Professional Documents
Culture Documents
CBLM Food Processing
CBLM Food Processing
1
CBLM for Food Processing NCll
Prepared and Developed by: Ma. Carina Santiago-
Villanueva
HOW TO USE THIS COMPETENCY – BASED LEARNING MATERIAL
Welcome!
Remember to:
Work through all the information and complete activities in each section.
Read information sheets and complete the self-check. Suggested
references are included to supplement the materials provided in this
module.
Most probably, your trainer will also be your supervisor or manager. He
is there to support you and show you the correct way to do the things.
You will be given plenty of opportunities to ask questions and practice on
the job. Make sure you practice your new skills during regular work
shifts. This way, you will improve your speed, memory and your
confidence.
Use the Self-Checks, Operation Sheets or Task or Job Sheets at the end
of each section to test your own progress. Use the performance.
When you feel confident that you have had sufficient practice, ask your
Trainer to evaluate you. The results of your assessment will be recorded
in you Progress Chart and Accomplishment Chart.
You need to complete this module before you can perform the next
module, Test Systems Network.
UNIT DESCRIPTOR : This unit deals with the knowledge, skills and
attitudes required to process foods by salting, curing and smoking. Include
packaging using plastic bags only.
LEARNING OUTCOMES:
Definition of Terms:
Salting: This is the most basic and most ancient form of preserving meat. This
process keeps the meat from going off by sucking it like a vacuum removing
most of the moisture where bacteria thrive and survive. By doing so, the meat
tends to be dry and tough but makes it a little salty.
Curing: This process is like salting where nitrates are simply added to the meat
which prevents the meat from spoiling. In this process, there is a little use of
salt but instead more on nitrates that makes the meat softer and less dry.
Nitrates contribute to the yet delicious pink color and added flavor with the use
of herbs and spices.
A. Equipment
C. Utensils
11. Casserole Pot- A cooking utensil used for cooking, stewing food
and in cooking sugar concentrates
12. Saucepot- a cooking utensil usually a pot with cover and two
handles used to cook sugar concentrates.
1. Smoking tray- a tray like container made of bamboo used to place the
fish
5. Hair nets- worn on the head to protect from hair falling to food
preparation/processing
6. Hand Towels- at least 3 pieces used for personal use and for wiping
utensils
1. The food items that can be processed and preserved are : fish,
meats, eggs, vegetables
3. A. hair net
B. smokehouse
C. chopping/cutting board
D. casserole pot
E. strainer
F. earthen pots
G. impulse sealer
H. salinometer
I. chiller
J. steamer
Information Sheet 1.2
• Emulsification: The breaking up of fats and oils to allow them to mix in water.
Once this is accomplished, they remain suspended in water until rinsed away.
• Saponification: The process of making fat soluble and easier to remove. Alkali
cleaners react with animal or plant fat, creating soap that is suspended for
rinsing.
• Wetting agents: Used to lower the surface tension of water, helping the
water to contact all surfaces of the soil and the equipment.
Water. Water used for sanitation must be potable whether it is from a private
well or a municipal source. Potable means that it is fit for human consumption
without further treatment. In all situations, sufficient boiler capacity is need to
provide enough hot water for the entire cleaning process. Cold water will not
dissolve fats, so the plant must supply enough hot water to facilitate the entire
sanitation process.
Portable equipment can be used for wet cleaning of hard-to-reach areas. It may
require hot-water feed or have built-in heaters to create hot water. In addition,
it can incorporate detergent and create foam.
The following steps are basic procedures for effective cleaning and sanitizing.
Each step in the process depends on effective completion of the prior step.
The sanitation process starts with a dry pickup of scrap, paper, packaging,
and product or ingredient spills. This should be ongoing during the
manufacturing shift to prevent excess buildup and prevent insanitary
processing conditions.
2. Cover electrical panels or motors with plastic and secure the plastic to
prevent forcing water into areas that may result in damage.
3. Lock out or tag out moving equipment, such as blenders, to prevent injury
(i.e., equipment someone may have to reach into). Do not place equipment
parts on the ground (floor) or on stairs or platforms where there is foot
traffic, as this may only create more bacterial niches and result in
recontamination of clean parts. Instead, have racks or clean-out-of-place
(COP) tanks for these
parts.
4. Follow dry cleaning with a hot-water rinse to break up fat, remove visible
soils, and combine with mechanical action to prepare surfaces for cleaning.
Water temperature for cleaning is very important, depending on the soils
present. Generally, the water temperature used is approximately 5°F above the
melt point temperature of fat. This means that the recommended temperature
will be between 130 to 160°F. As proteins denature and bind to surfaces,
making removal more difficult, do not let the water temperature reach 185°F or
higher.
5. Dry pickup and rinse are very important steps to remove as much soil as
possible as most chemical cleaners are not designed to remove excess soils
or gross contamination.
Wash all equipment and environmental surfaces with detergent and hot water.
Here again, the water temperature is most effective between 130°F and 160°F,
depending on the cleaning chemicals used. Cleaning may involve several steps
and cleaning compounds used may contain several ingredients, depending on
the soils to be removed, hardness of water, and prevention of scale formation.
The chemicals used will be selected to control soils identified in Table 1.
Chemical mixing, if not done by an automatic dispenser, is very important to
cleaning effectiveness and cost control. Train sanitors to properly mix
chemicals, and if verification of chemical strengths is required, use test strips,
titration chemicals, or pH/conductivity probes available with some ATP
devices. Ensure that they understand that excess chemical will not make
cleaning easier; in fact, it may make it more difficult by harming equipment,
leaving chemical film, and wasting money. Conversely, too little chemical does
not save money as it is not going to clean as effectively and will ultimately
result in failures such as reduced shelf life and quality, microbiological
problems, or regulatory noncompliance reports, or control action. A pumping
system with pressurized air is an effective means of applying cleaning
compounds with the creation of foam. Foaming cleaners are most effective
when large areas need to be cleaned, and they should be left on the equipment
long enough to break down soils but not long enough to dry, making removal
more difficult.
Once the chemical has been applied to the surface, it will require contact time
to penetrate and break up soil, but not so long that it begins to dry. Use
mechanical action as needed to remove soil and prevent buildup that can
contribute to biofilm formation. As a rule, scrub contact surfaces on a daily
basis and indirect surfaces such as frames at least once a week.
Once the cleaning process is completed, the rinsing process will remove soils
suspended in detergent. Rinse all surfaces with hot (130 to 160°F ) water to
remove all soap. Use care to avoid overspray or water spray into floors and
drains that might result in the creation of aerosols.
Sanitizing
Once cleaning is complete and prior to application of sanitizer, it is a good idea
to conduct basic monitoring, beginning with organoleptic inspection:
• Look in, around, and under equipment and structures for indications of soil
removal.
• Does the environment smell clean or are there sour or musty odors?
• Feel equipment surfaces for grease or grit from incomplete soil removal.
Provide the proper tools to monitor, including a flashlight; mirror (no glass)
for inspecting difficult-to-reach locations; test strips or kits to monitor
cleaning and sanitizing solutions; thermometer for checking water
temperature; a ladder or lift to inspect high equipment and overhead
structures; and a notepad and pen to record findings.
The final step in the process is to apply sanitizer to all cleaned and rinsed
surfaces to destroy hidden microorganisms. Effective use of sanitizers is
integral to controlling microorganisms for the purpose of food safety and
product shelf stability. It must be understood that sanitizing does not replace
thorough handwashing or equipment and facility cleaning. Factors such as
organic materials, especially protein, decrease the effectiveness of sanitizers
against microorganisms. Therefore, plant employees must be trained to
properly wash hands and clean equipment/facilities, and to remove all
carbohydrate, fat, and protein soil and biofilms prior to sanitizing. The
sanitizing step will supplement effective cleaning through the reduction of
microorganisms to a level considered safe.
The selection of sanitizers will be determined to a great extent by the
microorganisms to be controlled in the operation, as well as corrosiveness
and cost. Table 3 identifies many of the common sanitizers for food plant use.
An effective sanitizer will pass an efficacy test requiring that 99.999% of
harmful microorganisms be killed within 30 seconds. All sanitizers used in the
plant must be listed in the USDA Approved Chemical Compound book, and an
MSDS must be provided for each sanitizer and be available to employees.
Sanitation employees handling sanitizers must be trained to properly handle
and prepare them at the appropriate effectiveness level and be provided with
strips or chemical kits to test them. They must also be trained to clearly
identify any container bearing sanitizer with the type that it contains.
Operational Sanitation
Although this is a regulatory requirement, it should also be an objective of the
plant to ensure that product does not become contaminated from the effects of
operational processes:
GMPs: These are possibly the most important factor in the maintenance of
sanitary operating conditions. These include employee dress, hand washing
and maintenance of hand-wash facilities (providing hot water, soap and
towels), prevention of employee traffic from raw- to cooked-product areas, food
and tobacco control, and disease control. These controls must be enforced with
plant visitors as well.
