GTN 3202 TEKNOLOGI PENGELUARAN PERTANIAN DAN MAKANAN

Introduction Food products: Marine products Livestock and livestock products Fruits and vegetables Cocoa-based products Cereal products Convenience foods

The essence of food preservation -Understanding the factors contributing to food deterioration and spoilage -Controlling the factors responsible for food deterioration and spoilage Changes that may occur due to the food spoilage: -physical changes -chemical changes -biological changes

Physical changes

structural transformation stickiness and caking crispness crystallization viscosity and consistency changes mechanical damage

Factors causing food spoilage

growth and activity of microorganisms insects, parasites and rodents natural food enzymes temperature moisture and relative humidity oxygen/air light time

A) Processing of foods by the application of heat

Advantages of heat processing: preserve food by destroying natural enzymes. destroying microorganisms insect and parasites Improves eating quality Improve nutritive value of foods by destroying antinutritional Improves digestibility of starches (gelatinization), protein (denaturation), release of bound niacin. Readily available, relatively economical and simple to control.

Classification of food for heat processing

High/medium acid foods (pH < 4.5) Most fruit and some veg. Peaches, lemon juices, pineapples, tomatoes, onions Processed to destroy yeasts, moulds, enzymes (environmental stress, m/o easily destroy by heat <100) Temp. UP to 100 Low acid food (pH >4.5) Carrot, corn, milk, seafood (fish, crab), chicken, meat Need to be more severely treated. eg: 121oC, 3min or equiv. To destroy heat-resistant pathogenic bacteria (Bac. Cereus, Clostrodium botulinum)

Blanching

Done by heating food rapidly to a predetermine temperature, hold for a preset time and cool rapidly to ambient temperature Passing through an atm. of saturated steam / a bath of hot water Equipment used : Steam blancher Hot water blancher Individual quick blancher (3 section)

Blanching (cont.)

Purposes: - enzyme deactivation - reduce microorganism (surface) - soften tissue (facilitate filling)

Effect on foods (depends on T-t) - Nutrient loss-minerals, vitamins (steam<hot water- solubility) - Color & flavor changes - Textural changes (tissue)

BLANCHER

STEAM / HOT WATER BLANCHER

Food conveyor

HOT WATER BLANCHER

BLANCHED UNBLANCHED

UNBLANCHED BLANCHED

BLANCHED

UNBLANCHED

BLANCHED SQUID

Continuous heat processing

Liquid / semi-liquid product (can be pumped through a system) Direct system (steam infusion/injection) - heating medium = steam - steam + product mixed directly - will diluted product by steam condens. - brought back by flash cooling

Indirect system (plate heat and tubular exchanger) - product separate from heating medium (water / steam) - no physical contact

3 main process for continuous flow heat processing Aseptic system (sterile) high & low acid food Pasteurization process (destroy m/o cause spoilage) - high acid food - * heat- rapidly cooled-filled into sterile pack - low acid need higher temperature but go through same principle as * (to make sure no survival pathogenic bact)

- hot-filled process - high acid food (sauces, puree) - heat to pasteurization temp & filling DIRECTLY into container - will lose product quality through cooling (eg: cooling increase viscosity, difficult to fill)

Indirect system plate heat exchanger

Direct system steam infusion

Pasteurization

Relatively mild heat treatment generally below 100oC, extent keeping quality for a few days or several weeks To inactivate the enzymes and destroy heat-sensitive organisms and pathogens depending on the pH of the food.

Methods Low temperature long time (LTLT) or Holder method High temperature short time (HTST) Ultra pasteurization (Fig 1)

HTST

Sterilization

Foods are heated at a sufficiently high temperature for a sufficiently long time to destroy all microbial and enzymic activity Cause changes a) nutritive value b) sensory quality attributes (changes in flavor, color and texture).

AIM : to achieve sterilization and maintaining the nutritive value and sensory attributes by reducing the time of processing.

