Fruit Yoghurt Manufacturing Process

Pamantasan ng Lungsod ng Maynila
College of Engineering and Technology

Department of Chemical Engineering
FRUIT YOGHURT
I. Introduction
Yoghurt is a milk product obtained by the fermentation of milk by the

action of symbiotic cultures of Streptococcus thermophilus and Lactobacillus
delbrueckii subsp. bulgaricus and resulting in reduction of pH with coagulation.
These starter micro-organisms are normally viable, active and abundant in the
product to the date of minimum durability (Hoolasi, 2005).
The word “yoghurt” is derived from Turkish “jugurt”, used to describe any
fermented food with an acidic taste. Historically, yoghurt was made by fermenting
milk with indigenous microorganisms.
Yoghurt is also a healthy consumable product that is able to reduce
microbial population particularly in our digestive system which provides
immunity against colon cancer. It inhibits the growth of Heliobacter pylori, the
bacteria that is responsible for ulcers.It also helps in cutting down calorie and
thus helps in burning fat. Hence, the production of yoghurt targets the people
who want to live a healthier and longer life.
II. Types of Yoghurt
Set Yoghurt
This type of yoghurt is incubated and cooled in the final package and is
characterized by a firm jelly like texture.
Stirred Yoghurt
This type of yoghurt is incubated in a tank and the final coagulum is
"broken" by stirring before cooling and packing. The texture of stirred yoghurt will
be less firm than a set yoghurt somewhat like a very thick cream.
Drinking Yoghurt (Yoghurt Drink)

Yoghurt drink is a yoghurt in a form of beverage.
Frozen Yoghurt
Frozen yoghurt is inoculated and incubated in the same manner as stirred
yoghurt. However cooling is achieved by pumping through a whipper / chiller /
freezer in a fashion similar to ice-cream. The texture of the finished product is
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mainly influenced by the whipper/ freezer and the size and distribution of the ice
crystals produced
III. Brief History

Around 6000 B.C., Neolithic Herdsmen people from Central Asiabegan the
practice of milking their animals, and the natural enzymes in the carrying
containers (animal stomachs) curdled the milk, essentially making yogurt. Some
historians also believed that the making of yoghurt accidentally began around
500 B. C., in the Balkan because the summer temperature in those region were
suitable for yoghurt production.
The yoghurt reached the Western Europe in 1542, under the reign of
Francois I. The king was suffering from severe diarrhea and doctors could offer
no cure. Suleiman the Magnificent, the Sultan of the Ottoman Empire and an ally
of the throne of France, sent a doctor who cured the king with yogurt.
At the end of the 19th century, Stamen Grigorov, a Bulgarian medical
student discovered the Lactobacillus Bulgaricus. Later, Elie Metchnikoff, a
Russian scientist who worked at the Pasteur Institute, Nobel Prize in Medicine in
1908, has been influenced by Grigorov’s work. He published theories about the
potential benefits of yogurt. This information made the yoghurt a popular
foodstuff in the United States
In 1919, the industrialization of yoghurt production began when Isaac
Carasso, modernized the technique used by the nomadic shepherds of Anatolia
(former name of Turkey) which known as bacterial fermentation. This
development led to his company – Danone, which was named after his son, “Little
Daniel” and started in Barcelona, Spain. Later, it became Dannon, the
Americanized name of the company.
In 1929, Armenian Immigrants Sarkis and Rose Colombosian established
“Colombo and Sons Creamery” in Andover, Massachusetts. It was sold as
“madzoon”, and later, it was changed into “yoghurt”.
In 1933, yoghurt with fruit jam was introduced and patented by Radlická
Mlékárna dairy in Prague, Czech Republic. A decade later, the Danone also
introduced their first fruit yoghurt.
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IV. MANUFACTURING COMPANIES IN THE PHILIPPINES
NESTLE PHILIPPINES
Location: Makati
Distributor of the Nestle Fruit
Selection Yogurt
AB PASCUAL FOODS INC.

Location: Makati City
Distributor of Creamy Delight
HACIENDA MACALAUAN INC.

Location: Brgy. Mabacan,
Calauan, Laguna
V. RAW MATERIALS
 MILK
Milk is a white liquid produced by the
mammary glands of mammals. Milk is
primarily compose of lactose, which is
converted into lactic acid via fermentation
that is used in yoghurt production
 STARTER CULTURES
Starter cultures are substances that
promote lactic fermentation for the
production of yoghurt. The starter culture
used for the production of yoghurt are
Streptococcus Thermophilus and
Lactobacillus Bulgaricus
Streptococcus Thermophilus
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Streptococcus thermophilus is an essential

lactic acid bacterium that is capable of
producing lactic acid and small quantities
of formic acid, which promotes outgrowth
of Lactobacillus delbrueckii Subsp.
Bulgaricus.
Lactobacillus delbrueckii Subsp.

Bulgaricus (Lactobacillus bulgaricus)
Lactobacillus bulgaricus is a rod shaped,
gram positive, non-motile bacterium that
has the ability to produce amino acids to
stimulate the growth of Streptococcus
thermophilus.
 FRUCTOSE & SUCROSE

Sugars that are required in jam making
for the flavoring of yogurt.
 FRUITS
Fruit is usual, sweet food (such as
blueberry, banana or orange) that grows
on a tree or bush. Fruits are used as a
natural flavoring in yoghurt. (Merriam
and Webster, 2008)
Common Fruits Used in Yoghurt Production

1. Berries
a. Strawberries
b. Blueberries
c. Raspberries
d. Blackberries
e. Bananas
2. Melon
3. Mango
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VI. MANUFACTURING PROCESS
FRUIT FLAVORING PREPARATION
A. FRUIT HARVESTING
Fresh fruits are ready to harvest either
by manual or by machine. Picking
fruits that are needed for the yogurt
production is also done in here.
MANUAL FRUIT
HARVESTING
B. WASHING/DRYING
The fruits are being transported by
conveyor through a washing
equipment to remove tangible
contaminants that will the quality of
the yogurt. Then the fruits are being
conveyed and dried using the dryer.
WASHING EQUIPMENT
AND DRYER
C. CRUSHING
The fruits are passed through fruit
crusher for size reduction and
consistency, which is being prepared
for jam making.
FRUIT CRUSHER
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D. MIXING
Mixing involves the making fruit jam
which is to be used as the flavoring in
fruit yogurt. Specific amounts of
crushed strawberries, water, artificial
coloring fructose and sucrose are
being mixed uniformly at a constant
MIXER temperature of 60°C to dissolve the
solids. Then after producing the fruit
jam, it is heated again for about 1
hour to remove unwanted bacteria.
YOGURT PREPARATION
A. MILK STORING
The production of yoghurt begins with the raw
material, milk, which is stored and pumped in
bulk storage tanks. Before storing in the tank, the
raw milk is being tested and checked for foreign
and unwanted contaminants. Milk storage tanks is
made of stainless steel. Milk storage tanks are
closed which can hold from 1000-10000 liters of
raw milk.
MILK STORAGE TANK
B. PREHEATING/PRE-PASTEURIZATION
The raw milk is pumped through the plate heat