Spill control: All areas within the building, storage and office areas, as well as
processing areas, must be kept clean, neat and free of soil or spills. Ingredient
spills in storage or manufacturing areas must be cleaned up immediately.
Excess accumulation of spilled product, ingredient or other material (i.e.,
grease) in or around the production area must be cleaned up for food safety
and employee safety.
Idle equipment control: Idle equipment, not currently in use, will be covered to
prevent contamination from ongoing operations, maintenance, or sanitation
activities. If not covered, equipment will be washed on a daily basis and, in all
cases, washed and sanitized prior to use in production.
Overhead control: Overhead structures (i.e., pipes, beams, lights, etc.) are to be
clean, free of condensation as well as dust buildup, and rust and flaking
materials (paint, silicone, tape and plastic.) Place overheads on the master
sanitation schedule to prevent buildup of soils that can drop onto product
surfaces or product.
Packaging control: Direct product-contact packaging (i.e., film and bags) will be
covered while in storage areas to prevent accidental contamination. Packaging
materials returned to storage will be dry, clean and sealed.
Door control: Doors (including silos, compactor areas) should remain closed
during operations unless they have operating air curtains to prevent the entry
of pests and outdoor dust or soil.
Maintenance control: Food-contact equipment contaminated by maintenance
activity before or during operations should be properly cleaned and sanitized
before contact with food product or packaging.
a. True
c. True
d. More
e. True
f. True
h. True
i. True
j. Not so
Performance Objective: After completing this task, the trainees will be able
to demonstrate how to do the proper handwashing technique
4. Right palm over left dorsum with interlaced fingers and vice versa
CRITERIA YES NO
4. Right palm over left dorsum with interlaced fingers and vice
versa
5. Palm to palm with fingers interlaced
Action Steps:
Resources required:
• Red Tags
Target Outcomes:
Action Steps:
• Labeling supplies
Target Outcomes:
Action Steps:
• Define "clean"
Resources required:
Target Outcomes:
• Work place becomes free of dirt and stains which is the starting point
for quality.
• Prevents accidents.
Action Steps:
Resources required:
• Support from those who can create documentation, job aids, and visual
aids
Target Outcomes:
• Avoid mistakes.
Action Steps:
• Presentation tools for sharing best practices with other work areas
Target Outcomes:
Resources required:
• Reduces accidents
Action Steps:
Resources required:
Target Outcomes:
• Better communication
1. Weighing Scale
Parts:
eyepiece
mirror tube
adjustment screw
cover plate
prism
3. Salinometer-
Raw foods such as meat, fish and vegetables may contain harmful bacteria that
can spread very easily by touching:
other foods
worktops
chopping boards
knives
You should keep raw foods away from ready-to-eat food, such as salad, fruit
and bread. This is because these types of food won't be cooked before you eat
them, so any bacteria that get onto the food won't be killed.
don't let raw food such as meat, fish or vegetables touch other food
don't prepare ready-to-eat food using a chopping board or knife that you
have used to prepare raw food, unless they have been washed thoroughly
first
wash your hands thoroughly after touching raw meat, fish or vegetables
and before you touch anything else
cover raw meat or fish and store on the bottom shelf of the fridge where
they can't touch or drip onto other foods
don’t wash raw meat before cooking
wash, peel or cook vegetables unless these are described as 'ready-to-eat'
on the packaging
It's important to read food labels to make sure everything you’re going to use
has been stored correctly (according to any storage instructions) and that none
of the food is past its ‘use by’ date.
Food that goes off quickly usually has storage instructions on the label that say
how long you can keep the food and whether it needs to go in the fridge.
This sort of food often has special packaging to help keep it fresh for longer.
But it will go off quickly once you’ve opened it. This is why the storage
instructions also tell you how long the food will keep once the packaging has
been opened. For example, you might see ‘eat within two days of opening’ on
the label.
3. Use by dates
You will also see ‘use by’ dates on food that goes off quickly. You shouldn’t use
any food after the ‘use by’ date even if the food looks and smells fine, because it
might contain harmful bacteria.
The 'best before' dates marked on most foods are more about quality than
safety. When this date runs out, it doesn't mean that the food will be harmful,
but its flavour, colour or texture might begin to deteriorate.
An exception to this is eggs, which have a best before date of no more than 28
days after they are laid. After this date the quality of the egg will deteriorate
and if any salmonella bacteria are present, they could multiply to high levels
and could make you ill.
If you plan to use an egg after its best before date, make sure that you only use
it in dishes where it will be fully cooked, so that both yolk and white are solid,
such as in a cake or as a hard-boiled egg.
Types of Meat
1. Pork
Pork is one of the most popular forms of meat in the world. Despite
some confusion on the issue, pork is classed as red meat. This is because it
contains a large amount of myoglobin, a protein responsible for the red color
of meat. Bacon, Ham, Hot dogs, Jamon, Prosciutto, Salami, Sausages and
Spam are some meat products that uses pork.
Benefits
Pork is a particularly significant source of thiamine (vitamin B1).
The content of this important vitamin is much higher than in other
meat and plays an essential role in glucose metabolism and
protecting cardiac health.
Much cheaper than most other meat.
Pork contains decent amounts of selenium and zinc, which are
responsible for boosting the immune system, defending
against stress, and optimal hormone production.
Concerns
When most people think of red meat, they probably imagine beef. There are
many different beef products and cuts of beef, ranging from hamburgers to rib
eye steaks. While mainstream health advice often dictates selecting the leanest
cuts of red meat, fatty cuts of beef are perfectly healthy.
Benefits
Despite fearmongering over the fat content of beef, the main fatty acid in
beef is none other than oleic acid. If you haven’t heard of it before, then
it’s the main fat in olive oil (and known as “heart healthy”)
Beef contains a wide variety of beneficial compounds that
include creatine, conjugated linoleic acid (CLA), and glutathione
Concerns
Benefits
Because sheep graze on pasture all day, the omega 6 to 3 ratio is very
low- and optimal—compared to other meats.
Lamb contains a broad range of health- protective nutrients, especially
zinc, selenium and B vitamins.
Concerns
4. Chicken
Alongside beef and pork, chicken is one of the ‘big three’ popularity-wise.
However, chicken is a different classification of meat and comes under the
poultry category. People commonly refer to as “white meat” rather than red.
As one of the most popular foods in the world, there are all sorts of
chicken-based foods. These range from fried and roasted chicken to chicken
soup and even chicken popcorn.
Benefits
Turkey is another type of white meat, probably best known for its
appearance at the Christmas table! It has both a deeper yet drier taste than
chicken and is a less prevalent form of poultry. As mentioned above, the most
popular kind is probably roast turkey, but you can find a variety of processed
and unprocessed turkey products.
Benefits
Turkey is among the most protein-dense of all meats, offering 17.5 grams
of protein in only 149 calories.
Similar to chicken, turkey also provides a significant amount of B
vitamins, potassium, selenium and phosphorus.
Turkey provides an inexpensive source of high- quality protein.
Concerns
6. Venison
Benefits
As deer live and feed in the wild, venison is one of the healthiest and
most natural varieties of meat. The excellent omega 6 to 3 ratio
(2:1) shows the benefits of an animal living on a natural diet.
Venison has more vitamins and minerals than beef despite having
significantly fewer calories. In short, venison is possibly the most
nutrient-dense meat out there.
Concerns
While there are no major health concerns, one obstacle could be the
price; venison costs a lot. Expect to pay around $30 for one pound of
venison steak.
7. Duck
Duck is one of the less popular types of meat. However, it has immense
popularity in Chinese populations, where ‘ Peking duck’ is a showpiece dish.
Like chicken and turkey, we can consider duck as a kind of white meat.
Benefits
Fish as Food
Fish has been an important source of protein and other nutrients for
humans from time immemorial.
Species
Over 32,000 species of fish have been described, making them the most
diverse group of vertebrates. In addition, there are many species of shellfish.
However, only a small number of species are commonly eaten by humans.
Grading and Sorting of the Raw materials for salting, curing and smoking
Learning Objectives:
Quality grades are reflective of the eating quality of beef. Beef carcasses
are cut between the 12th and 13th rib, making the ribeye easy to view. United
Sates Department of Agriculture (USDA) Graders evaluate the distribution on
marbling in the ribeye. The age or maturity of the animal is also factored into
the quality grade.
The ribeye on the left is the one most of you probably leaned towards. It
has a greater amount of marbling in the ribeye. Marbling is thw white pieces of
fat that are seen inside the lean. Additionally, it has a brighter, more cherry-
red coloredribeye. The ribeye on the right does have less fat along the ribeye.
However, it has less marbling than the other ribeye. In addition it has a duller
color to the meat.
The USDA grading system breaks down the quality grades of beef into
Prime, Choice, Select, Standard, Commercial, Utility, Cutter and Canner.
Prime is the highest quality of beef available. They have the most
marbling and are sure to provide a wonderfully juicy and extremely tasty eating
experience. The high level of marbling makes them great for grilling and other
dry cooking methods.
Choice is still high quality beef that has less marbling than Prime.
