if possible).
b) Name and address of the manufacturer.
c) List of ingredients used (the ingredients should be listed in
descending order of the proportions used), net weight/volume.
d) Instructions for use (if any).
e) Storage instructions.
f) Indicate the ‘Use By’ or ‘Best Before’ date.
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