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I. PRODUCT DESCRIPTION

Cream style corn is a product that is made up of partially whole cut kernels and scraped-off residues left on the cob with reasonably tender texture offering some resistance when chewed but are not hard or tough (FAO/WHO, 1994). It is packed in a creamy component, consisting of the natural starch from corn, salt and sweetener, which has a smooth consistency but may have the possibility of a moderate but not excessive separation of free liquid (FAO/WHO, 1994; Matz, 1991). This canned product is processed by heat to maintain good quality of food and prevent spoilage.

II. PRODUCT SPECIFICATION

Canned Cream Style Corn U.S. Grade B / U.S. Extra Standard pH Kernel Color Consistency Cob Tolerance Husk Tolerance Silk Tolerance Damaged Corn Kernel Tolerance Maximum Limit of Lead Content Maximum Limit of Tin Content Minimum Fill Can Size Average Net Weight 5.9 6.5 Golden or Yellow Smooth and Creamy 3 1 cm /600 g 2 7 cm /600 g 150 mm in 28 g 10 pieces per 600 g 1 mg/kg 250 mg/kg corn product should occupy 90% of the lot capacity of the can container 2T can (307 x 409) Not less than 15 oz. (425 grams)

III. INGREDIENTS LIST AND PROPORTIONS

For the purpose of producing 12 pcs. of No. 2 (307x409) cans of cream-style corn, each containing 500 mL of the food product; the following list of ingredients with their respective proportions are presented hereunder: Table 1. List of Ingredients and proportions for 12 2T cans of cream-style corn 1. Ingredient Corn Specification 15 to 19 days after the appearance of silk, yellow corn, with creamy consistency of the kernel Refined, Sucrose Refined, 99% NaCl Soft (Distilled) Proportion 6.123 kg of corn kernels only (not including the husk, silk and cob) or 20 kg of corn as purchased 119.25 g 36.03 g 1,500 mL

2. 3. 4.

Sugar Salt Water

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1 pc. of No. 2 can = 16.907 oz. = 500 mL 16.907 oz. = 479.305 g 12 pcs. of No. 2 can = 202.884 oz. = 6,000 mL

*preparation of syrup should be equal to EP weight of the corn 1,500 mL of corn= 2.875 kg EP weight of corn 3,000 mL of product 1,500 mL of syrup

2% salt =30 mL 36.03g refined salt 1,500 mL of syrup 5% sugar = 75 mL= 119.25g refined sugar

* Density Sucrose: 1.59 g/cm = 1590 g/L Salt: 1201 kg/m = 1201 g/L

IV. INGREDIENTS FUNCTIONS 1. CORN In cream-style corn, corn is the main ingredient, it is the food base in the canned product. It provides low water and cellulose, protein and a large amount of starch. It are also provides notable sources of the B vitamins and iron in the product. Corn is the main source of starch in the product, the natural starch in the corn hydrates when added with water, thus, it improves the consistency of the cream by making it pasty and viscous. 2. SYRUP (comprised of sugar, salt and water) In canning, syrups are added to fruits and brines are added to vegetables to improve the flavor, fill the spaces between the pieces of canned product, and aid in the transfer of heat during processing.

2.a. SUGAR

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Sugar is the sweetening agent and the color, taste and texture modifier in the product. It also provides energy from the calories it contains. Sugar has hydration effects and competes with salt and corn for water making the product more tender. The dissolved sugar increases the viscosity of the liquid and thereby retards the convection currents. 2. b. SALT Salt is added mainly for flavor. It also increases the boiling point of water enabling the processing time to be longer that aids in decreasing the susceptibility of the product to biological reactions that are caused by microorganisms or enzymes. It also modulates the water activity of the product by competing with the corn and sugar for water. 2. c. WATER Water is the main solvent in the product. It dissolves sugar and salt to help the homogenization of the flavor and consistency of the syrup. It also aids in the transfer of heat for the processing of the product.

