LESSON 3

1. A Pre-processing operations 1. B Preliminary Operations 2. Filling 3. Exhausting 4. Sealing 5. Processing (Thermal Processing) 6. Rapid cooling 7. Drying 8. Labelling 9. Warehousing

Canning Operations ( Basic Steps in Canning) 1.A 1.B 2. 3. 4. 5. 6. 7. 8. 9.

Warehousing

Cans are placed inside corrugated boxes and stored at warehouses for product observation and quality inspection for at least two weeks. The conditions of storage affects the quality of the product.

Labelling

Cans are properly labelled indicating lot/batch and date of manufacture.

Drying

Cans are usually air dried to remove adhering moisture on the cans to prevent corrosion. After the cans are cooled down to room temperature, these are dried thoroughly to remove excess moisture adhering on the cans or bottles.

Sterilants

Chemicals that can be used to achieve sterilization are called

True

Commercial sterilization does not eliminate the presence of all microbes; rather, it targets those pathogens that cause spoilage and food borne diseases, while allowing many non pathogenic organisms to survive. True or false

Glass

Defined as an inorganic product of fusion which has cooled to a rigid state without crystallizing. This is typically used for preserves, jams, jellies , pickles, sandwich spreads, sardines, etc. Also used for other food products like seasonings and condiments, sauses, softdrinks, wines, beer etc.

Botulinum Cook

Due to this potential impact on food safety, C. botulinum was studied and a tailored thermal process was designed known as the

Product compatibility

Enable liquid and solid foods to be stored for long periods of time without adverse effects on the quality or flavor of the product.

1. Types of organisms to be destroyed 2. The rate of heat penetration to the slowest heating point 3. Initial temperature of the food 4. Size and type of container used 5. Temperature and pressure at which the process takes place 6. The acidity of the product 7. The Aw (water activity)

Factors influencing processing time: 1. 2. 3. 4. 5. 6. 7.

1. Brine 2. Syrup 3. Broth 4. Oil 5. Tomato Sauce 6. Juice

Filling medium 1. 2. 3. 4. 5. 6.

The Aw (water activity) of the food

Food with Aw of 0.85 and below such as fruits packed in syrup are generally processed in boiling water bath. This is because the presence of sugar in the packing medium had resulted in reducing the free water in foods which is needed by microorganisms for their growth and reproduction.

True

For cannery purposes; foods are classified according to their pH values as: Alkaline foods- above 7 Low acid- pH 5-6.8 Medium Acid- pH 4.5-5.0 Acidic - pH 3.7-4.5 High Acid- below pH 3.7 True or false

Clostridium sporogenes or P.A. 3679

For commercial sterility, reference organism used is ________________ or _______________ which is more heat resistant than the former

1. Pasteurization or water bath processing 2. Processing under pressure

Give the two Conventional Methods of Thermal Processing: Format: 1.

1. Safety 2. Product compatibility 3. Consumer Acceptability

Glass Packaging Integrity and Product Compatibility Benefits: Format: 1.

True

If no canning medium is used, the products are filled as close to the top of the can to reduce discoloration True or false

steam jacketed kettle

In an industrial or commercial process, a ______________________________ may be used in place of the pot on the stove.

Botulinum Cook

In thermal processing, this '______________________' is known as F0=3 and is the minimum thermal treatment to apply in order to reach commercial sterility.

100, 82

It should be noted that exhausting must be done by exposure of the filled cans/jars to a temperature of ______ C( 212 F) for at least 15 minutes to attain an internal temperature of 180 F ( ___ C) at the slowest heating point in the canned food. Format: comma

The acidity of the product

Low acid products( foods with pH above 4.5 require processing under pressure, that is at 240F ( 115 C) or 250 F (121 C) while acid products such as fruit juices or acidified vegetables with pH less than 4.5 are processed in a water bath processor ( Boiling water only without pressure).

Sulfur resistant

Meat products are generally packed in cans that have been lined with ____________________________ materials.