Heat processing using hot oil (frying)

Preservation of food achieved by reduction of water activity (aw), shelf life extension destruction of enzymes and microorganisms frying also done to improves taste, flavor and acceptability of foods types of food low moisture foods (dry)- long shelf life (potato chips, corn chips) high moisture foods short shelf life (French fries, doughnuts, fried chicken)

Oil get heated by heat transfer through the metal (frying pan) Food surface heated by heat transfer from oil Water evaporation, crust formed. Moisture removed, surface temperature rises(~oil). Internal T .rise towards 100oC Crust is porous, water lost through crust is replaced by oil Chips (dried by frying) fried at low temperature (180-190C) to allow the plane of evaporation to move inside the food before crust formation, browning and loss of flavor. Fried food (moist in the centre) are fried at higher temp. (195-200C) to Cook thoroughly, destroy m/o Enable rapid crust formation to seal the moisture inside (juiciness)

Heating by irradiated energy

Electromagnetic energy. Transmitted as wave, penetrate food and then are converted to heat. i) Microwaves Specific frequencies assigned for food use 2450 MHz and 925 MHz (Fig. 2) Lower frequency will penetrate food deeper Microwave are not hot. They do not heat up food directly. The food will not develop crust and will not brown. Microwave penetrate 1-2 inch inside food. Further heating is by conduction

Fig.2: Electromagnetic spectrum

Theory

Food molecule (water, H+, O-) act as dipolestiny magnets aligning themselves in a magnetic field. As the magnetic field alternates several million cycles/sec (frequency), the polarized molecule also oscillates in the field, creating friction between the molecules. This friction will generate heat. (Fig. 3) Microwave can be applied in Dehydration Pasta drying. Time reduced from 8 hours to 90 min Baking. Final drying of biscuits and crisp bread Thawing/ defrosting Blanching. No leaching of vit/mineral will occur.

Fig.3: Microwave diagram (home scale)

ii) Infrared radiation

Electromagnetic radiation emitted by hot objects. This energy is absorbed by food that gets heated up. (Fig. 4) The rate of heat transfer depends on Surface temperature of the heating and receiving materials. Surface properties of the two materials. Shapes of the emitting and receiving bodies. Generally infra red radiation has lower penetration efficiency than microwave energy. Limited to food surface. Used to dry low moisture foods, cocoa, grain, malt and pasta.

DIFFERENT OF MW & IR
Microwave
a) Include molecular friction in water molecule to produce heat b)Heating determined by moisture content of food c) Heat throughout the food d) aim: preserve food (blanching, dehydration, pasteurization)

Infrared radiation
a) Simply absorbed energy and converted to heat b) Heating depends on surface characteristics c) Limited to the surface of food d) aim: alter quality heating by changing the surface colour, flavour and aroma. Eg: final step of chips processing.

Evaporation

Removal of solvent, mostly water from liquid food by boiling. (Fig. 7) Differ from drying because final products are still liquid. Advantages: Increases solid content Pre concentrate foods (milk, coffee, juices) prior to drying. Reduce cost of drying, storage and transportation. Greater convenience e.g fruit juice concentrate, condensed soup, tomato.

Extrusion

This process combines several unit operations including mixing, kneading, cooking, shearing, shaping and forming. Consist of a barrel with a rotating screw which compresses and work the food to a semi solid mass. It is then forced through a die at the discharge end of the screw. The product is then cut by a revolving knife and dried. The product may be coated or enrobed.

The product can also be cooked during the process and this is known as extrusion cooking. It will reduce the water activity of the food. Eg. Corn flakes, TVP, animal feed, snack and confectionary.

DIRECT EXPANDED EXTRUDED SNACK

ANIMAL FEED PELLET

EXTRUDER

Advantages of extrusion

versatility. Wide ranges of product possible merely by changing the ingredients and operating conditions. reduces cost. Higher production rate. no process effluents. Equipment used : Single screw extruders (Fig. 5) Low operating cost, need less skill High shear (breakfast cereals, snack foods) Medium shear (breading, semi moist pet foods) Low shear (pasta and meat products) Twin screw extruders (Fig. 6) The screw rotates within a `figure of 8 shaped bore in the barrel.

Advantages of using twin screw extruders.

versatile. Can handle oily, sticky or wet materials that slip in single screw. Higher material content can be used Single screw twin screw Moisture 30% 65% Fat 4% 20% Sugar 10% 40% the screw can be directed forward (for pressure release and for addition of ingredients) and reverse (compression of food from extrusion) Less wear and tear Can handle fine powder to grains.