exchanger. The plate heat exchanger consists of
heating and the cooling treatment stage. The raw
milk is preheated at a temperature of 161°F for 15
seconds to remove the unwanted bacteria that will
affect the quality of the yoghurt that will be
produced. Then the pre-pasteurized milk is cooled.
PLATE HEAT EXCHANGER
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C. CENTRIFUGATION/EVAPORATION
The pre-pasteurized milk is now transferred
into the centrifuge with a capacity of 5000 to
10 000 liters that running over 4700
revolutions per minute (rpm). Centrifuge
separates the light cream and the heavy
skimmed milk. Then the heavy skimmed
milk passes through its evaporator to
decrease water content and increase the
solid level of the skimmed milk. It creates a
SKIMMING DISK
CENTRIFUGE
vacuum inside while boiling to prevent
burning and promotes condensation.
D. HOMOGENIZATION
Homogenization prevents the creaming of the
milk. The homogenizing piston lets the
insoluble fat globules to be crushed under
high pressure ranging from 10 to 15 MPa for
the fat to be mixed with the milk.
HOMOGENIZATION TANK
AND PISTONS
E. LACTIC FERMENTATION
Lactic fermentation includes the
addition of starter culture. Once the
relevant yoghurt culture has been
added to the milk, incubation follows.
The end of the incubation phase is
often controlled by the pH value. The
pH value should ranging from 4.2 to
4.5. Fermentation is done within 5 to
FERMENTATION TANKS 8 hours at a temperature of 43°C.
Reaction:
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F. COOLING
As soon as the pH value reaches 4.2 to 4.5, the yoghurt is pumped out of
the incubation tanks and must be cooled from the incubation temperature
of 15 to 22 °C, to stop acidification.
G. FLAVORING
Flavoring involves the addition of the flavors in the yogurt. The yogurt and
the fruit jam is mixed and to be filled in the packaging column.
H. FILLING
The flavored yogurt is being pumped
and transported to the filling column.
The yogurt containers are conveyed
through the filling machine. The air in
this stage is strictly filtered and
controlled to avoid contamination.
FILLING COLUMN
I. PACKAGING
Filled yogurt containers are
transported into the heat sealing
column. The yogurt is tightly sealed
using aluminum seal with printed
manufacturing and expiration date on
it.
HEAT SEALING COLUMN
QUALITY CONTROL
Quality control is an extremely important factor in any food processing
facility, especially when it comes to the production of dairy products like yogurt.
Bacteria control is strictly implemented. For health and safety reasons, the
government regulates all of the raw materials that are used in the yogurt
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production process. Before the production of yogurt, manufacturers conduct a

test on the raw milk. Once it is confirmed for processing, it is unloaded and
pumped in their milk storage tanks. For the flavoring process, fruits are carefully
washed before mixing. Every process has temperature control for the standard
production and consistent process.
PROCESS FLOWCHART
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MANUFACTURING PROCESS FLOWCHART
PLANT LAYOUT
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FRUIT JUICES
DEFINITION OF JUICE
It is the liquid obtained from or present in fruit or vegetables. To be labeled
as a fruit juice, the Food and Drug Administration (FDA) mandates that a product
be 100% fruit juice. For juices reconstituted from concentrate, the label must
state that the product is reconstituted from concentrate. Any beverage that is less
than 100% fruit juice must list the percentage of the product that is fruit juice,
and the beverage must include a descriptive term, such as “drink,” “beverage,” or
“cocktail.” In general, juice drinks contain between 10% and 99% juice and added
sweeteners, flavors, and sometimes fortifiers, such as vitamin C or calcium.
These ingredients must be listed on the label, according to FDA regulations.
HISTORY OF JUICE
Juice wasn't really possible until 1869, when a dentist in New Jersey, a Dr
Thomas Welch, developed a process to pasteurize bottles of Juice to stop the
Juice from fermenting into alcohol. Before then, you couldn't just have Juice,
unless you made it and drank it right away.
Canned and bottled Juices were all you could get until the 1940s and
1950s. In the 1940s, as part of the war effort, American researchers developed
frozen concentrate. By the 1950s, the Juice market exploded, with orange Juice
leading the way.
DIFFERENT TYPES OF FRUIT JUICES

TYPE DEFINITION
 Aguamiel Aguamiel is the sweet juice or sap

from an agave plant. It is procured
from many different varieties of agave
plant, though not all yield a juice that
is worth getting.
Apple Juice Apple Juice is the juice extracted from

apples. In small scale juicing
operations, at home and for apple
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cider, apples are pressed to extract

their juice.
Bug Juice Bug Juice is a beverage. Exactly what

the beverage is varies by area, and by
tradition, but it appears to always be a
soft drink.
Cranberry Juice Cranberry Juice is a bright red fruit

juice, sweetened with sugar. Most
juices sold are 1/3 cranberry juice,
with the remainder being water and
sugar to make them palatable.
Grape Juice Grape Juice can be red or white. To

make it, the whole grape is crushed
including the seeds.
Lemon Juice Lemons are primarily used for their

juice, as a souring agent, to refresh
the taste of foods, or to prevent food
browning. Lemons weren't really
available at all to Europeans or North
Americans until the end of the 1800s,
and then only to the rich.
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Nectar Nectar is a marketing term that came

about in the late 1980s for a non-
pure, diluted fruit juice to distinguish
it from other non-pure fruit drinks. A
Nectar will contain added water,
added sugar or honey to sweeten it,
and often contains fruit pulp to make
it thicker than juice.
Commercial Orange Juice Commercial Orange Juice tastes
orangier than fresh oranges, and
Orange Juice that you have squeezed
yourself. The reason for this is that
oranges meant for juicing can be left
on the trees longer, and to develop
better flavour.
Pickle Juice Pickle Juice is juice that has been
used to pickle a food item. Though it's
usually presumed to be juice that
cucumbers in one form or another
were pickled in, that's not strictly true:
the juice can be from beets, pickled
peppers, etc..
Pineapple Juice Pineapple Juice is a sweet, yellow-
coloured juice squeezed from
pineapples: not from the whole
pineapple, but from the trimmings
after the pineapple is cut for canning.
It can be bought sweetened or
unsweetened, in cans, bottles, as a
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frozen concentrate or as a powder.

Pomegranate Juice Pomegranate Juice is the unsweetened
juice of Pomegranates. You cut the
pomegranates in half and juice as you
would a citrus fruit.
Tomato Juice To make Tomato Juice, tomatoes are

cooked to develop the taste and
release the juice, then strained to
remove excess fibres and seeds, and
then canned or bottled. It differs from
Tomato Sauce in that Tomato Sauce is
cooked further until it reduces and
becomes thick, and flavourings are
definitely added, such as herbs and
spices.
Manufacturing Companies of Fruit Juices in the Philippines
1. Zest-O Corporation
Zest-O Corporation is one of the largest beverage companies in

the Philippines and a Philippine market leader in ready-to-drink juices. It was
founded by Chinese-Filipino businessman Alfredo Yao. The company's juices
currently offer eleven different flavors: orange, mango, grape, pineapple,
strawberry, guyabano, apple,calamansi, mango-orange, mango-calamansi and
mango-lemon lime.
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2. Green Choice Selection Inc.
Greenchoice Selections, Inc. X It is started by a group of health-conscious

individuals who wanted an alternative to the “sugar-laden, store-bought
powdered juice drinks” available in the market, and came together and developed
Squeeze–C Calamansi Concentrate.
3. Dole Philippines Inc.,
Founded in Hawaii in 1851, Dole Food Company, Inc., with 2010 revenues of
$6.9 billion, is the world's largest producer and marketer of high-quality fresh
fruit and fresh vegetables. Dole markets a growing line of packaged and frozen
foods, and is a produce industry leader in nutrition education and research. The
Company does business in more than 90 countries and employs, on average,
36,000 full-time, regular employees and 23,000 full-time seasonal or temporary
employees, worldwide.
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4. Profood International Corporation
Profood International Corporation is the largest Philippine-based dried mango

