FOOD AND FOOD BY PRODUCT

PROCESSING INDUSTRIES
Pallo, Z.V. & Rosales, S.J.

INTRODUCTION
The technology applied in manufacturing
industries is being applied to food.
The demand for uniform quality processed
food increases because homemakers work
away from home.

HISTORY
THEN

NOW

Former production is done

in farms and homes.
Examples of early
developments are milling of
grain, fluid milk processing,
baking and processing of
sugar and candy.

With central processing is

the establishment of grade
and quality standards.
Recent developments
applied freezing to meat,
produce and readily cooked
products.
Production enterprises are
single-product oriented,
where much of basic food is
from manufactured sources.

ECONOMICS
The food industry is almost twice the size of
the chemical industry.
Food industry invests less in facilities and
equipment, and more in employees which
varies in sections.

TABLE 1. Size of Some Manufacturing Industries

Source: The Statistical Abstract of the United States, 1981. Data are for 1977.
Value Produced
109 dollars

Value Added by
Manufacturing
109 dollars

New Capital
Expenditures
109 dollars

Total Employees
103

All industries

1359

585.2

47.5

13,691

Food

192.9

56.1

4.2

1,500

Chemicals and
allied products

118.2

56.7

8.2

54

Petroleum

93.9

16.4

2.3

101

Paper

52

22.2

3.3

486

Textiles

35

16.1

1.2

765

Rubber

38

19.7

1.6

564

Stone, clay and

glass

37

19.1

5.7

484

Leather

3.7

0.096

243

TYPES OF FOOD PROCESSING

Refining and Milling

Drying

Canning

Pasteurization and
Sterilization

Concentration

Fermentation

Freezing

Irradiation

Packaging

REFINING AND MILLING

Refining is conversion of food product by
various processes.
Sugar from cane or beet
Evaporation

Clarification

Milling

Cane
preparation
for milling

Crystallization

Centrifugation

Drying

Refining

Growing and
harvesting of
cane

REFINING AND MILLING

Milling is the process of
converting grain into flour by
mechanical process.
Modern industry has made
innovations in various
measurements.
Production of free-flowing
flour is made by clustering
flour particles through
addition of moisture and
spray-drying.
Use of air classification can
separate high-protein and
high-starch fractions, thus
permit custom bending.

PROCESS
1. Grain is cleaned.
2. A small amount of water is
added to prevent the outer
part of the kernel from
pulverizing.
3. Moistened grain is crushed to
break kernel into chunks.
4. Product is sifted to remove
germ and bran, and
separated chunks by size.
5. Resulting flour is sieved to
remove large particles.

CANNING
Fresh food are preserved for
long term storage by heat
treatment and sealing into airtight containers.
The containers are metal.
The usual method of heat
treatment is to place
containers in a steam pressure
vessel and processed at 121C.
Acidic food (below pH 4.5)
require less process time than
food at pH 4.5-7.0.
Vegetables need to be treated
longer than fruits.

PROCESS
1. Raw food is packed into
the container.
2. Container is sealed.
3. Whole package is heated
to cook food and sterilize
the container and
contents.

CANNING
Agitated cooker is used
for adequate heat
penetration and shorttime treatment.
Agitated cooker consists
of preheater, cooker, and
cooler.
Other kinds of agitated
cookers are the rotary
pressure sterilizer and the
newer, crateless retort
system.

PROCESS

1. The cans are placed in

individual compartments.
2. They are then rotated by a
revolving reel on spiral
track, guiding it to the inlet
to the outlet continuously.

CANNING
ROTARY PRESSURE STERILIZER

CRATELESS RETORT SYSTEM

On the right is the pressure cooker

and the left is the pressure cooler.

Consists of one or more pressure

vessels mounted above the water
tank, equipped with submerged
conveyer.
Each vessel is prefilled with hot water
to cushion the fall of containers and
maintain the initial temperature
during loading.

CONCENTRATION
Food with high percentage
of water may be partially
dehydrated as a method of
preservation.
Milk is evaporated from a
solid content of 8.6% to a
more concentrated 45%.
Fruit juices are also
concentrated before
marketing.
The usual practice is to
reduce the volume to a
third of its original volume.