Consumers are going to receive a delicious and juicy eating experience. Tender
cuts are still great for grilling and other dry cooking methods, while less tender
cuts are more suitable for a liquid added type of cooking.
The quality of pork depends on its color, texture, and marbling which
can be determined by visual evaluation or scientific tests such as ultimate pH.
Fresh pork is more tender and juicy when it is reddish-pink, firm and non-
exudative. The chart below helps to demonstrate the variations in pork
quality. The USDA does not grade pork in the same way it does in beef. Pork
carcasses are not ribbed, and grades of pork are determined by back fat
thickness and carcass muscling.
Lamb Grades
Poultry Grading
Conformation
The structure or shape of the bird may affect the distributionand amount
of meat, while certain defects detract from its appearance. Some of the defects
that should be noted are breasts that are dented, crooked, knobby, or V-
shaped; backs that are crooked or hunched; legs and wings that are deformed;
and bodies that are definitely wedge-shaped.
Fleshing
The drumsticks, thighs, and breast carry the bulk of themeat. There is,
however, a definite correlation between the covering of the flesh over the back
and the amount of flesh on the rest of the carcass. Females almost invariably
carry more flesh over the back and will generally have a more rounded
appearance to the breast, thighs, and legs. The common defects in fleshing are
breasts that are Vshapedor concave, rather than full and rounded; breasts that
are full near the wishbone, but taper sharply to the rear; legs and drumsticks
that are thin; and backs that have insufficient flesh to cover the vertebrae and
hip bones.
Fat Covering
Fat in poultry is judged entirely by accumulation under theskin. This is
true even for chicken parts. Accumulations occur first around the feather
follicles in the heavy feather tracts. Poorly fattened birds may have some
accumulation of fat in the skin along the heavy feather tracts on the breast.
Then, accumulations will be noted at the juncture of the wishbone and keel
and where the thigh skin joins the breast skin. At the same time,
accumulations will be noted around the feather follicles between the heavy
feather tracts and over the back and hips. Well-finished older birds will have
sufficient fat in these areas and over the drumsticks and thighs so that the
flesh is difficult to see. Fowl which have stopped laying have a tendency to take
on excessive fat in the abdominal area. Younger birds will generally have less
fat under the skin between the heavy feather tracts on the breast and over the
drumsticks and thighs than mature birds.
Feathers
Processors try to eliminate the problem of feathers by movingpoultry to
slaughter after feathering cycles are over. There is, for instance, a very short
period within which the slaughtering of ducklings must be done. With other
classes, the period is longer and attention is given primarily to noting if the
bulk of the pins have sufficient brush on them to facilitate picking.
Protruding feathers have broken through the skin and may or may not have
formed a brush. Nonprotruding feathers are evident but have not pushed
through the outer layer of skin. Before a quality designation can be assigned,
ready-tocookpoultry must be free of protruding feathers that are visible to a
grader during examination of the carcass at normal operating speeds. However,
a carcass may be considered as being free from protruding feathers if it has a
generally clean appearance (especially on the breast and legs)and if not more
than an occasional protruding feather is in evidence during a more careful
examination of the carcass. Hair on chickens, turkeys, guineas, and pigeons;
and down on ducks and geese must also be considered.
Poultry halves (fig. 15) are prepared by making a full lengthback and breast
split of the carcass to produce approximately equal right and left sides.
Portions of the backbone must remain on both halves. The cut may be no more
than one-fourth inch from the outer edge of the sternum (breastbone).
Front poultry halves (fig. 16) include the full breast with corresponding back
portion, and may or may not include wings, wing meat, or portions of wing.
Rear poultry halves include both legs and adjoining portion of the back.
Quarters consist of the entire eviscerated poultry carcass which has been cut
into four equal parts, excluding the neck.
Breast quarters (fig. 17) consist of half a breast with the wing and a portion of
the back attached.
Breasts are separated from the back at the shoulder joint and by a cut running
backward and downward from that point along the junction of the vertebral
and sternal ribs. The ribs may be removed from the breasts, and the breasts
may be cut along the breastbone to make two approximately equal halves; or
the wishbone portion may be removed before cutting the remainder along the
breastbone to make three parts.
Breasts with ribs are separated from the back at the junction of the vertebral
ribs and back. Breasts with ribs maybe cut along the breastbone to make two
approximately equal halves; or the wishbone portion may be removed before
cutting the remainder along the breastbone to make three parts.
Split breasts with back portion or breast halves with back portion (fig. 19) are
prepared by making a full-lengthcut of front poultry halves without wings. If
labeled “splitbreast(s),” centering of the cut is not required to producetwo
approximately equal halves.
Legs (fig. 20) consist of the attached thigh and drumstick, whether jointed or
disjointed. Back skin is not included. The patella (kneebone) may be included
on either the drumstick or thigh.
Thighs (fig. 21) are disjointed at the hip joint and may include the pelvic meat,
but not the pelvic bones. Back skin is not included. Thighs may also include
abdominal meat (flank meat), but not rib bones.
Thighs with back portion (fig. 22) consist of a poultry thigh with back portion
attached.
Drumsticks (fig. 23) are separated from the thigh and hock by cuts through
the knee joint (femorotibial and patellar joint) and the hock joint (tarsal joint),
respectively.
Wings (fig. 24) include the entire wing with all muscle and skin tissue intact,
except that the wing tip may be removed.
Wing drummettes (fig. 25) consist of the humerus (first portion) of a wing with
adhering skin and meat attached.
Boneless-skinless breasts (fig. 26) or breasts with rib meat are prepared from
breasts cut as described for “breasts” and for “breasts with ribs.”
Tenderloins (fig. 27) are the inner pectoral muscle which lies alongside the
sternum (breastbone). Tendons may be present.
Boneless-skinless thighs (fig. 28) are prepared from thighs cut as described for
“thighs.”
Boneless-skinless drums (fig. 29) are prepared from drums cut as described for
“drumsticks.”
How can you tell the difference between a good egg and a bad egg? Eggs
are rated and graded into three classifications determined by the United States
Department of Agriculture (USDA). If you have chickens and plan on selling
eggs, grading and sizing is required. As a general rule, you should grade all
your eggs before you store, sell or consume them. At Southern States, we can
help you get the job done. Follow these steps to understand how to grade and
size eggs.
When grading eggs, both the interior and exterior quality is measured.
This process does not take into account weight or shell color. According to
USDA guidelines, eggs are graded and labelled as AA, A, and B U.S Grade AA
eggs are nearly perfect. The whites are thick and firm and the yolks are free
from any defects. The shells are clean and without cracks. U.S Grade A eggs
appear to be the same as Grade AA, but the difference is a slightly lower
interior quality. U.S Grade B eggs are noticeably different. They may have slight
stains and be irregular in shape and size. The quality of the interior is further
reduced. Grade B eggs are not sold in supermarkets, but are used
commercially in powdered egg products or liquids eggs.
Grading Eggs
Exterior Grading
Begin the egg grading process by checking the quality of the shell. The
ideal eggshell is clean, smooth and oval in shape with the one end slightly
bigger than other. Eggs with cracked or broken shells should be discarded. If
you are selling the eggs, remove any unusual shapes, textures or thin spots on
the shell. While they are edible, they break easily and will be unacceptable
because of their appearance.
Interior Grading
Grading the interior of the eggs is performed by a method called
candling. Using an egg candlerwill allow you to examine the air cell, the egg
white (called albumen) and the yolk. Candling also lets you check for spots and
cracks. Listed below are the different components to observe when candling an
egg:
Air Cell Depth - the air cell is the empty space between the shell and the white
usually found at the bigger end of the egg. As the egg ages, the air cell depth
grows and the quality of the egg diminishes.
White or Albumen – the white of the egg is called the albumen. The quality is
based on its clarity and thickness. Look for a clear color without discolorations
or floating foreign matter. Thick albumen allows limited movement of the yolk
and indicates a higher quality egg.
Yolk – the quality of the yolk is determined by the distinctness of its outline
and other features like size, shape and absence of any blemishes or blood
spots. It should be surrounded by a dense layer of albumen.
Spots – candling can help reveal foreign matter like blood spots or meat spots.
Eggs with interior spots should not be sold.
USDA Grade Standard Chart: This table is a quick reference for determining
the grade of an egg by candling. (From the article: Proper Handling of Eggs:
From hen to Consumption by the Virginia Cooperative Extension)
Sizing Eggs
If you plan on selling your eggs, you need to sort and size them. Large
and extra-large eggs are the best sellers. You might be surprised to learn that
eggs are not sized individually, but rather sized by the combined weight of one
dozen eggs. A size breakdown by weight can be found in the chart on the right.
While there are a few things to learn about grading and sizing eggs, the
process is not difficult. You will be able to master the technique quickly with
just a little bit of practice.
