FOOD PROCESSING INDUSTRY

::Content::

1. Introduction of Food Processing.

2. About Fermentation and Fermented Products.

3. Processed Foods: Cheese/ Yogurt.

4. Processing of Foods: Food Spoilage and Preservation.

5. Conclusion.

Introduction of Food Processing :

Food processing is the set of methods and techniques used to transform raw ingredients into food or to transform food into other forms for consumption by humans or animals either in the home or by the food processing industry. Food processing typically takes clean, harvested crops or butchered animal products and uses these to produce attractive, marketable and often long shelf-life food products. Similar processes are used to produce animal feed.Extreme examples of food processing include the delicate preparation of deadly fugu fish or preparing space food for consumption under zero gravity.

Industrial Cheese Production

The productive enterprises concerned with food processing are known as The Food Processing Industry.

The History of Food Processing:

The origin of food processing goes all the way back to ancient Egypt, yet the period of those developments seems to symbolize the history of the culture of mankind.Nowadays, bread, which is characterized by its use of the fermentation action of yeast and which uses wheat flour as its raw material, is baked all over the world.The origins of beer also go back to Babylon and Egypt in the period from 3,000 to 5,000 BC.The foundation of the modern industry was built up with the introduction of machinery and technology of new methods from Germany. Nowadays, the processed foods that are thriving in grocery shops are modern processed foods and traditional foods, but their manufacturing technology, process control and manufacturing and packaging environmental facilities have been advanced and rationalized to an incomparable extent in the last 30 years. As a result, products with high quality and uniformity are now being manufactured. This is based on the advancement of food science, and is, moreover, due to the general introduction of hygienics, applied microbiology, mechanical engineering, chemical engineering, electronic engineering and high-polymer technology.

History and principle of Food Processing:

Benefits and Drawbacks:

Benefits:Benefits of food processing include toxin removal, preservation, easing marketing and distribution tasks, and increasing food consistency. In addition, it increases seasonal availability of many foods, enables transportation of delicate perishable foods across long distances and makes many kinds of foods safe to eat by de-activating spoilage and pathogenic micro-organisms.Processed foods are usually less susceptible to early spoilage than fresh foods and are better suited for long distance transportation from the source to the consumer.

Processed seafood - fish, squid, prawn balls and simulated crab

sticks (surimi).

Processing can also reduce the incidence of food borne disease. Fresh materials, such as fresh produce and raw meats, are more likely to harbour pathogenic micro-organisms (e.g. Salmonella) capable of causing serious illnesses.

Drawbacks:

Any processing of food can have slight effects on its nutritional density. Vitamin C, for example, is destroyed by heat and therefore canned fruits have a lower content of vitamin C than fresh ones. Another safety concern in food processing is the use of food additives. The health risks of any additives will vary greatly from person to person, in example sugar as an additive would be detrimental to those with diabetes.Food processing is typically a mechanical process that utilizes large mixing, grinding, chopping and emulsifying equipment in the production process. These processes inherently introduce a number of contaminate risks. Food manufactures utilize industrial metal detectors to detect and reject automatically any metal fragment

About Fermentation and Fermented products:

Fermentation in food processing typically is the conversion of carbohydrates to alcohols and carbon dioxide or organic acids using yeasts, bacteria, or a combination thereof, under anaerobic conditions. A more restricted definition of fermentation is the chemical conversion of sugars into ethanol. The science of fermentation is known as zymurgy.Fermentation usually implies that the action of microorganisms is desirable, and the process is used to produce alcoholic beverages such as wine, beer and cider.

Fermentation is also employed in the leavening of bread, and for preservation techniques to create lactic acid in sour foods such as sauerkraut, dry sausages, kimchi and yogurt, or vinegar (acetic acid) for use in pickling foods.French chemist Louis Pasteur was the first known zymologist, when in 1856 he connected yeast to fermentation. Pasteur originally defined fermentation as "respiration without air".

Beer fermenting at a brewery

Bean-based Soy sauce, stinky tofu, soybean paste, Beijing mung bean milk.

Grain-basedBeer, bread, rice wine, malt whisky, grain whisky, idli, dosa.