producer and the standard-bearer of world-class processed fruit products from
the Philippine Islands. From the small company that once catered only to the
local market, Profood International Corporation has grown to become the leading
producer of various dried fruits, fruit preserves, purees, concentrates and juices.
Its products are available all over the Philippines and exported to many countries
in Asia, Europe, Canada and the United States.
MANUFACTURING PROCESS OF APPLE JUICE
Raw Material
 Apple
Apples are more widely grown
than any other fruit; apple trees of one
kind or another are grown all around
the world. Apple production can vary
from one year to the next by as much
as 20 percent, depending on the climate
of any given year. There are hundreds
of apple cultivars, but only about 20
cultivars are commercially important.
More than 90 percent of this production is represented by 14 cultivars and
only five of these account for most of the world's apple production: Delicious,
Golden Delicious, McIntosh, Rome Beauty and Granny Smith.
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MANUFACTURING PROCESS
HARVESTING
The majority of the apple crop is hand
harvested because only a very small
percentage of that crop is intentionally
harvested for further processing. To use
mechanical harvesting, a grower or
cooperative of growers must be producing
at least 40 000 bushels, in order to justify
the cost by the use of Harvesting Trucks.
Since apple processing is mainly thought of
as a salvage operation, the amount of
apples available to process is largely dependent on the size of the fresh market
harvest and its quality. Consequently, processing apples are harvested and stored
in the same manner as premium, fresh market apples. One advantage that apples
have over other more perishable fruit crops is that the fruit may be successfully
kept in storage for a few weeks to several months. However, to maintain their
high quality for processing over storage time periods, it is extremely important
that they are picked at the proper stage of maturity and storage conditions are
optimized for specific apple cultivars. The processor must determine when the
apples for processing are to be harvested.
STORING
Since most processors cannot use the
whole harvest they receive, as they receive
it, some fruit is stored, short term, as they
come in, not refrigerated. Other fruit is
stored refrigerated in a temperature range
of 1 to 4°C, depending on the cultivar. The
next level of storage is controlled
atmosphere. Controlled Atmosphere
storage usually consists of a modified
atmosphere, 2 to 3 percent oxygen and 1 to
4 percent carbon dioxide, at a reduced temperature. The exact specifications are
adjusted to the cultivar being stored. Apples can maintain quality under these
conditions for 4 to 6 months.
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WASHING
Fruit are then spray washed and

sorted (removing damaged and diseased
fruit). Using Fruit Washer.
GRINDING
To prepare them for juicing, a disintegrator,

hammer mill or grating mill may be used to grind
the apples. The mashed apples need to be free of large
pieces yet not so fine that pressing becomes difficult.
The type of extraction equipment may dictate the
chopping method to achieve highest efficiency. The
hammer mill adjusts more easily to different pulp
consistencies.
EXTRACTION
Extraction may be accomplished through

pressing chopped apple continuously or in
batches. There are a number of pressing systems:
1. The hydraulic cider press is one of the

oldest methods of pressing ground apples but is
still widely used in commercial setups around the
world. Since the ground apple pulp passes directly
from the chopper to the press cloth, this method usually does not involve using
enzymes in the mash.
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2. The bladder press is an effective batch system. The Willmes Pressor is a

horizontal, cylindrical screen lined with press cloth material, with a large
inflatable tube in the centre that inflates and presses pulp up against the loth-
covered wall . The whole assemblage is rotated after it is filled and closed and as
the tube is being inflated. Juice is expressed into a catch trough below and
collected from a drain. Pressure on the tube reaches a maximum of 6
atmospheres or approximately 600 kPa. Usually a press aid is needed to keep the
pulp from adhering to the press cloth and stopping the free flowing of the juice.
Cleaned rice hulls work very well and a good grade of disintegrated wood pulp
works well also, but is more absorbent.
3. Continuous screw presses can be used successfully with slippery apple

pulp with the addition of press aids. Ground apples and a press aid are fed into
the top of the press and are gradually pressed down by a tapered screw revolving
at 3 to 5 rpm. Stationary paddles or interrupter bars in the path of the screw
prevent the mass from slipping on the screw. The cylinder around the screw is a
reinforced screen through which the juice travels to a drainage pan at the bottom.
At the bottom, the pomace is forced through an annulus that is partially closed
by a sliding cone.
SCREENING
Apple juice from any of the presses described
is invariably cloudy and contains particles that can
be removed by screening. A cylindrical "cider"
screen, which is made of stainless steel screening of
approximately 100 to 150 mesh, revolves on a system
of rollers. The revolving action keeps the screen clean
by causing the pomace to gather into small balls and
finally into a continuous roll which falls off the end of
the slightly sloping screen. A stainless, dewatering
shaker screen can also be used. Screened juice
reduces the load on the filter.
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PASTEURIZATION
The most important method of

preserving apple juice is pasteurization in a
Pasteurizer Tank, which involves heating
the juice to a given temperature for a length
of time that will destroy all organisms that
can develop, if juice is put hot into
containers that are filled and hermetically
sealed. Flash pasteurization is, true to its
name, the rapid heating of juice to near the
boiling point (greater than 88°C) for 25 to 30
seconds. Steam or hot water passes the juice between plates or through narrow
tubes that are heated. Design of the heat exchanger provides juice flow
turbulence and even heating to prevent scorching and burn-on in the unit.
FILTRATION
To obtain a brilliantly clear apple juice
polish filtration is necessary in a Tubular
Micro filtration. Untreated juice can be rough
filtered in large capacity filters with large filter
areas that can be easily cleaned. The juice
from this method has superior flavour and
excellent body. It may have a slight haze that
increases with time as proteins and tannins
react. Filtering juice that has not been
depectinized reduces the filtration rate to
about 1/3 of enzyme treated juices.
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PACKAGING
Juice can be canned or bottled in cans,
glass or plastic. Cans used are enamel or
lacquer lined to resist corrosion from the juice.
As the cans travel the canning line, they must
pass through a can washer, be filled from filling
machines and immediately sealed on a can-
closing machine. After closure cans should be
positioned or inverted so that the hot fill will be
in contact with the lid and thus, pasteurize it.
From here, the cans must be removed to a cooling room where they will be cooled
to near 38°C to stop the effect of high heat on the contents. If cooled to a
temperature lower than 35°C, the labels will tend to detach, the can will not dry
and will be susceptible to surface rusting. This necessitates that the cans travel
continuously from washing, to filling to cooling to labelling and packing.
PROCESS FLOWCHART
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ICE CREAM
I. History of Ice Cream
Our love affair with ice cream is centuries old. The ancient Greeks, Romans, and
Jews were known to chill wines and juices. This practice evolved into fruit ices
and, eventually, frozen milk and cream mixtures. In the first century, Emperor
Nero reportedly sent messengers to the mountains to collect snow so that his
kitchen staff could make concoctions flavored with fruit and honey. Twelve
centuries later,Marco Polo introduced Europe to a frozen milk dessert similar to
the modern sherbet that he had enjoyed in the Far East. The Italians were
especially fond of the frozen confection that by the sixteenth century was being
called ice cream. In 1533, the young Italian princess Catherine de Medici went to
France as the bride of the future King Henry II. Included in her trousseau were
recipes for frozen desserts. The first public sale of ice cream occurred in Paris at
the Café Procope in 1670.
Frozen desserts were also popular in England. Guests at the coronation banquet
of Henry V of England in the fourteenth century enjoyed a dessert
called cremefrez. By the seventeenth century, Charles I was served creme ice on
a regular basis. Eighteen-century English cookbooks contained recipes for ice
cream flavored with apricots, violets, rose petals, chocolate, and caramel. Other
early flavorings includedmacaroon and rum. In early America, George
Washington and Thomas Jefferson were especially fond of ice cream. Dolley
Madison was known to serve it at White House state dinners.
Because ice was expensive and refrigeration had not yet been invented, ice cream
was still considered a treat for the wealthy or for those in colder climates. (In a
note written in 1794, Beethoven described the Austrians' fear that an
unseasonably warm winter would prevent them from enjoying ice cream.)
Furthermore, the process of making ice cream was cumbersome and time-
consuming. A mixture of dairy products, eggs, and flavorings was poured into a
pot and beaten while, simultaneously, the pot was shaken up and down in a pan
of salt and ice.
The development of ice harvesting and the invention of the insulated icehouse in
the nineteenth century made ice more accessible to the general public. In 1846,
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Nancy Johnson designed a hand-cranked ice cream freezer that improved

production slightly. The first documented full-time manufacturing of ice cream
took place in Baltimore, Maryland, in 1851 when a milk dealer named Jacob
Fussell found himself with a surplus of fresh cream. Workipg quickly before the
cream soured, Fussell made an abundance of ice cream and sold it at a discount.
The popular demand soon convinced him that selling ice cream was more
profitable than selling milk.
However, production was still cumbersome, and the industry grew slowly until
the industrialization movement of the early twentieth century brought electric
power, steam power, and mechanical refrigeration. By the 1920s, agricultural
schools were offering courses on ice cream production. Trade associations for
members of the industry were created to promote the consumption of ice cream
and to fight proposed federal regulations that would call for selling ice cream by
weight rather than volume, and the disclosure of ingredients.
The Prohibition era proved to be very profitable for the ice cream industry. Denied
alcoholic beverages, many people ate ice cream instead. Breweries were often
converted to ice cream factories, although it is likely that some of the plants were
merely fronts for illegal liquor sales. Although the repeal of Prohibition in 1933
and the ensuing depression slowed ice cream sales, the industry continued to
grow. The movie industry was especially instrumental in the promotion of ice
cream and scenes depicting stars enjoying the frozen concoctions were plentiful.
Ice cream parlors sprang up in every town and the parlor employee, the so-called
soda jerk, developed into a cultural icon.
II.Companies
Magnolia, Inc.
Aurora Boulevard, Quezon City
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Selecta
Amang Rodriguez Avenue
Manggahan Light Industrial Park
Pasig City, Metro Manila
Dan Eric’s Grand Ice Cream