1. Poultry halves
2. Front poultry halves
3. Rear poultry halves
4. Quarters
5. Breast quarters
6. Leg quarters
7. Split breast
8. Legs
9. Thighs
10. Drumsticks
11. Wings
12. Wing dummettes
13. Tenderloins
14. Wings
15. Neck
Washing and Cleaning Guidelines of Raw materials for Salting, Curing and
Smoking
Learning Objectives:
1. Identify the steps in cleaning the raw materials for food processing.
Washing raw poultry, beef, pork, lamb, or veal before cooking it is not
recommended. Bacteria in raw meat and poultry juices can be spread to other
foods, utensils, and surfaces. We call this cross-contamination.
Using a food thermometer is the only sure way of knowing if your food
has reached a high enough temperature to destroy foodborne bacteria. Cook all
raw beef and veal steaks, roasts, and chops to a minimum internal
temperature of 145 degree F as measured with a food thermometer before
removing meat from the heat source. For safety and quality, allow meat to rest
for at least three minutes before carving or consuming. For reasons of personal
preference, consumers may choose to cook meat to higher temperatures.
Callers to the USDA Meat and Poultry Hotline sometimes ask about
soaking poultry in salt water. This is a personal preference and serves no
purpose for food safety. If you choose to do this, however, preventing cross-
contamination when soaking and removing the poultry from the water is
essential. Meat or poultry should be kept in the refrigerator while soaking.
Cross-Contamination
Wash hands with warm water and soap for 20 seconds before and after
handling food, and after using the bathroom, changing diapers, tending to a
sick a person, blowing your nose, sneezing and coughing, and handling pets.
Packaging materials from raw meat or poultry also can cause cross-
contamination. Never reuse them with other food items. These and other
disposable packaging materials, such as foam meat trays, egg cartons, or
plastic wraps, should be discarded.
Washing Eggs
Washing Produce
Before eating or preparing fresh fruits and vegetables, wash the produce
under cold running water to remove any lingering dirt. This reduces bacteria
that maybe present. If there is a firm surface, such as on apples or potatoes,
the surface can be scrubbed with a brush. Consumers should not wash fruits
and vegetables with detergent or soap. These products are not approved or
labelled by the U.S. Food and Drug Administration (FDA) for use on foods. You
could ingest residues from soap or detergent absorbed on the produce.
When preparing fruits and vegetable , cut away any damaged or bruised
areas because bacteria that cause illness can thrive in those places.
Immediately refrigerate any fresh-cut items such as salad or fruit for best
quality and food safety.
Fillet Knife
Scaling tool
Bucket or other container for discarded parts
Water source to keep the fish and work surface clean
Zip top plastic bags store the fish if necessary
Scale the Fish
Always work with one fish at a time. Hold the head with one hand and,
using a scaling tool, dull knife or spoon, apply short, raking motions, moving
from the tail toward the head. Use caution around the sharp edges of the fins.
Repeat the action on both sides of the fish, around the fins and up to the gills.
Rinse the fish in water when you’ve finished.
Once you’ve removed the spine, make a cut behind the head and along
the pectoral or belly fins. Hold the fish by the head with one hand, grasp the
skin with the other, and pull toward the tail. Rinse the fish when it’s
completely skinned.
On the belly of the fish, insert the knife into the anus, near the tail.
Slowly slide the knife toward the head of the fish and stop at the base of the
gills. Open the abdominal cavity, grab the entrails, pull, and remove. Some fish
have a kidney located by the spine, which you can remove with a spoon.
Always remove the darkened inner membrane (only some fish have this)
with a scraping motion- the membrane negatively affects the flavour. Remove
the head, if desired, by cutting behind the gills. Rinse the fish and the internal
cavity.
Fillet
Use the fillet method on large fish to negate the need for scaling or
skinning. Lay the fish on its side and hold the head. Insert the fillet knife
behind the pectoral fin and cut downward to, but not through, the backbone.
Turn the knife flat with the sharp edge pointed toward the tail and use a
sawing motion to slowly work down toward the tail; stay as close as possible to
the backbone. Once you’ve cut through to the tail, turn the scale side down on
the table. Insert the knife between the flesh and the skin and use the same
sawing motion to remove the meat. Repeat the process on the other side of the
fish and rinse in cold water when you’re finished.
Steaking
For the most part, use meats with whole muscle groups in their anatomical
connection. Pork loin and belly, beef hindquarter or brisket, mutton legs and
even duck breast are popular cuts for dry-curing.
2.)
If necessary, trim off any excess fat, tendons, or meat. Say you're trying to
make Capicola charcuterie. You might buy a boneless pork shoulder, and then
cut the picnic end of the pork shoulder from the pork butt, leaving you with
two distinct cuts of meat. You can then use the picnic end of the shoulder in a
sausage, for example, and the butt in your dry-cure charcuterie.
3.)
For larger cuts of meat, consider stabbing the meat with a prong for better salt
coverage. You don't have to stab the meat before applying the dry rub, but for
certain cuts of meat — larger cuts or cuts like pork belly, which are often
covered with a lining of fat — stabbing the meat allows the salt and nitrite mix
to penetrate deeper into the meat, improving the efficiency and effectiveness of
the cure.
4.)
Decide whether you want to cure with a pre-mixed curing salt or mix your
own.Dry-curing with salt will sap away the moisture from the meat and
intensify the flavor of the meat, but it still won't eliminate the possibility of
botulism spores germinating. [2] To combat botulism, sodium nitrite is often
used in combination with salt as "curing salts," "Instacure #1," and "pink
salts." Botulism is a dangerous illness characterized by paralysis and
respiratory problems caused by the bacteria Clostridium botulinum.[3]
Consult manufacturer's instructions for how much curing salt to use alongside
regular salt. Usually, a 10:90 ratio of pink salt to regular salt is called for.
If you are particular about exactly what goes into your cured meat, it might be
best to add the sodium nitrite on your own. (See next step.) Most casual curers,
however, will find it easiest to use pre-mixed curing salts, where they won't
have to fuss with the ratio of salt to sodium nitrite.
Why are pink salts pink? Manufacturers of pink salt purposely dye the salt for
cooks so that they don't confuse curing salt with regular salt. That's because,
in large quantities, sodium nitrite is toxic. [4] Accidentally using pink salt
instead of regular salt in your chicken soup, for example, could be very
unfortunate. The pink dye itself does not influence the final color of the cured
meat; the sodium nitrite does.
5.)
Use a ratio of 2:1000 sodium nitrite and salt, if mixing your own curing salt. If
you want to make your own curing salts, be sure to nail the ratio of sodium
nitrite to salt. For every 2 grams (0.071 oz) of sodium nitrite, for example, use
1,000 grams (35.3 oz) of salt. Another way to do this is to take the total weight
of your salt, multiply it by .002, and use that much sodium nitrite in your mix.
6.)
Mix up your spices along with your curing salt. Spices add a rich dimension of
flavor to your cured meats. While it's important not to get too carried away
and spice the meat to oblivion, a good spice mix will intensify flavors and add
distinct profiles to your cures. In a small spice grinder, grind up your spices
and add them to the curing salt/salt mixture. Here are some suggestions for
spices to use:
Peppercorns. Black, green, or white are essential in most spice mixes. There's a
reason they call peppercorns the "master spice."
Sugar. A little Demerara sugar adds a touch of caramel sweetness to your cure.
Coriander and mustard seed. Adds smokiness to the meat.
Star anise. Silky and slightly sweet, a little bit goes a long way. Slightly nutty.
Fennel seed. Adds a pleasantly green or grassy dimension to the cure.
Citrus zest. Adds a light, pleasantly acidic element that cuts through fattier
pieces of meat.
7.)
With your hands, rub the curing salt and and spice mix over the entire cut of
meat. Cover a tray with parchment and line the bottom generously with your
curing salt and spice mix. Place your meat on the bed of curing salt (fat side
up, if appropriate) and cover the top of the meat with your remaining mix for
equal coverage. If desired, cover the top of the meat with another piece of
parchment, then another tray, and finally a pair of bricks or another heavy
object to weight the meat down.
Do not use metal trays for this step without parchment. The metal reacts with
the salt and sodium nitrite. If using a metal tray for underlayment, always use
a piece of parchment between it and the salt mix.
If you have a round piece of meat and want to keep it (more or less) round, you
don't have to weight it down. The salt will do its job naturally. Weighting down
is preferable for a pork belly, for example, that you later want to roll into shape.
8.)
Refrigerate the meat for 7 to 10 days. Allow for adequate airflow by leaving at
least a small portion of the meat uncovered. After 7 to 10 days, a lot of the
moisture should have been drawn out by the salt.
9.)
After 7 to 10 days, remove from the refrigerator and rinse off all the salt/spice
mix. Under cold water, remove as much of the salt/spice mix as possible and
allow to briefly air-dry over an elevated rack. Take a paper towel, as insurance,
and wipe away any excess moisture before proceeding to the next step.
10.)
Roll up the meat (optional). Most cured meats will not need to be rolled into
shape at this point, but some will. If you're taking pork belly, for example, and
trying to make pancetta, you want to start with a rectangular piece of pork
belly and roll up the longer end very tightly. The tighter the roll, the less space
there is for mold or other bacteria to inhabit.