Vegetable-based Kimchi, mixed pickle, Indian pickle

Fruit-based Wine, vinegar, cider, perry

Honey-based Mead, metheglin

Fermented products:

Dairy-based Cheese, kefir, kumis (mare milk),cultured milk products such as yogurt

Fish-based Fish sauce, Garum, jeotgal, rakfi, shrimp paste

Meat-based Chorizo, Salami, pepperoni

Tea-based Kombucha

Batter made from Rice and Lentil (Vigna mungo) prepared and fermented for baking idlis and dosas

Convenience food, or tertiary processed food, is commercially prepared food designed for ease of consumption. Products designated as convenience foods are often prepared food stuffs that can be sold as hot, ready-to-eat dishes; as room-temperature, shelf-stable products; or as refrigerated or frozen products that require minimal preparation (typically just heating).These products are often sold in portion controlled, single serve packaging designed for portability for "on-the-go" eating.Convenience food can include products such as candy; beverages such as soft drinks, juices and milk; fast food; nuts, fruits and vegetables in fresh or preserved states; processed meats and cheeses; and canned products such as soups and pasta dishes.

Processed Food: Cheese/ Yogurt

A rack of convenience foods

Processed cheese, process cheese, cheese slice, prepared cheese, or cheese food is a food product made from normal cheese and sometimes other unfermented dairy ingredients, plus emulsifiers, extra salt, food colorings or whey Many flavors, colors, and textures of processed cheese exist.The Laughing Cow is an example of processed cheese.Although processed cheese was first invented in 1911 by Walter Gerber of Thun, Switzerland, it was James L. Kraft who first applied for an American patent for his method in 1916.

Processed cheese (wrapped slices)

Advantages:Processed cheese has several technical advantages over unprocessed cheese, including extended shelf-life, resistance to separation when cooked, and uniformity of product.The use of emulsifiers in processed cheese results in cheese that melts smoothly when cooked. Disadvantages:Processed cheese is often criticized for its possible health effects (associated with chemical preservatives, artificial colors/flavors, and trans-fats), inferior taste, and small range of flavors, which is far narrower than the range for unprocessed cheeses and normally very mild.

Processed cheese:

Yogurt is a dairy product produced by bacterial fermentation of milk.The bacteria used to make yoghurt are known as "yoghurt cultures". Fermentation of lactose by these bacteria produces lactic acid, which acts on milk protein to give yoghurt its texture and its characteristic tang.Dairy yoghurt is produced using a culture of Lactobacillus delbrueckii subsp. bulgaricus and Streptococcus salivarius subsp. thermophilus bacteria.

Yogurt

In addition, Lactobacillus acidophilus, bifidobacteria and Lactobacillus casei are also sometimes added during or after culturing yoghurt.The milk is first heated to about 80 °C (176 °F) to kill any undesirable bacteria and to denature the milk proteins so that they set together rather than form curds. The milk is then cooled to about 45 °C (112 °F). The bacteria culture is added, and the temperature is maintained for 4 to 7 hours to allow fermentation.

Yoghurt:

Varieties:Sweetened and flavoured yoghurt.Strained yoghurts.Beverages.

Processing of Food: Food Spoilage and Preservation:

Food processing is the set of methods and techniques used to transform raw ingredients into food or to transform food into other forms for consumption by humans or animals either in the home or by the food processing industry. Food processing typically takes clean, harvested crops or butchered animal products and uses these to produce attractive, marketable and often long shelf-life food products. Similar processes are used to produce animal feed.

Spoilage is the process in which food deteriorates to the point in which it is not edible to humans or its quality of edibility becomes reduced. Various external forces are responsible for the spoilage of food. Food that is capable of spoiling is referred to as perishable food.

Food Spoilage:

Rotten Apple

Harvested crops decompose from the moment they are harvested due to attacks from microorganisms. These include bacteria, mold, yeast, and enzymes.

Bacteria:Various bacteria can be responsible for the spoilage of food. When bacteria breaks down the food, acids and other waste products are created in the process. While the bacteria itself may or may not be harmful, the waste products may be unpleasant to taste or may even be harmful to one's health.

Yeasts:Yeasts can be responsible for the decomposition of food with a high sugar content.The same effect is useful in the production of various types of food and beverages, such as bread, yogurt, cider, and alcoholic beverages.