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V. PROCESS FLOW DIAGRAM

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VI. LIST OF EQUIPMENT AND UTENSILS

Table 2. List of equipment and utensils Quantity 200 2 3 5 10 Unit ml piece piece piece pair Equipment / Utensil dishwashing liquid sponge strainer / colander knife plastic gloves Step Specified Washing utensils Washing of corn Cutting and scraping off remaining layer of corn Preparation of syrup Specifications Weighing scale to be used for corn and triple beam balance for salt and sugar Cooking of corn in syrup Deep enough for ~15 L or more of syrup no defects Basin or pail filled with water with or without ice.

piece

weighing scale

1 5 5 1

piece piece piece piece

triple beam balance plastic bowls / food containers spoons deep casserole

1 1 12 1

piece piece piece piece

ladle gas stove 2T cans thermometer

Filling of corn and syrup Exhausting filled cans and Cooling sealed cans

1 1 1 3 12 2

set piece set piece piece piece

water bath can sealer retort clean towels labels carton boxes / baskets / trays

Sealing of cans Processing of cans Drying, Labeling, and Storage of cans

Correct labels (i.e. net content)

* All utensils to be used should be clean. Rinse with distilled water if necessary.

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VII. MANUFACTURING PROCEDURES AND PARAMETERS

Manufacturing Procedures
1. Purchasing Corns o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o 14. Cooling of cans 15. Drying, Labeling, and Storage of cans o o o o o

Parameters
Same maturity, preferably corns with light green husks (15-19 days after appearance of silk) Same variety of corn No apparent defects of corn Removes husk and silk without any damage As much as possible less waste Kernels are clean and shiny Total removal of other debris Water used should be clean and free of any contaminants Cut should be constant; depth of 1/8 in. Avoid chaffs Use a clean knife for cutting corn Wear transparent gloves Do not include chaff when scraping Use a clean knife to scrape off the layer Wear transparent gloves Use clean container for corn Use a clean weighing scale Weigh the edible parts (i.e. cut and scraped) of corn Syrup should equal EP weight of corn Composition: 2% salt:2% sugar Use a clean container for the syrup Use clean utensils in preparing the mixture Heat to boiling Stir continuously for 10 minutes Use a clean stirrer Use clean water to wash 2T cans 2T cans should not have defects Mixture should have creamy texture Consistency permits corn to flow from can Leave in. headspace Exhaust to 180F (~82C) Use clean thermometer to measure temperature Seal immediately Make sure temperature of filled can is maintained at ~180F Reject defective sealed cans Processed at uniform high initial temperature of 180F Processed at 250F (~121C) for 85 minutes in a retort Cool to 110F (~43C) Use water to cool Air dry cans or use a machine to dry the cans Correct labels (i.e. net content) Store cans in a dry warehouse or storage room

2. Husking and Silking of Corn 3. Washing of Corn

4. Cutting of corn

5. Scraping off remaining layer of corn

6. Weighing of corn (EP weight)

7. Preparation of syrup

8. Cooking of corn in syrup

9. Washing of 2T cans 10. Filling of corn and syrup to 2T cans

11. Exhausting filled cans

12. Sealing of cans

13. Processing of cans

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VIII. PRODUCTION MONITORING FORMS A. PERSONNELS PERSONAL PROTECTIVE EQUIPMENT AND HYGIENE FORM PPE and Hygiene Accessories/nail Illness polish/make up

Name

Lab Gown

Hairnet

Boots

Clean Hands

Other Concerns

B.ACQUISITION OF RAW MATERIALS FORM Ingredient Quantity Corn Refined sugar Refined salt Date of Purchase: ___________________ Place of Purchase: ___________________ Weight Cost Remarks

C. INGREDIENT STORAGE TEMPERATURE Ingredient Corn Refined sugar Refined salt Storage Temperature

D. EQUIPMENT AND UTENSILS MONITORING FORM Equipment/Utensil Weighing scale Knife Containers (e.g. bowls) Metal spoon Basting spoon Can Thermometer Exhaust Can Sealer Retort Stove Quantity Condition Remarks

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E. CAN FILLING INSPECTION FORM Can 1 2 3 No. of cans filled: _____ Size of can: __________ Weight (~500g) headspace