If you are rolling the cured meat, it helps to start with an even square or,
usually, rectangle. Cut off pieces of meat on all four sides until you have a neat
rectangle. Save the scraps for soups or render off the fat separately.
11.)
12.)
Truss your meat to help it keep its shape while it ages (optional). Especially if
dealing with a rolled piece of meat, trussing will help the meat stay tightly
rolled and keep its shape. Use butcher's twine and simply tie off every inch
until the length of the meat is trussed. Remove any dangling pieces of twine
with shears.
13.)
Label the meat and hang in a cool, dark place for anywhere from two weeks to
two months. A walk-in refrigerator is ideal, being cool and dark, but anywhere
that doesn't get a lot of light and doesn't exceed 70 degrees Fahrenheit (21
degrees Celsius) will work.
B. Wet-Curing Meat
1.)
Choose your piece of meat. Wet-brining is great for ham or other smoking
recipes. Try wet-curing your Christmas ham, for example, and then finishing it
off in the smoker for a delicious recipe.
2.)
Mix up your brine cure. Making a simple brine, and then adding the nitrites in
the curing salt (which will cure the meat) is all it takes to wet-cure meat. Try
this basic brine recipe, or research brines with added nitrite for a different kind
of taste. In one gallon of water, bring the following ingredients to a boil and
then allow brine to cool completely:
2 cups brown sugar
1 and 1/2 cups kosher salt
1/2 cup of pickling spice
8 teaspoons of pink salt (not to be confused with sodium nitrite)
3.)
Place your meat in a brining bag. A brining bag is essential for larger cuts of
meat, like a Christmas ham. Smaller cuts of meat can simply go in resealable
freezer bags, but make sure that there's enough room for the meat and brine to
rest comfortably in. For larger cuts of meat, Place the brining bag in a larger tub or
container first, and then fill with brine. Add 1⁄2 gallon (1.9 L) to 1 gallon (3.8 L)
of ice water to the brine to dilute
the concentrated brine. Mix thoroughly before sealing.
4.)
In the refrigerator, brine your meat one day for every two pounds of
meat. If you have a five pound piece of meat, brine for approximately two and a
half days. Turn the meat every 24 hours if possible. The salt in the brine tends
to be thicker on the bottom half of the brine and turning the meat allows the
brine to work evenly.
Change the brine after 7 days during the curing process to help prevent
spoiling.
5.)
Rinse the cured meat thoroughly in fresh cold water to get rid of the
crystallized salt on the surface of the meat.
6.)
Set the meat on a wire mesh screen to drain for 24 hours in a well
ventilated area and store in the refrigerator for up to 30 days.
7.)
Smoke the meat. Wet-cured meat, such as ham, is great after smoking.
Smoke your wet-cured meat in a smoker and serve on a special occasion.
You have to be attractive and attention grabbing to your customers, you have
to address every type of food separately; each having its own shelf life,
protection requirements, and regulations that need to be adhered to.
Taking all of that into account, and making your product look great? It’s a tall
order. With careful foresight, your packaging can protect and preserve your
food products, as well as help garner brand loyalty and ensure high sales.
Obviously you know what you’re selling. But do you know enough? The more
intricate your knowledge is of your product the better, especially when you
attempt to package it. Ask yourself:
Allergens are an important consideration, not just in the food products, but
elsewhere in your facility. Facilities that process nuts, dairy, or shellfish need
to have certain best practices set in place so that cross contamination is kept
to a minimum.
The Food Allergen Labeling Act requires you to be compliant, especially if you
process any of these 8 major allergen groups:
Milk
Eggs
Fish (e.g., bass, flounder, cod)
Crustacean shellfish (e.g., crab, lobster, shrimp)
Tree nuts (e.g., almonds, walnuts, pecans)
Peanuts
Wheat
Soybeans
Be sure your facility is compliant with the Food and Drug Authority if you
process any of the major allergen groups. Any sort of mislabeling can be
disastrous to your brand!
It also wouldn’t hurt to properly vet any third party packagers you might deal
with for the same reasons. There is grunt work involved with this. Properly
cleaning and maintaining your machinery is just as important as packaging
your product safely.
There are rules and regulations laid out by both the FDA about this:
You should know what nutritional information, dates, and ingredients you
need listed on your package. The FDA recently began updating the nutrition
labeling guidelines for the first time in 20 years, so make sure you are clear on
what is required to be on your packaging and labeling before you go to market
with new foods. If you aren't confident in compliance, finding a food labeling
consultant is never a bad idea.
Protection
Product packaging in the food industry is unique because it must allow the
contents inside to stay fresh and safe for consumption, even after long hours of
shipment and distribution. Because of this, certain products will require
specific types of packaging materials that protect them against temperature,
manhandling, etc. Frozen food, dry grocery items, and perishables each need a
different type of packaging to maintain freshness. It is also important to choose
a packaging material that will withstand contamination.
Different barrier materials can affect the overall look of your packaging, and
work better with certain films. Fresh foods like meats and produce will
need an t i fog additives to maintain visibility and visual appeal.
Working with a packaging professional can help you choose the best materials
for your specific products. They will know which combinations work best, and
can help maintain your product's’ shelf life.
Budget
Understand the costs of the total production FIRST, and then source your
materials and labor. If your business cannot afford its ideal packaging design,
don’t give up on it. Food packaging is constantly evolving and changing, so in a
year or two your design could very well be within reach.
Trends
Keep an eye on your competition, too. Don’t be the last one to jump on a
packaging trend! Staying on top of trends will provide insights as to what
elements of design are standard for certain products, and what can be
improved on. Be careful, however. While it is certainly important to be
innovative in your packaging design, deviating too much from widely-
recognized norms can actually confuse consumers and drive them away from
your product. Bottom-line: During your packaging design process, try your
best to strike a balance between being creative and being familiar.
Check out some excellent packaging in your industry to get inspired. Speak to
your target market in every step of your design, from the certifications you
choose to display, to the packaging material and its impact on the
environment.
Brand Personality
A product’s packaging design should reflect the brand image of the company
that manufactured it, and food product packaging is no exception. Make sure
that the packaging chosen for your business’s food product appeals to your
target audience.
Tiny things like the colors of certain elements of the packaging or whether or
not the p a c k a g e i s r e s e a l a b l e can make or break the purchase. The key is
to do
the proper research on your target markets and identify what your ideal
customers want or what they struggle with.
Types of Packaging
Unit Descriptor This unit deals with the knowledge, skills and
attitudes required to process foods by fermentation and pickling
After all tools are used and calibrated, proper cleaning and sanitizing are done.
Cleaning and sanitizing are important in combating the bacteria present prior
to food preparation. Wiping and removing dirt are done to remove dirt
followed by using detergents and soap plus chlorine to totally eradicate the
bacteria present.
Unlike fish and meats, vegetables and fruits have higher perishability
and greater variation. That is why it is important to know how to select the
good quality of fruits and vegetables. Sorting and grading of fruits and
vegetables are based on size and ripeness. It is important to be familiarized
with the characteristics. Fruits are of good taste when ripe. Fruits must be
preserved and vegetables must be cooked immediately to prevent any damage
in the vitamin content of some fruits like the ascorbic acid in bananas which is
greatly affected when overripe.
Fruits and vegetables are sorted by size, color and rind quality after they
are harvested. Vegetable quality depends on favorable conditions of their
growth, the season of their harvest, the variety of the fruits, degree of maturity
size and uniformity of shape and the presence of defects. Injured, bruised and
misshaped appearance of fruits and vegetables.
A. Write true if the statement is correct and if incorrect write the correct
word or words that will make the statement true.
1. A dial thermometer can be calibrated either by hot or
cold method.
2. Fruits and vegetables are sorted by size, color and
rind quality one month after they are harvested
3. Cutting fruits and vegetables into smaller pieces with
uniform cubes approximately ¼ inch by ¾ inch cube is
julienne strip cut
4. Peeling is removing the cover of fruits and vegetables
5. Diagonal slicing is cutting fruits and vegetables
diagonally
1. True
2. Right after
3. Dicing
4. True
5. True
Materials :
Carrots
Cucumber
Onions
Knife
Cutting/chopping board
Chopping
Mincing
Slicing
Peeling
Diagonal Slicing
Dicing
CRITERIA YES NO
Chopping
Mincing
Slicing
Peeling
Diagonal Slicing
Dicing
** NOTE: IF STUDENT GOT 100% CORRECT ANSWER IN THIS TASK, HE/SHE
CAN NOW MOVE ON TO THE NEXT INFORMATION SHEET. IF NOT, REVIEW
THE INFORMATION SHEET AND GO OVER THE TASK AGAIN
Selecting and Preparing Fish and Other Marine Products for Fermentation and
Pickling
1. Live fish or whole round- transported and marketed alive. All parts
are intact and may be alive or dead.