808 Armela Compound Km. 17
Interior West Service road
South Superhighway
Parañaque City
Nestle Philippines, Inc. Ice Cream Division

710 Aurora Blvd. Quezon city
Quezon City
Metro Manila
III.Raw Materials
Milk fat provides creaminess and richness to ice cream and contributes to its
melting characteristics. The minimum fat content is 10% and premium ice
creams can contain as much as 16% milk fat. Sources of milk fat include milk,
cream, and butter.
The total milk solids component of ice cream includes both the fat and other
solids. The other milk solids consist of the protein and lactose in milk and ranges
from 9 to 12% in ice cream. The nonfat solids play an important role in the body
and texture of ice cream by stabilizing the air that is incorporated during the
freezing process. Sources of nonfat solids include milk, cream, condensed milk,
evaporated milk, dry milk, and whey.
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Sweeteners are used to provide the characteristic sweetness of ice cream.

Sweeteners also lower the freezing point of the mix to allow some water to remain
unfrozen at serving temperatures. A lower freezing point makes ice cream easier
to scoop and eat, although the addition of too much sugar can make the product
too soft. Sweeteners used include sugar (sucrose) and corn syrups.
Stabilizers are proteins or carbohydrates used in ice cream to add viscosity and
control ice crystallization. Over time during frozen storage small ice crystals
naturally migrate together and form larger ice crystals. Stabilizers help to keep
the small crystals isolated and prevent the growth of large crystals, which causes
ice cream to be coarse, icy and unpleasant to eat. Stabilizers used include
alginates (carageenan), gums (locust bean, guar), and gelatins.
Emulsifiers are used to help keep the milk fat evenly dispersed in the ice cream
during freezing and storage. A good distribution of fat helps stabilize the air
incorporated into the ice cream and provide a smooth product. Emulsifiers used
in ice cream include egg yolks and mono- and diglycerides.
A wide range of flavorings are used in ice cream. Flavorings include natural and
artificial flavors, fruit, nuts, and bulky inclusions such as chocolate chunks and
candies.
Picture Raw Material Sources

Milk Fat Fresh Milk
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Protein and Lactose Skim Milk
Sweeteners Sugar
Stabilizers Alginates
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Emulsifier Egg Yolk
Flavorings Fruits
IV. Unit Process
A. Preparation of Raw Materials
Making of Mango Pulp

1. Fruit selection
Several requirements need to be met:
 Lack of insect infestation
 Lack of mechanical injuries
 Stage of maturity
 Uniform colour and texture
 pH value of 3.5 to 4.0
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The receiving area must be clean, well ventilated, and free of insects, rodents or
other animals. It is not advisable to hold the fruits too long before processing to
avoid spoilage.
2. Washing
The washing pit should be filled with water containing 15 ppm chlorine in order
to reduce microbial load and impurities from the fruit. A second washing with
clean water is made to eliminate residual chlorine.
3. Blanching
This operation is done to inactivate enzymes, eliminate air inside the fruit tissues,
remove off-flavours and aromas, fix fruit colour and soften the tissues for further
pulping.
Two methods are currently used to effect blanching: dip in boiling water or direct
steam injection. The thermal treatment is applied such that internal fruit
temperature reaches 75°C. This usually requires 10 minutes in boiling water, or
6 minutes with steam. Fruit is blanched unpeeled.
4. Peeling and cutting

Pulp is separated from the seed manually with knives made of stainless steel, on
a working bench. Mango pieces are placed in clean plastic containers and taken
to the pulping machine.
5. Pulping
Mesocarp pieces are passed through a fine mesh to remove undesirable particles.
After pulping, a smooth puree is obtained. Recommended mesh size is 0.5 mm.
coarser material is separated in the process and disposed properly. The pulp is
transferred in containers to the kettle.
6. Thermal treatment
A heat treatment is applied in the kettle to prevent chemical and microbial
spoilage. In this treatment the pulp reaches 95 ° C and is held for 10 min. with
continuous stirring.
7. Additives
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The use of additives is recommended to extend the pulp shelf life. Commonly
used additives include 0.39 percent citric acid to decrease pH and prevent
microbial growth and enhance effectiveness of preservatives as sodium benzoate
(0.5 percent).
To prevent discoloration 0.1 percent ascorbic acid is used as antioxidant.

Additives are incorporated to the pulp right before the thermal treatment is
finished (ca. 5 min before) by dispersing in hot water or pulp and proper stirring.
Final product should have pH values between 3.4 to 3.5.
8. Packing
The pulp is packed when hot in plastic containers, sealed immediately and
flipped over so the internal part of the lid gets in contact with the hot product. All
packing materials must be clean before used.
9. Cooling
Hot containers are cooled with fresh water at the lowest temperature attainable.
After cooling, lid closings should be inspected. Finally, containers are cleaned and
labels affixed to be sent to a fresh, clean storage place.
B. Conditioning of Raw Materials
BLENDING
The milk fat source, nonfat solids, stabilizers and emulsifiers are blended to
ensure complete mixing of liquid and dry ingredients. Premeasured amounts of
eggs, sugar, and additives are blended with the milk for six to eight minutes.
PASTEURIZATION
Ice cream mix is pasteurized at 155°F (68.3°C) for 30 minutes. The conditions
used to pasteurize ice cream mix are greater than those used for fluid milk
because of increased viscosity from the higher fat, solids, and sweetener content,
and the addition of egg yolks in custard products.
HOMOGENIZING
By the application of intensive air pressure, sometimes as much as 2,000 pounds
per square inch (141 kg per sq cm), the hot mixture is forced through a small
opening into the homogenizer. This breaks down the fat particles and prevents
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them from separating from the rest of the mixture. In the homogenizer, which is
essentially a high-pressure piston pump, the mixture is further blended as it is
drawn into the pump cylinder on the down stroke and then forced back out on
the upstroke.
AGEING
Ice cream mix is aged at 40°F (5°C) for at least 4 hours or overnight. Aging the
mix cools it down before freezing, allows the milk fat to partially crystallize and
the gives the proteins stabilizers time to hydrate. This improves the whipping
properties of the mix.
ADDING OF LIQUID FLAVORS

Liquid flavors and colors may be added to the mix before freezing. Only
ingredients that are liquid can be added before the freezing, to make sure the mix
flows properly through the freezing equipment.
C. Heart Of The Process