F. EXHUASTING MONITORING FORM Can 1 2 3 Time started: ______________ Time ended: _______________ Temperature Remarks

H. SEALING MONITORING FORM No. of successful sealed cans: _______ No. of defective cans: _____________ Can 1 2 3 Defects (if any) Remarks

G. PROCESS MONITORING FORM Can Time 1 2 3 No. of cans processed: _____________ Time started: ____________________ Time ended: _____________________ Temperature Remarks

I. WASTE MONITORING FORM Waste Weight

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J. HEAT PENETRATION FORM Heating Time (min) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 Retort Temperature (C) Product Temperature (C) Can A Can B Can C Lethal Rate, L (C)

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IX. APPLICABLE CUT-OUT TEST/S

Physico-chemical Procedure 1. Tear off the rim of the cover. 2. Measure the seam length, cover hook, and body hook using a micrometer. 3. Compare the obtained dimensions with the measurements of the 2T can recommended by General Milk Company as shown below.

Standard Seam Dimensions for 2T Can Can Part (inches) Open top height Sealed height Seam length Seam thickness Counter sink depth Cover hook length Body hook length 2T can (301 x 409) 4.556 + 0.005 4.547 + 0.005 0.106 0.118 0.053 0.057 0.120 0.131 0.072 0.082 0.072 0.082

Can Condition Take note of the appearance of the can externally, like dents, buckles, holes, panels, and all other conditions affecting the cans shape. Take note also of any indication of rusting or corrosion inside. Vacuum Through puncturing a can with a vacuum gauge, its vacuum is determined. The can should be in room temperature; any colder then the vacuum is higher, any warmer then the vacuum is lower. To minimize deterioration of the lid due to the pressure required to penetrate the can, it is punctures near the edge. Reading is made to the nearest half an inch. It may require tapping of the gauge a few times to be able to overcome friction hence, obtain a correct reading. Severely dented can read full for it contains a very small headspace (this is not always accurate), and the puncture tip may penetrate the product so the gauge will fail to register. The air in the gauge itself may have a larger error, making the reading lower. Headspace

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There are two types of headspaces. The gross and the net headspace. The gross headspace is the distance from the top to the double seam, vertically. This is the top edge of a glass jar to the top level of the product inside the container. The net headspace on the other hand is the distance from the topmost layer of the product to the inside surface of the lid. Net Weight Net weight is determined by subtracting the weight of the dried empty container from the weight of the full container (basically the weight of the product or gross weight). Drained Weight Empty the container of its contents upon a mesh of a circular screen while controlling the length of time draining it. Weigh the drained solids exactly two minutes after it is placed on the screen (screen may be placed directly on the balance and then subtracting its weight after). Percent Fill of the Container Container must be filled to not less than 90% of its total capacity or the net headspace should not be greater than 10% of its internal height. Actual percent fill can be calculated in 2 methods a. Percent fill = 100 (net headspace) x C where C = percent can capacity per 1/32 headspace value of C for 301 x 409 (2T) can is 0.746 inch b. Percent fill (% fill) = inside height of can = net headspace x 100 inside height pH 1. With the indicator knob turned to the STBY position, immerse the pH meter electrode into pH 7.0 buffer solution. Turn the knob to the READ/pH position. Using the adjustment knob, correct the reading pH 7.0 2. Turn the indicator knob to the STBY position and clean the electrode by squirting distilled water from a wash bottle. Dab gently with tissue paper.

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3. Calibrate the pH meter using pH 4.0 buffer solution. Remember to turn the indicator knob to STBY when withdrawn from the test solution. 4. The pH meter is now ready to be used. 5. For solid sample, cut into small pieces and blend until homogenous mass is obtained. Weigh 5g and dilute to 20mL by adding distilled water. Filter, discard the residue. 6. For liquid, sample, obtain ca. 10mL sample. Immerse the calibrated electrode into the test solution and turn the indicator knob to the READ/pH position. 7. Do the pH measurement 3 times. Wash the electrode between trials. * Calibration of pH meter may vary for each brand. Water Activity (Aw) 1. Fill sample holder with 2g sample. Do not overfill to avoid soiling the probe later. Seal. 2. Refrigerate for 10 minutes. 3. Insert the sample in pre-calibrated water activity meter. Close the receptacle to avoid escape of humidity and sample temperature shifts. 4. Allow sample to equilibriate. 5. Read Aw. * Water activity meter calibration may vary from each brand.