3. Dressed Fish- the fish is drawn further to remove the gills, fins,
scales, head, and tail. This is already prepared for cooking or for
special preparation to improve the presentation
Cleaning and eviscerating are done by making a slit on the belly cavity of the
fish to remove the gills and fins. In some cases, scaling is done with the use of a knife
or scaler beginning from the tail toward the head. If head and tail are removed, cut off
gills with head followed by cutting the oval fin. For small fishes, cleaning is done by
removing the head and the gut in one stroke or using the index finger to nob.
C. Skinning Fish
Skinning fish involves the removal of the fish skin. This is done by
removing skin along backbone and cutting off a narrow strip of skin to
the entire length of the backbone. To do this, loosen the skin from top to
bottom then draw the skin off toward the tail. Make sure fish is fresh so
that skin can easily be drowned off.
D. Cutting Fish
Most of the time, fishes are cut depending on the desired sizes and manner of
cooking or processing them. Consumer’s preference is always considered.
E. Dressing Fish
Fish head
Tails
Viscers or internal organs
Scales
1. Weigh the fish. Then wash it with clean water to remove the slime
2. Lay the fish flat on the cutting board. Holding the knife on the right
hand, and head of the fish with the left hand. Then scale the fish.
3. 3. Cut the tail and the head of the fish leaving only the trunk or body
of the fish.
4. Cut the dorsal and ventral fins using kitchen scissors.
5. Remove the internal organ and with the use of a sharp knife, scrape
the belly cavity, blood and false kidney.
6. Wash very well in clean water.
7. Weigh the dressed fish and determine the % left after dressing by
following the formula:
F. Splitting Fish
1. Weigh the fish. Then wash it with clean water to remove the slime
2. Lay the fish flat on the cutting board. Holding the knife on the right
hand, and head of the fish with the left hand. Then scale the fish.
3. 3. Cut the tail and the head of the fish leaving only the trunk or body
of the fish.
4. Cut the dorsal and ventral fins using kitchen scissors.
5. Remove the internal organ and with the use of a sharp knife, scrape
the belly cavity, blood and false kidney.
6. Wash very well in clean water.Weigh the dressed fish and determine
the % left after dressing
(Alcoholic)
o Alcoholic fermentation
o Acetic Acid Fermentation
o Lactic Acid Fermentation
Ingredients:
Procedure:
1. Extract the juice of ripe pineapples and measure
2. Add 1 cup of sugar per quart of extracted juice. Stir very well.
3. Heat to 60°C. Cool to lukewarm.
4. Add 1 tablespoon of active dry yeast per 15-20 liters to heated
juice placed in a clean, narrow necked flask. (1 ½ tsp. per quart
juice)
Plug the mouth of flask loosely with sterile cotton for fermentation.
At the desired end point of fermentation which is shorter for sweet wines than for dry wines, heat wine to 50°C.
Decant clear and aged liquid in containers for at least a year.
After period of aging, clarify by heating wine in a steam bath to 60°C.
Add 5% beaten egg whites, based on volume of wine. Stir and maintain temperature for 15 minutes. Cool and filter.
Guava Wine
Ingredients:
Procedure:
1. Choose only ripe and sound fruits. Cut into squares and
measure
2. Boil water and fruit together until fruit is soft. Strain and
measure juice. Add the sugar to the juice.
3. Heat to 70°C and cool before adding yeast in the same
proportion as for pineapple wine up to clarification, if
desired
4. Heat to 70°C and cool before adding yeast in the same
proportion as for pineapple wine up to clarification, if
desired
1. Combine fruit peels and cores. Grind or crush them. Boil in water
until it reaches the desired softness. Then strain the juice through a
cheesecloth.
2. Add ¼ pound of sugar for every liter of juice extracted from fruit peels
and cores. Do not add sugar when using ripe fruit because ripe fruits
are sweeter.
3. Add ¼yeast for every liter of juice. Stir very well then place in glass
jars. Cover with a clean cheesecloth and let the mixture stand fopr
about two weeks to undergo alcoholic fermentation.
4. After two weeks, separate the clear liquid from the sediment. Prepare
fresh unpasteurized vinegar (mother vinegar) which is the white
gummy mass that usually forms in the vinegar. Add this to the liquid
and mix very well to undergo acetic acid fermentation. Cover and
allow to stand for weeks until a sour taste or strong aroma enough to
use is attained.
5. Pasteurize to kill the bacteria. Filter the clear liquids, then pour in a
bottle and cover tightly ready for bottling.
Ingredients:
3. Dissolve ¾ cup d sugar in 4 cups coconut water and stir well ready for
pasteurization
5. Transfer and pour sterilized glass jars, half filled. Cool and add ¼ tsp. dry yeast by
dissolving it in lukewarm coco water solution or separately in a cup.
6. Cover the container with a clean cheesecloth or paper for sanitary purposes
and to hasten fermentation process. Allow the sugar solution to ferment for 4-7
days or until there are no more bubbles or carbon dioxide formed. This is
alcoholic fermentation, the first stage of fermentation.
7. Decant or filter the alcoholic solution to remove the yeast and other
solid materials. Pasteurize the alcoholic solution to 60-65°C (2 nd time) using the
device to cool immediately
9. Pasteurize again (3rd time) at 60°C to 65° to kill the microorganisms before
bottling the product. Filter until the vinegar becomes clear.
10. Bottle, label and store.
Transfer and pour sterilized glass jars, half filled. Cool and add ¼ tsp. dry
yeast by dissolving it in lukewarm coco water solution or separately in a cup.
Cover the container with a clean cheesecloth or paper for sanitary purposes
and to hasten fermentation process. Allow the sugar solution to ferment for 4-7
days or until there are no more bubbles or carbon dioxide formed. This is
alcoholic fermentation, the first stage of fermentation
Dissolve ¾ cup d sugar in 4 cups coconut water and stir well ready for
pasteurization
Add 1 cup vinegar starter to 4 cups alcoholic solution. Cover with clean
cheesecloth to allow the start of acetic acid fermentation, the 2nd and the last
stage of fermentation to occur to allow the presence of useful bacteria to
obtain sour taste. Let it stand for 1 month until the desired aroma and flavor
are attained. Allow the vinegar to age in glass or bottle container which is filled
to full capacity. Filter again.
Pasteurize again (3rd time) at 60°C to 65° to kill the microorganisms before
bottling the product. Filter until the vinegar becomes clear.
1. 7
2. 5
3. 10
4. 6
5. 1
6. 3
7. 8
8. 2
9. 4
10.9
Task Sheet 2.1.3
Materials :
4. Cool the solution and add yeast to allow the alcoholic fermentation to
set in for 7 days.
** Note: if student got 100% correct answer in this task, he/she can now move
on to the next information sheet. If not, review the information sheet and go
over the task again
Performance Criteria
Criteria Yes No
Did the student...
1. Strain freshly collected coco water and
measure?
Salt in Fermentation
1. Temperature of Fermentation.
The temperature should be favourable for the growth of lactic acid
and bacteria. A temperature of 30°C or 86°C allows organisms to grow.
Above and below those temperature will greatly affect the fermentation
process.
2. Rate of Fermentation.
The rate of fermentation process varies depending on the salt
concentration. Greater concentration of brine slows down fermentation,
the less the concentration, the faster the fermentation.
It has been studied that fermented fruits and vegetables are potential
sources of probiotics. In Asia, some common and popular fermented product is
the kimchi,( traditional Korean traditional fermented vegetable) sauerkraut or
sour cabbage ( Fermented vegetable from China).
Kamias
Mustasa
Cabbage
Mangga
Kimchi (prepared as a side dish) usually stored at low temperature to prevent
production of strong acid, over ripening, and extended period of optimum taste. It is
characterized by its sour, sweet taste differing from sauerkraut and pickles.
Ingredients:
Cabbage or radish
Green pepper
Onion
Ginger
Salt
spices
Procedure:
1. Prebrine the vegetables
2. Blend with various spices like red pepper, garlic, green onion, and ginger.
Add other seasonings and vegetables.
3. Ferment at low temperature (2°C-5°C). Fermentation usually last in one
week at 15°C, but took only 3 days if the fermentation temperature is at
25°C.
Burong Mangga- is the phrase that Filipinos use to refer to fermented green
mangoes in the Philippines. It’s simply a matter of pickling the fruit in salt.
Ingredients:
6 pieces of green mangoes (hilaw na mangga) with very firm flesh
half cup of white rock salt
2 cups of water
Procedure:
1. Wash the mangoes thoroughly in running tap water.
2. Peel and cut each mango into three flat pieces — the middle piece would be
the large, flat seed.
3. Shave the flesh off the side of the seed (if you do this skillfully, you’ll end up
with two long, fat slivers off each mango’s seed).
4. Slice up the remaining flesh into long, fat slivers.
5. Arrange the fat slivers upright in a large jar.
Meanwhile, prepare the brine solution by boiling the water and the salt for five
minutes. Let cool.
To get different flavors, experiment with the brine solution. Add sugar or, for
color, small chili peppers that Filipinos call sili.
Self Check 1.6.1
2. Vinegar- acts as preservative. Also gives flavor to pickles and makes the
product crisp. It should be clear, free from sediment, and should posess
4% to 5% acetic acid. Vinegar with low acid content causes the pickles to
become soft. Never use vinegar that has a darkening effect. Avoid
prolonged boiling for it depletes the acetic acid which is important in the
preservation of pickles.