PROCESSES
Evaporation with evaporators

Reverse osmosis

Freeze concentration

FREEZING
Preservation of fresh food by freezing is made possible by
the realization that if food can be frozen very quickly
(supercooled) and maintained at low temperature to
prevent ice crystal formation, the quality will not be
greatly deteriorated and microorganisms will not
increase.
If the amount of water in food is reduced before freezing,
the quality of the final product is generally improved.
Freezing does not kill the microorganisms present in food
that causes spoilage, but only inactivates them.
Nutrients are not also destroyed by freezing.

FREEZING
UNPACKAGED FOOD
Freezes faster, but
dehydration is a serious
problem
Still or enforced air
Direct contact with a metal surface
cooled by a refrigerant
Immersion in a liquid refrigerant, such as
liquid nitrogen

PACKAGED FOOD
Fastest method available

DRYING
Sun drying preserve more fruits than any other
method.
Dried foods are easy to transport and to store,
because it occupies only a tenth of its original
volume.
Microbial growth is controlled because amount of
free water is insufficient for growth.
The nutritive value of dried food is usually
unchanged, but the vitamin content is greatly
reduced.

DRYING
When fruits are dried, their bright color
becomes dark brown unless treated with
sulfur dioxide (SO2) before drying.
Because consumers prefer moist dried fruit,
glycols are used to rehydrate and soften the
product without adding moisture.

TABLE 2. Types of Driers and Food Products

Source: The Technology of Food Preservation, 4 th ed., 1977

Drier

Product

Drum

Milk, vegetable juices, cranberries, bananas

Vacuum shelf

Limited products of certain foods

Continuous vacuum

Fruits and vegetables

Atmospheric continuous belt

Vegetables

Fluidized belt

Vegetables

Foam mat

Juices

Spray

Eggs, milk, coffee

Rotary

Some meat products, not usually for food

Cabinet

Fruits and vegetables

Kiln

Apples, some vegetables

Tunnel

Fruits and vegetables

Freeze

Meat, coffee

PASTEURIZATION AND STERILIZATION

PASTEURIZATION

STERILIZATION

Partially sterilizes milk for

human consumption.
Discovered by Louis Pasteur.
Most common method is
high-temperature-shorttime (HTST).
Purpose is to kill diseasecausing microorganisms and
inactivate enzymes to
improve storage and quality.

Process conditions severe

enough to kill or completely
inactivate all
microorganisms.
The sterilized product is
placed in a sterile container
under aseptic conditions
and sealed.
Milk treated can be stored
for several months at room
temperature.

PASTEURIZATION AND STERILIZATION

Free Falling Film System
Eliminates bad taste from
ultrahigh-temperature sterilized
milk.
Milk is preheated to 65C
conveyed in a vessel where steam
is maintained at 138-150C under
pressure.
Milk flows from the thin slits at
the bottom of horizontal feed
pipes forming a thin film.
Passage through the vessel takes
only to seconds, and
sterilized milk is collected in an
air-cooled cone-shaped bottom
of the vessel.

FERMENTATION
FERMENTATION

Decomposition of
carbohydrates
Produces carbon
dioxide but produces no
putrid odor

PUTREFACTION

Action of
microorganisms on
protein
Produces sulfurcontaining protein
products and hydrogen
sulfide

IRRADIATION

IRRADIATION
Irradiation has been approved as a safe
method of food preservation.
Joint Expert Committee on Food Irradiation
(JECFI) and the Internal Atomic Energy
Commission recommended that all major
categories of food can be safely treated if the
dose does not exceed 104 J/kg (106 rads).

PACKAGING
The purpose of packaging food is to make it possible to
ship and store it far from the place of production and
prevent deterioration during storage.
Many food processes have the container filled before
processing. Examples are metal cans, glass containers,
and plastic pouches.
Cardboard boxes, with inside liners or waxed- or plasticcovered paper, are commonly used to package dry foods.
Sacks made of finely woven cloth and coated paper is
used for large quantities.

PACKAGING
The advent of food sterilized before it has been
placed in its container has developed aseptic
packaging.
The advantages of aseptic processing and packaging
are much more shelter life and ability to store
perishable food, such as milk, without refrigeration.
The packages, usually rigid and rectangular
cardboard, are sterilized by the use of hydrogen
peroxide and heat. A process also uses ultraviolet
light added to peroxide sterilization.