Total Soluble Solids (TSS) 1. Clean the hand refractometer prism surface by squirting distilled water through a wash bottle. Dab the surface gently with tissue paper. 2. Place a considerable amount of liquid or liquefied sample (note dilution factor) on the prism and gently place the cover.

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3. Hold the refractometer against a source of light and read the soluble solids. Do the measure 3 times and report reading as Brix (Bx).

Microbiological A. Examination of Cans Remove any label on the can. Take note of the appearance of the can externally, if there are any dents, rusts, pinholes, evidence of leakage, defective seams, buckles, improper closures, and other physical defects. B. Opening of Can Clean and sterilize the top of the can using alcohol and then running passing it over a flame. With bulged cans, avoid flaming them and collect the gas instead. Test for pressure of carbon dioxide and/or hydrogen after. Cover the open can with sterilized petri dish. C. Preparation of samples Homogenize 25 grams of the sample with 225 ml of peptone water using a blender. Transfer the homogenized sample in a dilution bottle, aseptically and make serial dilutions up to 10 . D. Culturing of Cans Contents (product is low acid with pH > 4.5) 1. Mesophilic spore count Plate in duplicate the last three dilutions of the sample using Dextrose Tryptone Bromcresol Purple (DTBcP) Agar, then incubate at 30-37C for 4 days. 2. Mesophilis anaerobic sporeformers Inoculate in a liver broth 2 ml volumes of each of the dilutions 10 and 10
o -1 -2, -3

then 2-g portions of

the sample (2 liver broth tubes per dilution/measured portion). Seal the topmost layer with paraffin wax and incubate at 30-35 C for 2 days. Evaluated tubes for disintegration of liver and gas production. 3. Mesophilis anaerobic sporeformers producing H2S Plate in duplicate using sulfite agar. Overlay inoculated agar plate with about 5 ml of a cooled molten sulfite agar and allow it to set. Incubate plates for 30-37C for 2 days. 4. Thermophilic spore count

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Prepare dilutions and heat them in an 80C water bath for 30 minutes then immediately immerse the dilutions in an ice-cold water bath after. Plate in duplicate the last three dilutions into DTBcP agar then incubate at 53-57C for 2-5 days. Evaluate the plates for opaque colonies with yellow halo and a diameter of 2mm. 5. Thermophilic anaerobic sporeformers Inoculate in duplicate liver broth tubes (per dilution/measured portion) 2-g portions of the sample and 2 ml volumes of each of the dilutions 10 and 10 (in no. 4). Seal the topmost layer with paraffin wax and incubate at 53-57 C for 2 days. 6. Thermophilic anaerobic sporeformers producing H2S Using the same dilutions in no. 4 above, plate in duplicate with sulfute agar. Overlay agar plate with about 5 ml of the cooled molten sulfite agar and allow it to set. Incubate the plates at 53-57 C for 2 days. E. Examination of Cultures After incubation, inoculate the culture to make gram stain smears for representative tubes and determine if the canned product is commercially sterile or not. If not, determine the cause of spoilage.
o o -1 -2

Sensory 1. Test the canned product for color. The corn kernels should be golden or yellow in color. 2. Test the canned product for odor. The canned product should be free from any off-odor. 3. Test the canned product for texture. The corn kernels should have a texture that is reasonably tender offering some resistance when chewed but are not hard or tough (FAO/WHO, 1994). 4. Test the canned product for consistency. Its syrup should be creamy with a smooth consistency and with a tendency for moderate but not excessive separation of free liquid (FAO/WHO, 1994; Matz, 1991). 5. Test the canned product for overall quality. The finished product should practically be free from silk, husk and off-colored kernels but certain limits were set in case of its presence (See Product Specifications).

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