1. Prepare jars by sterilizing them for 10-15 minutes before use to kill
bacteria present.
2. Boil food in a large kettle or any casserole
3. Pack the product in glass jars allowing 3/16 of an inch for
headspace. Clean the rims of the jar by wiping with a clean damp
cloth.
4. Seal each jar tightly with its cover.
5. Place the sealed product in a kettle and simmer water for 15
minutes.
6. Allow the jars to cool and press the lid to check if seal is good. If
not, refrigerate or eat the contents immediately.
7. Store sealed jars in a cool dry place. Refrigerate after opening.
Ingredients:
4 cups green papaya
2 medium sized red/green bell pepper 1 large sized carrot
1 box raisin small
1 cup vinegar (4% acetic acid)
1 tsp. salt
1 cup white/washed sugar 2 medium sized onions
1 clove garlic
Procedure:
1. Select good quality raw materials
2. Weigh, wash and peel, and grate vegetables according to
desired cut. Squeeze to remove juice extracted from papaya and
drain.
3. Prepare sugar, salt and vinegar and mix thoroughly
4. Cook the solution until sugar dissolves
5. Pack the vegetables in sterilized bottle and pour solution while
hot. Observe proper headspace of 3/16 inch when filling into
jars. Remove bubbles.
6. Screw on caps and pasteurize for 5 minutes. Seal tightly
7. Cool and label. Refrigerate when opened.
**Proper measurement of the ingredients when cooking should
be observed, Hygiene and cleanliness should be obserbed.
c. Preparing Pickled mixed Vegetables
Sanitary Practices
1. Always wear PPEs for one’s safety and to assure clean, safe product
2. Wash and sanitize all utensils and equipment used to avoid any
contamination and for the consumers’ protection
3. Maintain cleanliness and orderliness during and after the process.
4. Sterilize the bottles.
3. Level of Substandard Quality- fish of protein content not more than 4.5%
and no more less than 2.5%, shall be sold under the name patis flavor
4. Mandatory label of information
a. The label statement of class or type shall be in accordance with the
stated protein content
b. The name and address of manufacturer/producer should appear
c. Added preservative or coloring shall be limited to that approved as food
grade and should be indicated in the label.
d. Net content shall be no less than the amount stated in the label
Fermented Products
a. Patis
Procedure:
1. Select fresh fish. Wash with clean water
2. Mix fish with salt ( 1:3)
3. Pack tightly in jars and store for 6 months.
4. The liquid patis is extracted or drained producing first class patis.
They are then filtered and packed in bottles.
5. Second extraction (soli), saturated brine is added and aged for 2
weeks. Second class patis is produced and bottled.
Flow Chart of Making Patis:
Filtering
Ground and solid as bagoong Adding saturated brine
Placing in bottles
Procedure:
CRITERIA YES NO
UNIT DESCRIPTOR : This unit deals with the knowledge, skills and attitudes
required to process foods by sugar concentration which include to prepare
equipment, tools, materials and utensils, prepare the raw materials, pack
sugar concentrated products and perform post- production activities.
Same with the tools and equipment used in curing and fermentation,
preparation of sugar concentrates require different equipment and tools to be used.
Cleaning and sanitizing should be done after use to ensure prolonged serviceability.
Packaging Materials
Thins cans
Pouches
Plastic jars
Glass jars
Cleaning and Sanitizing of tools and equipment
Stove/Gas Range
1. Clean the utensils thoroughly by removing dirt that adheres and wash
with soap and detergents and rinse.
2. Immerse in sanitizing solution, then dry using cloth
3. Stow the utensils clean
Cutting Implements and other tools and equipment
1. Clean immediately after using. Remove all remaining food particles and
wash with water and detergent
2. Rinse and dip in sanitizing solution
3. Wipe with damp cloth and stow away properly
Making Jam
Jam is a jelly-like product mad from fruit such as mangoes either crushed, cut,
or mashed cooked to moderate consistency. It contains not less than 45% of fruit by
weight and 55% of sugar.
Making Marmalade
Marmalades differ slightly from jams for it contains pieces preferable thin slices
of fruit suspended in a clear sparkling jelly. Unlike jams, they are cut in small
pieces or mashed. The best known marmalades contain citrus fruits such as
calamansi, oranges, lemons, limes and grape fruits. These have uneven texture and
slightly has acidic taste.
1. Wash the fruits well in detergent water (1/2 tsp. detergent in 4 cups
water)
2. Scrub with a soft clean brush if the skins are all dirty
3. To peel fruit more easily, blanch them in boiling water for 1 to 2 minutes
especially if the fruits have tough skin or peel.
4. Cut the fruit. If citrus is used, slice the peel finely so that the pectin can
easily be dissolved. If marmalades with little pith are desired, cut the peel
finely but do not discard the pith. Instead, cut it up roughly, tie it loosely
in a pieces of muslin cloth and cook with the peel until just before the
sugar is added.
5. Squeeze the bag and remove it. Add calamansi juice or citric or tartaric
acid
6. Test for pectin. Apply the test for pectin when peels are soft. Use the
same test as in jellies.
1. Cut the fruits into halves and remove the seeds when necessary.
2. Prepare syrup using 1 cup sugar per cup of water and immerse the
fruits.
3. Boil the syrup, add the fruits.
4. Let the fruits soak in the syrup overnight making sure all is covered with
syrup.
5. The next day, remove the fruit from the syrup and drain. Repeat the
process depending on the fruits used.
The amount of sugar to add depends upon the texture and acidity of the
fruit, though ¾ part sugar per part of fruit by weight is generally accepted. If
fruits are soft and sour, more sugar is needed. If the fruit is sweet or hard, less
sugar is required.
6. Cook the fruit over a slow fire and stir making sure that cooking is done
shortly for successive days in syrup to ensure plumpness and better
flavor. A 40% sugar may be used as initial sugar concentration allowing
the fruit to cook for few minutes to make it tender and to allow the syrup
to penetrate into the fruit. Let the fruit stand in that syrup overnight. 7.
7. The following day, drain the syrup and increase the sugar concentration
by 10%.
8. Boil the syrup.
9. Add the fruit and allow the mixture to simmer for 3 to 4 minutes again
and set aside overnight.
10. Repeat the process until a syrup of desired consistency is attained. Make
sure that the fruit is clear, plump, and thoroughly impregnated with the
syrup. Prevent the fruit from shriveling by cooking hard fruits
like kundol or papaya in water until tender before adding the sugar.
Fruits that are soft may be cooked in heavy syrup right away.
Be able to prepared kundol preserve given the following materials and ingredients:
Materials:
Mature kundol
Lime solution (apog)
Suagr
Water
Glass jars
PPEs
Procedure
1. Cut and peel the fruit according to desired size
2. Soak overnight in lime solution 1T in 4 qt. water
3. Blanch the fruit and drain
4. Simmer ion water for 15 to minutes until pieces become translucent
5. Prepare syrup using 1 cup sugar per cup water. Bring to a boil and add
the fruit. Simmer for 5 minutes.
6. Soak fruit in syrup overnight. Drain and add ½ amount of sugar
previously used and add ½ tsp. kalamansi juice per cup of syrup
7. Bring syrup to a boil. Add fruit and simmer again for 3 to 5 minutes and
soak overnight
8. On the third day, add sugar and acid again. Repeat step 7
Criteria Yes No
Yield refers to the number of finished product produced after computing the
production input and output.
Formula in getting the percentage yield:
Make your own production Report based on the following data provided.
Compute the input, output, and percentage yield.
Unit descriptor : This unit deals with the knowledge, skills and
attitudes required to process foods by sun drying, dehydrator, and solar drying.
It includes drying and dehydration of fruits, vegetables, herbs and spices, root
crops, fish and meat.
Information Sheet # 4.1
Benefits
Molds, yeast and bacteria need water to grow. When foods are sufficiently
dehydrated, microorganisms cannot grow and foods will not spoil. Dried fruits
and fruit leathers may be used as snack foods; dried vegetables may be added
to soups, stews or casseroles. Campers and hikers value dried foods for their
light weight, keeping qualities and ease of preparation.
Nutritional value
Drying methods
1. Solar drying is a modification of sun drying in which the sun's rays are
collected inside a specially designed unit with adequate ventilation for
removal of moist air. The temperature in the unit is usually 20 to 30
degrees F higher than in open sunlight, which results in a shorter drying
time. While solar drying has many advantages over sun drying, lack of
control over the weather is the main problem with both methods.
2. Oven drying is the most practical way to experiment with dehydration. It
requires little initial investment, protects foods from insects and dust
and does not depend on the weather. Continual use of an oven for drying
is not recommended because ovens are less energy-efficient than
dehydrators, and energy costs tend to be high. It is difficult to maintain a
low drying temperature in an oven, and foods are more susceptible to
scorching at the end of the drying period. Oven-dried foods are usually
darker, more brittle and less flavorful than foods dried by a dehydrator.