Reasons:

Signs of food spoilage may include an appearance different from the food in its fresh form, such as a change in color, a change in texture, an unpleasant odor, or an undesirable taste. The item may become softer than normal. If mold occurs, it is often visible externally on the item.

Signs:

Some spoiled foods are harmless to eat, and may simply be diminished in quality. But foods exhibiting certain types of spoilage may be harmful to consume.Uncooked or under-cooked animal flesh that spoils is typically quite toxic can result in serious illness or sometimes death. The toxic effects from consuming spoiled food are known colloquially as "food poisoning", and more properly as "foodborne illness".

Consequences:

A number of methods of prevention can be used that can either totally prevent, delay, or otherwise reduce food spoilage.Preservatives can expand the shelf life of food and can lengthen the time long enough for it to be harvested, processed, sold, and kept in the consumer's home for a reasonable length of time.Refrigeration can increase the shelf life of certain foods and beverages, though with most items, it does not indefinitely expand it. Freezing can preserve food even longer, though even freezing has limitations.Canning of food can preserve food for a particularly long period of time, whether canned at home or commercially. Canned food is vacuum packed in order to keep oxygen out of the can that is needed to allow bacteria to break it down. Canning does have limitations, and does not preserve the food indefinitely.Dried foods can last a long time, sometimes nearly indefinitely.

Food Prevention:

Food Preservation:

Food preservation is the process of treating and handling food to stop or slow down spoilage (loss of quality, edibility or nutritional value) and thus allow for longer storage.Preservation usually involves preventing the growth of bacteria, yeasts, fungi, and other micro-organisms (although some methods work by introducing benign bacteria, or fungi to the food), as well as retarding the oxidation of fats which cause rancidity. Food preservation can also include processes which inhibit visual deterioration that can occur during food preparation; such as the enzymatic browning reaction in apples after they are cut.Many processes designed to preserve food will involve a number of food preservation methods. Preserving fruit, by turning it into jam, for example, involves boiling (to reduce the fruit’s moisture content and to kill bacteria, yeasts, etc.), sugaring (to prevent their re-growth) and sealing within an airtight jar (to prevent recontamination).

There are many traditional methods of preserving food that limit the energy inputs and reduce carbon footprint.Maintaining or creating nutritional value, texture and flavour is an important aspect of food preservation, although, historically, some methods drastically altered the character of the food being preserved. In many cases these changes have now come to be seen as desirable qualities – cheese, yoghurt and pickled onions being common examples.

Preservation processes include:

Heating to kill or denature micro-organisms (e.g., boiling)Oxidation (e.g., use of sulfur dioxide)Ozonation (e.g., use of ozone [O3] or ozonated water to kill undesired microbes)Toxic inhibition (e.g., smoking, use of carbon dioxide, vinegar, alcohol etc.)Dehydration (drying)Osmotic inhibition (e.g., use of syrups)Low temperature inactivation (e.g., freezing)Ultra high water pressure (e.g., Fresherized®, a type of “cold” pasteurization; intense water pressure kills microbes which cause food deterioration and affect food safety)

Preservation processes:

Dehydration:Drying is one of the most ancient food preservation techniques, which reduces water activity sufficiently to prevent or delay bacterial growth.

Refrigeration:Refrigeration preserves food by slowing down the growth and reproduction of micro-organisms and the action of enzymes which cause food to rot. The introduction of commercial and domestic refrigerators drastically improved the diets of many in the Western world by allowing foods such as fresh fruit, salads and dairy products to be stored safely for longer periods, particularly during warm weather.

Freezing:Freezing is also one of the most commonly used processes commercially and domestically for preserving a very wide range of food including prepared food stuffs which would not have required freezing in their unprepared state. For example, potato waffles are stored in the freezer, but potatoes themselves require only a cool dark place to ensure many months' storage..

Freezing process

Refrigeration process

Cold stores provide large volume, long-term storage for strategic food stocks held in case of national emergency in many countries

Vaccum Packing:Vacuum-packing stores food in a vacuum environment, usually in an air-tight bag or bottle. The vacuum environment strips bacteria of oxygen needed for survival, slowing spoiling. Vacuum-packing is commonly used for storing nuts to reduce loss of flavor from oxidation.