FREEZING
Now the mixture must be frozen. It is pumped into continuous freezers that can
freeze up to 700 gal (2,650 1) per hour. The temperature inside the freezers is
kept at -40°F(-40°C), using liquid ammonia as a freezing agent. While the ice
cream is in the freezer, air is injected into it. When the mixture leaves the freezer,
it has the consistency of soft-serve ice cream.
D. Refining Process
Adding fruit and sweetened chunksFruits, swirls, and any bulky type of
flavorings (nuts, candy pieces, etc.) are added at this point. These ingredients can
not be added before freezing or they would interfere with the smooth flow of the
mix through the freezer. The ice cream at this point is soft and it is easy to mix in
the bulky flavorings so they are uniformly distributed throughout the ice cream.
Mixing in bulky flavorings after freezing also prevents damage to the pieces and
allows them to remain whole or in large chunks.
E. Packaging
Package
As desired, depending on the product.
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HARDENING
The ice cream is cooled as quickly as possible down to a holding temperature of
less than -13°F(-25°C). The temperatures and times of cooling will depend on the
type of storage freezer. Rapid cooling will promote quick freezing of water and
create small ice crystals. Storage at -13°F(-25°C) will help to stabilize the ice
crystals and maintain product quality. At this temperature there is still a small
portion of liquid water. If all the water present in the ice cream were frozen, the
ice cream would be as hard as an ice cube.
VI. PROCESS FLOWCHART
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CEREALS AND GRAINS
INTRODUCTION
A cereal, grain or cereal grain is a grass cultivated for edible components of
its grain, composed of endosperm, germ and bran. The word cereal is derived
from the word Ceres, the name of the Roman goddess of harvest and agriculture.
Cereal grains are grown in greater quantities and provide more food energy
worldwide than any other type of crop, they are therefore staple crops. Naturally,
cereals are rich source of vitamins, minerals, carbohydrates, fats, oils, and
proteins. However, when refined by the removal of the bran and germ, the
remaining endosperms is mostly carbohydrate and lacks the majority of other
nutrients. In some developing nations, grains in the form of rice, wheat and millet
constitutes a majority of the daily sustenance.
Cereal crops are interchangeably called grain crops. While there is a

whole grain which contains the endosperm germ and brain, pseudo cerealis not
partof the Poaceae botanical family, in which true grains belong, however they
are nutritionally similar and used in similar ways to true grains. The most
common pseudo-grains are buckwheat, amaranth and quinoa. Buckwheat is high
in protein, second only to oats, and rich in polyunsaturated fat. Amaranth is also
rich in protein and fat compared to other grains, with 77 percent of its fat content
being unsaturated. Quinoa is low-glycemic and contains all essential amino
acids. It also has a low fat content, most of which is polyunsaturated.
Breakfast cereals eaten plain or with milk are often cold cereals. These
cereals are ready to eat and usually made of corn, rice, or wheat rather than oats.
The grains are sometimes heavily processed to prepare them for packaging and
eventual consumption by the consumer. They are relatively shelf-stable,
lightweight, and convenient to ship and store. They are made primarily from corn,
wheat, oats, or rice, in about that order of the quantities produced, usually with
added flavor and fortifying ingredients. Hot breakfast cereals, on the other hand,
are made primarily from oats or wheat; those made from corn or rice is of minor
importance, being produced in relatively small quantities. The original hot cereals
required cooking in the home before they were ready for consumption, but now
some varieties are preprocessed so that they are ready for consumption with the
addition of either hot water or milk to the cereal in the bowl.
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Three Parts of Cereal

1. Endosperm
The endosperm is the starchy part of the grain, its energy source. This is
where the carbohydrates and most of the protein in the grain reside.
2. Germ
The germ is the grain's core, the seed that has the capability of sprouting
into a new plant. It contains antioxidants, more B vitamins, vitamin E, the
minerals zinc and magnesium, and some protein and fats.
3. Bran
The bran is the outer layer or shell, and its role is to protect the grain. It
contains fiber, B vitamins, and minerals.
Classification of Cereal Grains

A. Warm-Season Cereals
1. Millet
Millets are a group of highly variable small-seeded grasses, widely grown

around the world as cereal crops or grains for both human food and fodder.
Millets are important crops in the semi-arid tropics of Asia and Africa. The
most widely grown millet is pearl millet, which is an important crop in
India and parts of Africa. Finger millet, proso millet, and foxtail millet are
also important crop species. Millets are major food sources in arid and
semiarid regions of the world, and feature in the traditional cuisine of many
others. In western India, sorghum has been commonly used with millet
flour for hundreds of years to make the local staple, hand rolled flat bread.
2. Maize (Corn)
Maize known as corn is a large grain plant domesticated by indigenous
peoples in Mesoamerica in prehistoric times. The leafy stalk produces ears
which contain the grain, which are seeds called kernels. Maize kernels are
often used in cooking as a starch. Sugar-rich varieties called sweet corn are
usually grown for human consumption as kernels, while field corn varieties
are used for animal feed, various corn-based human food uses (including
grinding into cornmeal or masa, pressing into corn oil, and fermentation
and distillation into alcoholic beverages like bourbon whiskey), and as
chemical feedstock.
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B. Cold-Season Cereals
1. Rice
Rice is the seed of the monocot plants Oryza sativa (Asian rice). As
a cereal grain, it is the most widely consumed staple food for a large part of
the world's human population. Rice is normally grown as an annual plant,
although in tropical areas it can survive as a perennial. The varieties of rice
are typically classified as long, medium, and short grained. The grains of
long-grain rice (high in amylose) tend to remain intact after cooking;
medium-grain rice (high in amylopectin) becomes more sticky. Medium-
grain rice is used for sweet dishes, for risotto in Italy, and many rice dishes,
such as arros negre in Spain. Some varieties of long-grain rice that are high
in amylopectin, known as Thai Sticky rice, are usually steamed. A stickier
medium-grain rice is used for sushi; the stickiness allows rice to hold its
shape when molded. Short-grain rice is often used for rice pudding.
2. Oats
Oat is a species of cereal grain grown for its seed, which are suitable for
human consumption as oatmeal and rolled oats, one of the most common
uses is as livestock feed. Oats have numerous uses in foods; most
commonly, they are rolled or crushed into oatmeal, or ground into fine
oat flour. Oatmeal is chiefly eaten as porridge, but may also be used in a
variety of baked goods, such as oatcakes, oatmeal cookies, and oat bread.
Oats are also an ingredient in many cold cereals, in
particular muesli and granola. Historical attitudes towards oats have
varied. Oat bread was first manufactured in Britain, where the first oat
bread factory was established in 1899. In Scotland, they were, and still are,
held in high esteem, as a mainstay of the national diet.
3. Barley
Barley is a major cereal grain. It was one of the first cultivated grains
and is now grown widely. Barley grain is a staple in Tibetan cuisine and
was eaten widely by peasants in Medieval Europe. Barley has also been
used as animal fodder, as a source of fermentable material for beer and
certain distilled beverages, and as a component of various health foods. It
is used in soups and stews, and in barley bread of various cultures. Barley
grains are commonly made into malt in a traditional and ancient method of
preparation.
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4. Rye
Rye is a grass grown extensively as a grain, a cover crop and as a forage
crop. It is a member of the wheat tribe and is closely related
to barley and wheat. Rye grain is used for flour, rye bread, rye beer, crisp
bread, some whiskeys, some vodkas, and animal fodder. It can also be
eaten whole, either as boiled rye berries, or by being rolled, similar to rolled
oats. Rye is a cereal grain and should not be confused with ryegrass, which
is used for lawns, pasture, and hay for livestock. Rye is also used to
make crisp bread. Rye flour is high in gliadin but low in glutenin. It
therefore has a lower gluten content than wheat flour. It also contains a
higher proportion of soluble fiber.
5. Wheat
Wheat is a cereal grain which is the leading source of vegetable protein
in human food, having a higher protein content than other major cereals,
maize (corn) or rice. In terms of total production tonnages used for food, it
is currently second to rice as the main human food crop and ahead of
maize, after allowing for maize's more extensive use in animal feeds.
C. Pseudo Cereal Grains
1. Amaranth
Amaranth is a cosmopolitan genus of annual or short-lived perennial
plants. Some amaranth species are cultivated as leaf vegetables, cereals,
and ornamental plants. Amaranth seed flour has been evaluated as an
additive to wheat flour by food specialists.
2. Buckwheat
Buckwheat is a plant cultivated for its grain-like seeds, and also
used as a cover crop. Buckwheat is raised for grain where a short season
is available, either because it is used as a second crop in the season, or
because the climate is limiting. Buckwheat can be a reliable cover crop in
summer to fit a small slot of warm season for establishment. It establishes
quickly, which suppresses summer weeds. Buckwheat noodles play a
major role in the cuisines
of Japan (soba), Korea (naengmyeon, makguksu and memil guksu) and
the Valtellina region of Northern Italy (pizzoccheri). Soba noodles are the
subject of deep cultural importance in Japan. In Korea, guksu (noodles)
were widely made from buckwheat before it was replaced by wheat. The
difficulty of making noodles from flour with no gluten has resulted in a
traditional art developed around their manufacture by hand.
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3. Quinoa
A species of goosefoot, is a grain crop grown primarily for its
edible seeds. It is a pseudo cereal rather than a true cereal, as it is not a
member of the true grass family. As a chenopod, quinoa is closely related to
species such as beetroots, spinach and tumbleweeds. Protein content is
very high for a cereal/pseudo-cereal (14% by mass), but not as high as
most beans and legumes. The protein content per 100 calories is higher
than brown rice, potatoes, barley and millet, but is less than wild rice and
oats. Nutritional evaluations indicate that quinoa is a source of complete
protein.
Types of Cereals
Hot Cereals
It required cooking in the home before
they were ready for consumption.
Cold Cereals
These are cereals eaten plain or with
milk.
Whole-Grain Cereal
Whole-grain cereals feature whole
grains and very little or no added
sugars. Researchers at Columbia
University Medical Center have found
that oat-based whole grain cereals can
help reduce cholesterol and aid in
heart health.
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Bran Cereal
Bran cereals are high-fiber offerings
for your breakfast table. Fiber can
help keep you feeling full and aid in
digestion and regularity.
Sugary Cereal
Sugary cereals are often placed at a
child's eye level in the grocery store.
These cereals are often highly
processed and have loads of added
sugar and preservatives.
Organic Cereal
Cereals containing ingredients free of
pesticides and fertilizers. Organic food
also cannot be genetically engineered.
Most cereals use natural sweeteners
that are not overly-processed as well
as lots of whole grains.
HISTRORICAL BACKGROUND
1829 American clergyman Sylvester Graham used unsifted, coarsely
ground flour to invent the Graham cracker.
1860 Physician John Harvey Kellogg invented several grain-based
meat substitutes at the Battle Creek Sanitarium. Seventh-Day
Adventists, who also believed in vegetarianism, founded the
Western Health Reform Institute in Battle Creek, Michigan.
1863 The first ever breakfast cereal was Granola, invented in the
USA by James Caleb Jackson, a convinced vegetarian, who
was the operator of the Jackson Sanitorium in the state of New
York.
1876 Kellogg invented a food he called granola from wheat, oats, and
corn that had been mixed, baked, and coarsely ground.
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1894 Kellogg and his brother W. K. Kellogg invented the first