True

Metal cans are mostly preferred due to the following reasons: It has high conductivity of heat. It cannot be easily broken. Being opaque, so any possible bad effects of light on foodstuffs are avoided. Able to withstand the stresses imposed during thermal processing and cooling. Able to withstand the subsequent handling , which includes transportation, storage and distribution. True or false

Consumer acceptability

Most preferred by consumers because of the following reasons, o Aesthetic appeal o Quality Perception o Preferred Taste o Product Visibility and associated appetite appeal o Reseal Ability

Blue

Obtained by the addition of cobalt to a low-iron glass.

Clostridium botulinum

Once ________________spores germinate, if they are able to generate vegetative cells and these are able to grow, they can produce lethal neurotoxins.

True

Packaging Materials for Thermally Processed Foods 1. Capable of being hermetically sealed to prevent entry of microorganisms 2. Impermeable to liquids and gases, including water vapor. 3. Maintain the state of biological stability ( i.e. commercial sterility) that was induced by the thermal process alone or in combination with other chemical and physical processes. 4. Physically protect the contents against damage during transportation, storage and distribution. True or false

Foil Laminates

Pouches/Tetra Pack are now being used as an alternative packaging material for thermally processed foods. Aluminum alloys used in food contact may contain elements such as magnesium, silicon, iron, manganese, copper and zinc.

1. Selection 2. Cleaning 3. Skinning 3. Filleting 4. Brining 5. Marinating 6. Cooking

Pre-processing operations (fish products) 1. 2. 3. 4. 5. 6.

Temperature and pressure at which the process takes place

Processing at 250 F ( 121 C ) will require shorter time than at 240F ( 115 C). At different altitude and atmospheric pressure, temperature of processing must be corrected.

1. Come-up Time 2. Holding Time 3. Cooling time

Processing is divided into 3 stages 1. 2. 3.

Size and type of container

Products packed in big cans require longer heating than cans which are smaller. Glass jars require longer processing time than cans with the same capacity. This is because metal cans heat faster than glass jars or bottles.

Initial temperature of the food

Products with lower initial temperature are processed for longer time than those with higher initial temperatures.

True

Safe Thermal processing or canning depends on the following: 1. The use of proper filling and sealing operations that result in hermetically sealed containers capable of preventing the re-entry of microorganisms into the product after achieving commercial sterility. 2. The application of heat or other sterilization methods to the degree necessary to attain commercial sterility. 3. The use of post process handling procedures that protect the integrity of the sealed and processed containers. True or false

Pale green (half-white)

Slightly less pure materials are used, the iron content ( Fe2O3) rises and a pale green glass is produced.

The rate of heat penetration to the slowest heating point

Solid packed products heat longer than fruits in syrup. Products which heat primarily by convection, like fruit in syrup or vegetables in brine, heat faster than solid packed products, like corned beef or luncheon meat or fish fillet in oil. For this reason, meat and fish products require longer processing time.

1. Moist heat 2. Dry heat 3. Filtration 4. Irradiation 5. Chemical methods

Sterilization can be achieved by using (used numbering)

Botulinum Cook

The '____________________' equals 121.1°C for three minutes, or an equivalent process.

True

The basic purpose for the thermal processing of foods is to reduce or destroy microbial activity, reduce or destroy enzyme activity and to produce physical or chemical changes to make the food meet a certain quality standard. e.g. gelatinization of starch & denaturation of proteins to produce edible food. True or false

1. Heating the product after it is sealed ( for most foods). 2. Foods are filled hot into the container which is then sealed and held until the heat from the product sterilizes the inside surface of the container. The containers contents are then cooled( hot, fill, seal, hold and cold process). 3. In the aseptic process where the products are heated and cooled continuously before being filled into sterilized containers which are then sealed under aseptic condition.

The canning Process may be carried out in any of the following operations: Format: 1.

retort

The cans can then be loaded into a pressurized vessel called a "___________".

Sterilization

The complete removal or killing of all vegetative cells, endospores, and viruses from the targeted item or environment.