Dehydration

Dehydration (or drying) is defined as the controlled application of heat to remove most of the water normally present in the food by the process of evaporation or sublimation (freeze drying) Methods of drying 1) SUN-DRYING

mostly used in agricultural without drying equipment depends on weather more advanced (solar drying)

vine fruits (grape), tree fruits (peaches, pears, apricots), legumes, spices, fish etc. Small fruits (sultanas, raisins) were dipped in 2.5% potassium carbonate solution and 0.3% sodium hydroxide before drying. Larger fruits (peaches, apricots etc) are halves, pitted and sulphured enzymatic browning. Final moisture content from 1035% and 28-30% for intermediate moisture foods.

2) HOT AIR DRYING

Cabinet or tray drier Tunnel driers (Fig. 8) Conveyor belt drier (Fig. 9) Spray drying (Fig.11)

Spray drying (hot air drying) (fig. 11)

Fine dispersion of preconcentrated liquid is 1st atomised to form droplets and sprayed into a heated air (150-300oC) Flash evaporation produce dry powder Cool air exits from the bottom through a cyclone separator to collect entrapped particles The feed rate is controlled to produce an outlet temperature of 90-100oC

SPRAY DRYER

FRUIT JUICE POWDER

MILK POWDER

COCONUT MILK POWDER

3) HEATED SURFACE DRYING A) Drum (roller drying) (Fig 10) - In these drier heat is supplied to the food to be dried by conduction. - For drying out liquids/fluid - Eg. Beverages (Milo), baby foods (Nestum), cereals, milk powder

B) Vacuum shelf driers Consist of hollow shelves in a vacuum chamber. Food is placed in thin layers on flat metal trays Vacuum of 1-70 Torr is drawn in the chamber and... Steam or hot water is passed through the shelves to dry the food

VACUUM SHELF DRYER

B) Processing of foods by the application of low temperature 1) FREEZE DRYING (FD)

98% of the foods moisture is drawn off by EVAPORATING the ice, at temp. as low as -45oC

FOOD
FROZEN
Small food rapidly Liquid food - slowly

SUBLIMATION

Vacuum, low P, -45oC Increase T (ice-gas)

CONDENSATION

Gas is removed by vacuum pam & condensed in refrig. coil (condenser)

LAB-SCALE FREEZE DRIER

For fresh and cooked food Maintain sensory & nutritional Q High cost , slow process First stageby sublimation to approximately 15% moisture content.
Second stage: by desorption, that is raising the temperature in the drier ambient, while maintaining reduced pressure. FD product- some require rehydration prior to consumption

FREEZE-DRIED MANGO
FREEZE-DRIED MIXED FRUIT

* INSTANT TEA & COFFEE

FREEZE-DRIED MUSHROOM

FREEZE-DRIED SHRIMP

FREEZE-DRIED FISH FOOD

Types of freeze drier

Contact freeze drier (Fig. 12a) Food is placed in ribbed trays that are resting on heating plates.

Accelerated freeze drier (Fig. 12b)

Food is held between two layers of expanded mesh under slight pressure so that heat transfer occurs uniformly throughout the food.

Radiation freeze drier (Fig. 12c) Infra red radiation is used from radiant heaters to heat shallow layers of food placed in flat trays.

2) Freeze concentration (Fig. 13)

This process selectively removes water from foods without affecting any other components of foods. Flavor and color retention is high. This process involves fractional crystallization of water as ice and subsequent physical removal of ice. Water- freeze- followed by mechanical separation technique Instant coffee to maintain the flavour & aroma compound Fruit juices, vinegar, pickle liquors

C) High Pressure Processing

Effect of pressure is uniform and instantaneous throughout the sample, causes no disruption or changes in the shape, unlike heat treatment where in order to ensure that the interior of the product is adequately cooked, the exterior is overcooked. High pressure processing only needs energy to achieve the required pressure, and then the energy can be cut off and the pressure is maintained in a closed chamber. Heat treatment requires continuous energy throughout the process. create new functional properties to the food that cannot be created by thermal processing (eg: colour & nutrient). US, Europe, Japan

Packaging- flexible container (pouch / plastic bottle) Chamber filled pressure transmitting (oil, water) with liquid

Pump create pressure, transmitted to the food through liquid (3-5min), uniform - maintain shape

create new functional properties to the food that cannot be created by thermal processing (eg: colour & nutrient).
Eg: meat can denatured protein, but the colour is still pink Pressure inactivate most vegetative bacteria

HIGH-PRESSURE PROCESSING

Effect of high pressure processing

- denatures proteins - modify polysaccharides - better keeping quality

(Fig 14)

meat products, fruit juices & smoothies, seafood, dairy products, RTE [ready-to-eat] meals