precooked flaked cereal. They cooked ground wheat into a
dough, then flattened it between metal rollers and scraped it off
with a knife.
1905 Both Will Keith Kellogg and C. W. Post, a patient at the
sanitarium, founded businesses to sell such products as health
foods. Their success led dozens of imitators to open factories in
Battle Creek.
20th Century Breakfast cereals have continued to increase in popularity.
MANUFACTURING COMPANY OF CEREALS IN THE PHILIPPINES

 Nestle Philippines
Cabuyao, Laguna
RAW MATERIALS
Maize( Yellow or White Corn) Major raw material.
Sugar(White Sugar) Gives sweet taste to cereal.
Other Food Additives (salt, yeast, Enhance the taste, quality and shelf
sweeteners, flavoring agents, life of cereals.
coloring agents, vitamins, minerals,
and preservatives)
MANUFACTURING PROCESS OF CEREALS (Corn Flakes)
Harvesting
As soon as the parent plants and their seed kernels are reasonably dry,
harvest can begin. In developed countries, cereal crops are universally machine-
harvested, typically using a combine harvester, which cuts, threshes,
and winnows the grain during a single pass across the field. In developing
countries, a variety of harvesting methods are in use, depending on the cost of
labor, from combines to hand tools such as the scythe or cradle. If a crop is
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harvested during wet weather, the grain may not dry adequately in the field to
prevent spoilage during its storage. In this case, the grain is sent to a dehydrating
facility, where artificial heat dries it.
Milling
The milling process removes the corn kernels from the cobs and turns them
into flaking sized grits. The first step in this process is to dry clean the corn,
separating fines and broken from the whole corn. Occasionally wet cleaning
follows to remove surface dirt, dust and other matter. The clean corn is tempered
to 20 percent moisture. While moist, the majority of the outer bran or pericarp,
germ, and tip cap are removed, leaving the endosperm. The bulk of the corn
endosperm proceeds through the degerminator, is dried, cooled, and sifted.
Cooking
The corn grits are cooked in steam pressure cookers, at temperatures
exceeding 100C. This cooking process lasts for an hour and softens the hard
grits. During cooking additional water is incorporated in the form of steam which
condenses and the water content in the batch rises to 30-35%.
Drying
Moisture is driven from the pellets by passing through a 6 section gas
powered dryer. Usually, drying is done at 66℃ until the moisture content reduces
to 20%.
Rolling
The corn kernels are crushed in a flake roller to dive them a nice flat shape.
Two rollers turned opposite to each other and the kernel falls in the constricted
space between them.
Extrusion/Flaking
Extrusion is a process which uses steam and water wherein the premixed
solids are fed into the process. They are partially heated almost to boiling
temperature using an additional preconditioning stage and precooked more or
less intensively, depending on the water content and selectable retention time.
Toasting
The flakes are then tumble toasted in huge cylindrical ovens. The air in the
ovens is heated by 600⁰C gas flames and the flakes are tossed around in a
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rotating drum. The drum is angled so that the flakes whirl around and pass
through it quite quickly, and stops them spending too long in the fierce heat. The
product is air-popped through a toasting process for few seconds at high
temperatures on vibrating floors. The toaster is divided in 2 stages: first stage the
product receives a hot air flow making the product expand; the second stage with
lower parameters is to get the product gilding.
Coating
Corn flakes are sprayed with vitamins in a rotating drum. This is done
through spraying with a series of gel. It can be chocolate on demand and also
sprayed with flavors, minerals to make them as nutritious as possible. Liquids
metering and solids proportioning units allow the application of fat- or- water-
based solutions in combination with spices.
Cooling
The flakes are cooled to stability. Browning, expansion degree, texture,
surface structure, true-ness of form, storage stability, flavor, and numerous other
characteristics are essentially controlled by thermal treatment. Cooling offers a
multitude of solution which must be carefully matched.
Packaging
Corn flakes are bagged up with the help of a bagging machine, which uses
rolls of polythene. Cereal packaging traditionally has been mostly a matter of
placing filled plastic bags inside cardboard boxes. This is partially because this
packaging is economical, partly because it prevents moisture from spoiling the
cereal, and partly because it provides broad, uninterrupted areas for colorful
graphics and advertising. There are, however, other forms of cereal packaging,
including vacuum-sealed containers, metal tins and plastic cups or bowls
designed also to be used as the serving dish.
SHELFLIFE AND EXPIRATION DATES
Expiration dates are a recommendation for unopened cans, jars, bottles, or

packages. Once opened, the date is no longer valid in most cases, and shelf life
has to be estimated from that point forward. To determine the shelf life of
products, there is usually a microbial activity test conducted over a specific time
frame. For instance, in baked goods with an expected shelf life of 7 days, you
would send 4 or 5 of the product to a lab. They would use one to measure the
Food Processing 418