False

The gelatinized starch is not highly digestible and forms the nutritional basis for much of the world's population. True or false

True

The glass package has a modern profile with distinct advantages, including: Quality Image Transparency Surface Texture Color Decorative Possibilities Impermeability Chemical Integrity Design Potential Heat Processable Microwaveable Tamper Evident Ease of Opening UV protection Strength Hygiene Environmental Benefits True or false

heat exchanger

The length of the jacketed pipe, the temperature of the hot water or steam, and the speed at which the food material passes through the pipe all contribute to the heating efficiency of this device which is known as a "__________________________"

Clostridium botulinum

The main food safety concern related to ambient stable heat treated foods is

tubular heat exchanger

The simplest heat exchanger consists of a pipe which is jacketed by a second larger diameter pipe. This is called a __________________________.

Phase 1 = heating phase Phase 2 = holding phase Phase 3 = cooling phase

The sterilization process in canned product can be subdivided into three phases; namely; Format: Phase 1 =

True

The transfer of heat in products packed loosely in brine or syrup is principally by convection or transfer of heat by currents set up in the liquid True or false

quasi-sterilization

Therefore, "sterilization" is somewhat of a misnomer in this context, and commercial sterilization may be more accurately described as

True

Thermal Resistance of Organisms: - Vary according to the environment they are in: -- effect of pH and Aw -- effect of nitrite -- substrate composition - Vegetative cells are easily destroyed at 100 C - Bacterial spores are heat resistant - Destruction of bacterial spores by heat is logarithmic - Microbial heat resistance decrease with increasing temperature. True or false

Filling medium

These medium add flavor to the product, reduces the amount of processing by improving heat transfer and may reduce corrosion of the tin plate by excluding air.

Exhausting

This is done to; 1. draw in ends of the cans , 2. minimize corrosion , 3. to prevent unnecessary strains on the cans during processing ( buckling ) and 4. to produce a vacuum.

Dark green

This is obtained by the addition of chromium oxide and iron oxide.

Clostridium botulinum

This microorganism is a spore former, highly heat resistant, grows at pH equal or higher than 4.5 and is strictly anaerobic

1. Acid-resistant 2. Sulfur-resistant

To prevent interaction between products and the metal, cans are coated on the inside with an organic material. Two general kinds of organic coatings are used in the food industry: Format: 1.

Processing (Thermal Processing)

Use of steam under pressure or retort ( autoclave ) for low acid food and water bath processor for acidic foods. Time and temperature will be dependent on the type and nature of food and size of the pack. Modes of heat transfer in canned goods is thru convection and conduction.

Processing under Pressure

Used for low acid foods like meat, fish, poultry, vegetables, sweet potatoes, etc. (pH above 4.6)

Pasteurization or water bath processing

Used for naturally acidic foods and acidified foods like nata de coco and kaong in heavy syrup, pickled vegetables ( pH 4.6 or lower)

Amber (Brown in various color densities)

Usually obtained by melting a composition containing iron oxide under strongly reduced conditions. Carbon is also added. Amber glass has UV protection properties and could well be suited for use with light sensitive products.

1. To extend the keeping quality of food spoilage 2. It provides a means of changing the texture or form of the food itself. 3. Products can be used by consumers during off-season when these fruits and vegetables may not be available

Why do we thermally processed food? (clue: 3 items) format: 1.

Re-contamination

_________________occurs when microorganisms from the outside get back into the thermally processed food and begin to grow.

Metal Cans

alloy of iron with carbon and usually other elements. Tinplate, tin free steel, and nickel-plated steel coated with a very thin film of tin are the materials used to manufacture metal food cans.

Vitamins A and D and beta-carotene

are resistant to the effects of heat.

Sterilization

can be accomplished through either physical means, such as exposure to high heat, pressure, or filtration through an appropriate filter, or by chemical means.

True

canning has no major effect on the carbohydrate, protein, or fat content of foods. True or false

Acid resistant

coated cans are used primarily for fruits.

White flint (clear glass)

colorless glass, known as white flint, is derived from soda, lime and silica.

Exhausting

denotes removal of entrapped air and gases from the raw material and the container before sealing.