3. Electric deyhdrator produces a better-quality dried product than any
other method of drying. Electric dehydrators are self-contained units
with a heat source, a ventilation system, and trays to place the food on.
They are used to dry foods indoors. Therefore, as with oven drying,
they don't depend on the weather. Such dryers can be purchased or
made at
home and vary in sophistication and efficiency. Although an electric
dehydrator requires a fairly high initial investment, it maintains
low temperatures and uses less energy than an oven.
Caution
It is not recommended that microwave ovens be used for drying foods, because
the food will partially cook before it dries, imparting an overcooked flavor.
Microwave ovens can be used to dry some herbs quickly—but watch them
carefully to prevent them from catching on fire. Check the owner's manual for
drying recommendations.
Temperatures that are too high at the end of the drying period may cause food
to scorch. Temperatures between 120 and 140 degrees F are recommended for
drying fruits and vegetables. Temperatures up to 150 degrees F may be used at
the beginning, but should be lowered as food begins to dry. For at least the last
hour of the drying period, the temperature should not exceed 130 degrees F.
Selecting a dehydrator
Try drying several foods in your oven before buying a dehydrator. You will
become familiar with the process and pinpoint features to look for in the
appliance. Also, experiment with a variety of commercial dehydrated foods to
test your family's acceptance of dried foods. Remember, the equipment
available for commercial drying will probably produce a product superior to
that you can achieve at home.
Space requirements
Dehydrators vary in size and can be round, square or rectangular. You will
need to find a convenient space to operate it. Place the dehydrator near an
electrical outlet so that extension cords are not necessary. You should have
room to open the door and easily load and rotate the trays. When deciding
where to put the dehydrator, keep these points in mind:
Air flow
As much food surface as possible should be exposed to warm, dry, moving air.
Good air flow is extremely important in removing moisture from food. Some
dryers use natural convection only; others use a fan. The addition of a fan will
make even air circulation more likely. A fan with two speeds is desirable. High
speed is used at the beginning of the drying period when moisture is readily
available at the surface. Low speed is then used to slowly remove the remaining
moisture.
The two basic kinds of air flow systems are horizontal and vertical. Horizontal
flow moves air across the top and bottom of food and is considered the best
system. Vertical air flow is more easily blocked by food shelves.
Trays
Tray edges should be a quarter- to a half-inch high to prevent food from spilling
or falling off and to allow air to circulate. Trays should slide easily in and out.
Door
The door should be easy to open and close. Doors may swing up or down, right
or left. Some are removable. When open, the door should not interfere with
traffic passing by the dehydrator. You may need both hands to load and unload
the food trays so the door should stay in an open position by itself. It should
seal well and have strong hinges and latches that will withstand repeated use
as well as heat and humidity.
Cabinet
The cabinet should be built of a material that does not warp or get hot when in use
—double-wall construction of metal or plastic. It should be nonflammable and
easy to clean.
Safety
Look for the UL label and a grounded plug.
Capacity
Use common sense. If the capacity of the dehydrator does not look large
enough to accommodate the size of the loads you will dry frequently, it will not
be a good buy.
Procedures for oven drying
When using the oven drying method, it is important to know if your oven can
maintain the appropriate temperatures. Use an oven thermometer to test the
temperature of the oven at its lowest setting. Many ovens cannot maintain a
temperature below 200 degrees F. If your oven cannot, it is too hot for
successfully drying food, so alternative drying equipment must be used.
Tray placement
Trays upon which the food is placed must be at least 1½ inches narrower than
the inside of the oven to allow for air circulation. Allow at least 2½ inches
between trays and 3 inches of free space at the top of the oven for good air
circulation.
Ventilation
Place a fan outside the oven door to aid air circulation. Move it from side to
side occasionally. The room also should be well ventilated. Oven drying,
particularly if a fan is used, should be done with caution if small children are
around.
Maintain the temperature at 140 degrees F. Watch the temperature even more
carefully toward the end of the drying process. To prevent scorching, lower
temperature to 120 degrees F if possible. Examine the food often and turn
trays frequently, removing foods as they dry.
Never dry sulfured fruits in an oven or dehydrator, because the sulfur dioxide
fumes can be irritating. Use sulfite dips or steam, water or syrup blanching in
place of the sulfur treatment.
Separating foods
Different foods requiring similar drying times and temperatures can be dried
together. Vegetables with strong odors or flavors (garlic, onion and pepper)
should be dried separately. Don't dry strong-smelling vegetables outside in an
electric dehydrator, because dehydrators are not screened and insects may
invade the food.
Choosing a dehydrator
Because an electric dehydrator can be an expensive investment, choose a
specific brand or model carefully. Refer to the sidebar for features to look for
and evaluate before making your investment.
When is it dry?
Judging when food is dry requires experience. It is better to overdry than to
underdry. When in doubt, continue drying for an additional 15–30 minutes.
Check for doneness. Allow the product to cool before testing.
Vegetables are sufficiently dried when they are leathery or brittle. Leathery
vegetables will be pliable and spring back if folded. Edges will be sharp. Corn
and peas will shatter when hit with a hammer.
Fruits are adequately dried when moisture cannot be squeezed from them, and
if they are tough and pliable when cut. Fruit leathers may be slightly sticky to
the touch but should separate easily from the plastic wrap.
Meats should be extremely dry unless they are to be refrigerated or frozen for
long-term storage. Meat is sufficiently dried when it is dark-colored and fibrous
and forms sharp points when broken.
Herbs are dried when brittle. Their leaves shatter when rubbed together.
After drying
Even when a food tests dry, it may not be uniformly dry. Also, there is a chance
of contamination of dried foods, especially if racks have been exposed to the
open air for any time. Therefore, conditioning and pasteurizing should be done
before storing.
Caution
If any sign of mold growth occurs, destroy the product.
Freshly dried fruit can be added to the conditioning batch within the first five
days. Conditioning time will need to be lengthened to accommodate the
additional food.
Pasteurizing is recommended for foods that have been contaminated before or
during storage. It can be used as a second treatment for vegetables held in
storage if the vegetables do not have any mold on them. Keep in mind that this
treatment can cause quality changes. To pasteurize, use one of the two
following methods:
Both heat and pressure have long been used independently as means of
preserving food. For example, high pressure processing (HPP) at low or ambient
temperatures can prevent the growth of bacterial spores, and is an effective
means of preservation in moderate and high acid foods. However, low acid
foods (LAF) remain impervious to standard pressure processing at these
temperatures, which allow the Bacillus and Clostridium strains of bacteria to
flourish, and have traditionally been preserved through thermal processing.
But this technique requires relatively long periods of heating to ensure that all
the food within the target pack has been heated to the minimum temperature –
and the longer the heating period is, the greater the risk of degradation to the
food quality attributes (flavor, texture, nutrient content and color). How HPT
works food products are put through a pre-heating, holding and cooling
process in order to achieve the desired result. The equipment used is designed
to enable maximum compression heating which is vital for bacterial spore
inactivation. It must be able to maintain temperatures of up to 90°C, at
pressures of 600-800 MPa or higher (up to 1,500 MPa).
Firstly, the food product is placed in a holding unit and heated to a set
temperature.
The holding unit is then pressurised, and the temperature is increased. The
extent of these increases depends upon the composition of the food product
and its reaction to heat.
Once the required temperature has been reached it is maintained for a period
of time long enough to inactivate bacterial spores.
Decompression then takes place which cools the food product quickly, avoiding
degradation in terms of colour, taste, texture and nutritional value.
The advantage of HPT processing lies in the reduced thermal load applied to
products due to:
c. How successful is HPT? The results show that HPT processing is effective at
preventing reactivation in most – but not all – types of pathogenic
bacteria. Spore reaction Bacteria spores show different responses to HPT
processing – even between strains of the same species. For example,
proteolytic Clostridium botulinum strains were more HPT resistant compared to
the nonproteolytic strains. Curiously, those bacterial spores which are heat-
resistant differ in their response to the combined application of heat and
pressure.
The very heat-sensitive Bacillus coagulans strains are the most HPT-resistant
under a variety of conditions.
The intrinsic properties of the underlying food also play a part; research
suggests that spore inactivation may be affected by the food’s water content, or
its pH levels. Impact of packaging The effect of HPT processing on food
products also varies according to the barrier properties used. Ideally, food
packaging needs to be able to withstand changes in volume, (de)compression,
and temperature without any degradation of its aesthetic appeal. However, HPT
processing causes degradation to a certain extent in all forms of food packaging
Further work is needed The use of HPT processing to sterilize low acid, shelf-
stable foods remains a long term research challenge, although a more realistic
goal is that of prolonging the shelf life of low acid chilled foods. Further work
needs to be undertaken into bacterial spore inactivation in these chilled LAFs,
in particular into the non-proteolytic C. botulinum strain, which can germinate
and produce toxin at refrigeration temperatures. Other areas to be addressed
include:
2. The process of pre-heating, holding and cooling process are not necessary
to for food to achieve the desired