initial microbial activity, and then perhaps 2 days later, they would measure
another one, etc. Generally companies have an acceptable threshold of microbial
activity, so the shelf life is set by how many days it takes the product to reach
that level. The shelf life of cereal depends on a variety of factors, such as
the best before date, the preparation method and how and where the product is
stored. If you try to break a flake of cereal and there is no crackling sound, then
the cereal has probably gone bad – or more specifically the cereal is stale and has
lost its crunch. It could still be used for baking, but not very tasty to eat. Proper
food storage is the key to extending the expiration date of food. You can help
cereal stay fresh by storing it in a cool, dry, and dark place. Once prepared,
cereals like oatmeal and cream of wheat that have been cooked should be stored
in the refrigerator in a tightly closed container to keep out moisture and other
contaminants. In general, food last only as long as the quickest expiring
ingredient in the dish that it is prepared. Although, once you pour that milk into
your cereal you basically have about 10 minutes to finish the bowl to enjoy the
cereal at its best. Unopened cereals last for 6-8 months while opened cereal, 4-6
months. However, when cooked, it is only safe for 4-5 days.
PROCESS FLOWCHART
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CONFECTIONERY
MANUFACTURING PROCESS OF CANDY
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HARD CANDY MAKING PLANT
I. Introduction
What is called a candy is a manufactured product formed out of

hardened thick syrup obtained by boiling down saccharide (sugar, fructose,
lactose, thick malt syrup or powdered malt) or a mixture of saccharide with
milk products, oils and fats, fruits, wheat flour, acidifying additives, spices,
etc. Lately, candy products have become more diversified with the appearance
of those using a special sweetener, which does not promote tooth decay, or
containing vegetable fibres.
The technology of candy making is based largely on the science and art
of manipulating sugar, the principal ingredient in candy, particularly to
achieve textural effects. This is accomplished primarily by controlling the state
of crystallization of the sugar.
Candies are confections. They have sweet taste, and so have an almost
universal appeal. They contain relatively large amounts of the sweetness of the
known sugars, namely sucrose. Sugar (sucrose) in confections may be
crystalline and if so the crystals may be large or small; or the sugar may be
non-crystalline, that is amorous or glass-like. Whether crystalline or not the
sugary structure may be hard or soft, softness being favoured by a higher level
of moisture, by air shipped into the sugary mass, and by modifying influences
of other ingredients.
In candy making, there is always the addition of doctors. Doctors are
chemicals added to sugar mixture to inhibit the graining of the saturated
sugar solution. There are two classes of doctors: 1) Chemicals that will
hydrolize a portion of sucrose to invert sugar s(e.g. cream of tartar and acetic
acid). 2) Substances that will directly slow down the rate of crystallization (e.g.
invert sugar, dextrose, and corn syrup).
II. Brief History

Between the 6th and 4th centuries BCE, the Persians, followed by the
Greeks, discovered the people in India and their "reeds that produce honey
without bees". They adopted and then spread sugar and sugarcane
agriculture. Sugarcane is indigenous to tropical South and Southeast Asia,
while the word sugar is derived from the Sanskrit word Sharkara. Pieces of
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sugar were produced by boiling sugarcane juice in ancient India and

consumed as Khanda, dubbed as the original candy.
Before sugar was readily available, candy was based on honey. Honey
was used in Ancient China, Middle East, Egypt, Greece and the Roman
Empire to coat fruits and flowers to preserve them or to create forms of candy.
Candy is still served in this form today, though now it is more typically seen as
a type of garnish.
Before the Industrial Revolution, candy was often considered a form of

medicine, either used to calm the digestive system or cool a sore throat. In the
Middle Ages candy appeared on the tables of only the wealthiest at first. At
that time it began as a combination of spices and sugar that was used as an
aid to digestive problems. Digestive problems were very common during this
time due to the constant consumption of food that was neither fresh nor well
balanced. Banquet hosts would typically serve these types of 'candies' at
banquets for their guests. One of these candies, sometimes referred to as a
'chamber spice', was made with cloves, ginger, aniseed, juniper berries,
almonds and pine kernels dipped in melted sugar.
The Middle English word candy began to be used in the late 13th
century.
The first candy came to America in the early 18th century from Britain
and France. Only a few of the early colonists were proficient in sugar work and
were able to provide the sugary treats for the very wealthy. Rock candy, made
from crystallized sugar, was the simplest form of candy, but even this basic
form of sugar was considered a luxury and was only attainable by the rich.
III. MANUFACTURING COMPANIES IN THE PHILIPPINES
UNIVERSAL ROBINA CORPORATION

The leading branded snackfoods and beverage company in the Philippines.
Plant Location: Pasig City
Brand Names: Maxx, Dynamite,
X.O., Jojo Gummies, Star Pops,
Lush, Wiggles
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COLUMBIA INTERNATIONAL
One of the top candy and confectionerymanufacturer
Location:Caloocan City
Brand Names:VFresh, Frutos, ICool,Monami, Frooty, Pochi, Vozz
NESTLE PHILIPPINES
Location:BDO Rockwell, Amorsolo Dr, Makati, 1200 KalakhangMaynila
Brand Names:Kitkat, Buteerfinger, Fox’s, Baby Ruth, Polo
IV. CLASSIFICATION OF CANDY

 HARD CANDIES
A simple combination of sucrose and corn syrup or sucrose alone
treated with an acid doctor such as cream of tartar (e.g.
Butterscotch, buttered almonds, sugar sticks)
 TOFFEES, CARAMELS, AND FUDGE
The raw material are subjected to a prolonged mixing in the
uncooked state before actual boiling (e.g. creamy toffee, slab toffee,
clear fruit caramels, vanilla fudge, fruit fudge, garden mint kisses).
 NOUGAT AND MARSMALLOWS
Made by the rapid beating to produce aeration and impart them
their characteristic white appearance (e.g. albumen nougat, nougat
wafers, schaum marshmallows).
 DRAGEES
There is the progressive deposition of sugar from a supersaturated
sugar solution upon the surface of the candy to be coated (e.g. silver
dragees, chocolate coated dragees).
 PASTILLES, GUMS, AND JELLIES
Principles are hydrolysis and oxidation to produce a product with
a characteristic texture achieved by the use of gelatin, agar, gum
Arabic and citrus pectin (e.g. lemon squash gums, blackcurrant
pastilles, tangerine jellies).
 CANDIED FRUITS
Principles are brining, syruping, and glazing fruits to produce a
sweetmeat product (e.g. pears, apricots, pineapples, cherries).]
 ROCK CANDY
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a type of confectionery mineral composed of relatively large

sugar crystals. This candy is formed by allowing a supersaturated
solution of sugar and water to crystallize onto a surface suitable for
crystal nucleation, such as a string, stick, or plain granulated sugar.
 GUMMY CANDY
Also called gummies, or jelly sweets are a broad category of
gelatin-based, chewy candies. Gummi candy is sometimes combined
with other forms of candy, such as marshmallow, chocolate, or sour
sugar.
 COTTON CANDY
Also called candy floss, or candyfloss is a form of spun sugar.
Made by heating sugar and spinning the liquefied sugar out through
tiny holes where it re-solidifies in minutely thin strands of "sugar
glass," the final cotton candy contains mostly air.
 LOLLIPOPS AND SUCKERS
- a type of confectionery consisting mainly of hardened,
flavored sucrose with corn syrup mounted on a stick and intended
for sucking or licking.
 WAX CANDY
It is common name of a candy product made of colored and
flavored wax.
 LICORICE
a confectionery flavoured with the extract of the roots of the
liquorice plant.
V. RAW MATERIALS
SUGAR
Sugar is the principal ingredient in candy, particularly to achieve textural
effects. This is accomplished by controlling the state of crystallization of the
sugar. There are different stages that sugar undergoes. This stage depends on the
degree of temperature at which the solution is heated. This will produce type of
candy that is to be produced. The fact that sugar solidifies into crystals is
extremely important in candy making. There are basically two categories of
candies - crystalline (candies which contain crystals in their finished form, such
as fudge and fondant), and noncrystalline, or amorphous (candies which do not
Food Processing 424
contain crystals, such as lollipops, taffy, and caramels). Sugars that can be used
for candy making includes sucrose, glucose, invert sugar, corn syrup and burnt
sugar.
WATER
This is used as the solvent for the dissolving process of sugar that will be
used for the further processing of candy.
ADDITIVES
COLORANT
This serves as the colouring agent for candy. This is merely used so that
the candy that will be produced is pleasing to the eye of the consumers. Also, this
additive will be able to let us know what the flavour of the candy is.
FLAVORING
The flavouring additive for candy has a wide variety. It can be from
eucalyptus down to the fruity flavouring. As from the word itself, it adds flavour
to the candy.
Butylated Hydroxytoluene (BHT)