Commercial sterility

describes the situation where the growth of microorganisms is halted under a specific set of conditions.

Sterilant

effectively kill all microbes and viruses, and, with appropriate exposure time, can also kill endospores.

Thermal Processing

involves the application of heat to a food material for a specified period of time. In most thermal processes, the temperature to which the food must be heated will be given along with the time for which the material must be held at that temperature.

Sterilization

is a controlled heating process used to completely eliminate all living microorganisms, including thermo resistant spores in milk and other food.

Canning

is a food preservation method which is dependent on heat and hermetic sealing.

Sterilization or absolute sterility

is defined as the complete destruction of all microorganisms within a product. To achieve sterility in most foods, a temperature of 121˚C must be maintained for at least 15 minutes (or equivalent conditions). However, exposing many foodstuffs to such treatment can significantly alter their properties and reduce quality.

Steam or hot water

is introduced into the space between the two walls, which heats the contents of the kettle.

Vitamin B1

is sensitive to thermal treatment and the pH of the food.

Headspace

is the distance between the lid of the container and the contents. Too small headspace can bring about distortion of the can, whereas too large may cause oxidation and discoloration of the contents due to large amount of accumulated air in the can.

Clostridium botulinum

is the most potent toxin producing organism in low acid products.

Sealing

may be accomplished using manual sealing or the use of automatic can Sealers. Exhausted cans are sealed rapidly with an internal temperature of 180 F.

Rapid cooling

must be done for the following reasons: - prevent overcooking - avoid growth of heat resistant spores that survives thermal processing temperatures - prevent corrosion/ rusting of cans. - avoid undue strain on the seams of the cans which may lead to leakage.

water bath processing

pH < 4.5 - ___________________________ ( 212 F)- - - - - acidic foods

under pressure

pH > 4.5 - _____________________ ( 240-250 F) - - - - - -low acid and non-acid foods

4.6

pH _____ above will require steam under pressure ( Retort )

Processing under Pressure

process at 116 C ( 240F) to 121 C ( 250F)

Pasteurization or water bath processing

processing at 100 C ( 212 F) or lower.

121

standards have been established for the length of time canned foods must be held inside the retort to complete the desired thermal processing. It is important to keep in mind that the time is actually the "time at temperature". This means the process timing starts when the entire contents of the cans reach _______ degrees C.

Cooling time

the time required to cool down /lower the pressure inside the cooker prior to opening it.

Come-up time

time required to raise the temperature of the retort or cooker to the processing temperature.

Holding time

time the cooker is maintained at the processing tempt.

Commercial sterilization

uses heat at a temperature low enough to preserve food quality but high enough to destroy common pathogens responsible for food poisoning, such as C. botulinum.

Commercial Sterility

( synonymous with shelf stability) means the destruction of all viable microorganisms of public health significance as well as those capable of reproducing under normal or non-refrigerated conditions.

a) removes respiratory gases b) enzymes inactivation c) soften food d) facilitate preliminary operations e) reduce bacterial load

1B Preliminary Operations - Receiving/weighing raw materials - Separation of edible portions - soaking and washing - sorting and grading - Blanching a) b) c) d) e) -peeling and coring (use of abrasive, mechanical, lye, scalding, flame and steaming)

Filling

90% of total capacity of the container. Can be done manually or with automatic filling machines. Standard fill in weight must be observed. A headspace of 1/ 4 inch is used for products packed in liquids.

heat exchanger

A common way to heat a product in a continuous process is to pump it through a "___________________________" unit.

True

A key factor in thermal processing is to heat the product as rapidly as possible to the desired temperature and then cool it as quickly as possible once the heating period has been completed. True or false

Vitamin C

Although the anaerobic conditions of canned foods have a protective effect on the stability of vitamin _____, it is destroyed during long heat treatments.

Safety

An inert material from health and hygiene viewpoint.

38

At the end of the heating cycle, the cans are cooled under water sprays or in water baths to approximately _______ °C (100 °F)

4.5

Below pH _____ will require only a water bath processor /no pressure is needed.