Salting:Salting or curing draws moisture from the meat through a process of osmosis. Meat is cured with salt or sugar, or a combination of the two. Nitrates and nitrites are also often used to cure meat and contribute the characteristic pink color, as well as inhibition of Clostridium botulinum.

Sugar:Sugar is used to preserve fruits, either in syrup with fruit such as apples, pears, peaches, apricots, plums or in crystallized form where the preserved material is cooked in sugar to the point of crystallisation and the resultant product is then stored dry. This method is used for the skins of citrus fruit (candied peel), angelica and ginger.

Salting process

Vaccum Packing process

Canning:Canning involves cooking food, sealing it in sterile cans or jars, and boiling the containers to kill or weaken any remaining bacteria as a form of sterilization. It was invented by Nicolas Appert. Foods have varying degrees of natural protection against spoilage and may require that the final step occur in a pressure cooker. High-acid fruits like strawberries require no preservatives to can and only a short boiling cycle, whereas marginal fruits such as tomatoes require longer boiling and addition of other acidic elements. Low acid foods, such as vegetables and meats require pressure canning. Food preserved by canning or bottling is at immediate risk of spoilage once the can or bottle has been opened.Lack of quality control in the canning process may allow ingress of water or micro-organisms. Most such failures are rapidly detected as decomposition within the can causes gas production and the can will swell or burst.

Canning process

A modification of this process produces glacé fruit such as glacé cherries where the fruit is preserved in sugar but is then extracted from the syrup and sold, the preservation being maintained by the sugar content of the fruit and the superficial coating of syrup.

However, there have been examples of poor manufacture (underprocessing) and poor hygiene allowing contamination of canned food by the obligate anaerobe Clostridium botulinum, which produces an acute toxin within the food, leading to severe illness or death. This organism produces no gas or obvious taste and remains undetected by taste or smell. Its toxin is denatured by cooking, though. Cooked mushrooms, handled poorly and then canned, can support the growth of Staphylococcus aureus, which produces a toxin that is not destroyed by canning or subsequent reheating.

Pasteurization:Pasteurization is a process of heating a food, usually liquid, to a specific temperature for a definite length of time, and then cooling it immediately. This process slows microbial growth in food. The process of heating wine to preserve it longer was known in China since AD.1117, and is documented in Japan in 1568 in the diary Tamonin-nikki, but the modern version was created by the French chemist and microbiologist Louis Pasteur, after whom it is named. The first pasteurization test was completed by Louis Pasteur and Claude Bernard in April 1862.The process was originally conceived as a way of preventing wie and beer from souring.Unlike sterilization, pasteurization is not intended to kill all micro-organisms in the food.

Process of Pasteurization of milk

Nisin- It is often added to cheese to avoid the growth of endospore forming spoilage bacteria, its an example of bacteriocin, a protein that is produced by one bacterium and inhibits another. Nisin is present naturally in small amount in many dairy products.

Natamycin- an antifungal antibiotic used in foods. Example: Cheese.

Antibiotics:

Conclusion:

Thereby we conclude up this topic with a quick review about The Food Processing Industry. The productive enterprises concerned with food processing is Known as The Food Processing Industry. The Food Processing is the process of transforming food into other form for the consumption either by humans or animals or The Food Processing Industry. The origin of food processing goes all the way back to ancient Egypt, yet the period of those developments seems to symbolize the history of the culture of mankind and as man evolved from its ancient time, the processing of food has also entered a new era.

As every possible thing has some merits, it shows some demerits too. Like wise, preservation of food shows some merits like it minimizes the risk of toxins and its doesn’t gets spoiled easily like fresh foods. On the other hand its harmful on sone nutritional basis too.

Fermentation and processing of food gives certain new kind of products. Fermentation is done with the use of micro-organisms. Processed foods as discussed above are foods that are made for the consumption by humans or animals for example. Processed Cheese and Yoghurt.

Food spoilage is another important reason for making or producing processed foods. The reason behind this spoilage is bacteria and yeast, but through certain preventive measure it can be stopped. Food preservation can be done by certain methods like dehydration, refrigeration, canning, freezing, salting, sugar, vaccum packing, pasteurization and antibiotics.

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