A preservative and antioxidant used to retard rancidity in fats.
Carnauba Wax
A gum from the leaves of the Brazilian wax palm. Used as a glaze on candy
and gum as well as in polishes, varnishes and makeup.
Glycerol monostearate
An emulsifier (keeps water and oils mixed together).
Gums
Can come from Arabic, acacia, guar, locust bean, etc. Used to stabilize
emulations in candy coatings.
Gum Base
One of the main ingredients, between 15% and 30% in chewing gums.
Made from heating vegetable and synthetic ingredients (chicle, petroleum wax,
lanolin or rubber with a softener such as paraffin and antioxidants.
Magnesium stearate
A fat used to lubricant, binder, emulsifier and/or anti-caking agent. Used
in sugarless gums and mints, also as a release agent when creating pressed
candies.
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Modified starch
The basic ordinary starch, but this one has been modified by altering it
chemically, changing its thickening and jellying properties in order for it to be
used as a stabilizer in candy.
VI. MANUFACTURING PROCESSES AND EQUIPMENTS
DISSOLVING
Candy is made primarily from sugar and water. The desired quantity of
sugar and glucose are weighed into the kettle and dissolved to water at a
temperature of 180˚F (82˚C). Once the sugar and glucose is dissolved into the hot
water, the sugary water is pumped into the vacuum cooker.
Equipment:
SYRUP RESERVOIR
COOKING
The raw slurry (mixture of glucose, water and sugar) needs to go through
one more step to fully dissolve the crystalline sugar. This step is accomplished
using a cooker. Upon entering the cooker, the raw slurry flows through the
cooking oil. Here it is cooked under back-pressure to prevent it from boiling. The
sugar dissolves under this range of temperatures as shown in the sugar stages.
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Equipment:
CONTINUOUS VACUUM COOKER
Sugar stages
The final texture of candy depends on the sugar concentration. As the
syrup is heated, it boils, water evaporates, the sugar concentration increases, and
the boiling point rises. A given temperature corresponds to a particular sugar
concentration, and temperature is easier to measure than concentration, so
temperature is used as a marker for the necessary concentration. In general,
higher temperatures and greater sugar concentrations result in hard, brittle
candies, and lower temperatures result in softer candies. The stages of sugar
cooking are as follows:
Stage Temperature Sugar concentration

THREAD 110 to 112 °C
80%
(e.g., syrup) (230 to 234 °F)
SOFT BALL 112 to 116 °C
85%
(e.g., fudge) (234 to 241 °F)
FIRM BALL
118 to 120 °C
(e.g., soft caramel 87%
(244 to 248 °F)
candy)
HARD BALL 121 to 130 °C
90%
(e.g., nougat) (250 to 266 °F)
SOFT CRACK 132 to 143 °C
95%
(e.g., salt water taffy) (270 to 289 °F)
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HARD CRACK 146 to 154 °C

99%
(e.g., toffee) (295 to 309 °F)
CLEAR LIQUID 160 °C (320 °F) 100%
BROWN LIQUID
170 °C (338 °F) 100%
(e.g., liquid caramel)
BURNT SUGAR 177 °C (351 °F) 100%
The names come from the methods used to test the syrup before
thermometers became affordable. The "thread" stage is tested by cooling a little
syrup, and pulling it between the thumb and forefinger. When the correct stage is
reached, a thread will form. This stage is used for making syrups. For subsequent
stages, a small spoonful of syrup is dropped into cold water, and the
characteristics of the resulting lump are evaluated to determine the concentration
of the syrup. A smooth lump indicates "ball" stages, with the corresponding
hardness described. At the "soft crack" stage, the syrup forms threads that are
just pliable. At the "hard crack" stage, the threads are brittle. Once the syrup
reaches 171 °C (340 °F) or higher, the sucrose molecules break down into many
simpler sugars, creating an amber-coloured substance known as caramel. This
should not be confused with caramel candy, although it is the candy's main
flavouring.
COOLING
The processes that follow need the mixture, which is now rather hot, to be
cooled down. It is placed on the cooling table. They mixture experiences a
phenomenon named “Flash-Off”. Flash-Off is the rapid cooling of the slurry
combined with the loss of moisture from the slurry. After this Flash-Off, the
mixture is referred to as cooked and moves to the next stage of the process.
Equipment:
COOLING TABLE
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KNEADING
The next step in the process is to put the mass of candy through a series of
water cooled plows and formers in what are called a kneading machine. Various
additions and spices are mixed to give unique flavour from each manufacture.
This mixing required full kneading, which is given efficiently and in a short time
by this machine.Mixing not only thoroughly distributes flavour and colour but
reduces temperature and removes air bubbles produced from cooking and
mixing.
Equipment:
KNEADING MACHINE
MOLDING
The mixtures are then moved into the batch roller, which extrudes the
candy through cones and rolls it into a fat rope. Then, the batch is sent to the
sizing rollers, which reduces the rope to a smaller size and stretched to the
specified size. At this point, the candy rope is moved to the forming machine to
form it into the specified type of hard candy.
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Equipment:
MOULD FORMING MACHINE
COOLING
The conveyors then moved the formed candy to the cooling conveyor where
it is cooled for 6 to 15 minutes.
Equipment:
COOLING CONVEYOR BELT

SORTING
The candy now passes a belt inspector who checks candy for defects and
foreign material. This is not the final check that the candy may undergo but it is
a vital one.
WRAPPING
The sorted finished products are sent to the automatic wrapping machine
wherein each piece of candy is wrapped.
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Equipment:
CANDY WRAPPING MACHINE
WEIGHING
The candy travels across the Packaging area on overhead belts. At each
line, there is a brush. The brush can be raised and lowered (by pneumatics) as
needed to brush product from the overhead belt into the chute. This chute directs
the candy down unto the Vibrating Feeding Table, which spreads out and moves
the product to the Packaging Scale. The packaging scale is a radial feeding
bucket scale. The centre of the scale has a cone, which vibrates to spread the
candy to the radial feeder pans surrounding it. There are normally 14 radial pans
on a scale. Each radial feeder pan is controlled separately by the operator to
maximize efficiency. The radial feeder pans move the product into buckets, called
pool hoppers, which surrounds the scale. Beneath the pool hoppers are weigh
hoppers which have weigh cells to determine the weight of their contents. When
the weigh hopper is ready, it asks the pool hopper for product. The pool hopper
drops its contents to the weigh hopper. All the weigh hoppers then check to see if
some combination of their contents will combine to form a desired target weigh
(operator controlled).
Equipment:
WEIGHING SCALE
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PACKAGING
Finally, when the scale determines a combination of weigh hoppers, they
drop their contents to the Packaging machine below.The candy is heat sealed, all
commercially available hot or cold seal materials can be used including
polypropylene, cellophane, polythene-coated paper, and aluminum laminates and
sent to either a boxing operation or a bagging operation, depending on how they
are to be retailed and is now ready for shipping. The pool hoppers, once closed,
ask for more product from the radial feeder pans. The process is then repeated
with the weigh hoppers that dropped. The final product for the customer is
known as finished goods.
Equipment:
PACKING MACHINE FOR CANDIES
QUALITY CONTROL
There are two places for quality control—in the laboratory and on the floor
of the plant. The labs check the quality of all raw ingredients sent to the
manufacturing floor. They check the sugar quality and make sure they have what
was ordered. The chemists perform heat tests on the corn syrup, since poorly
processed syrup turns brown and can ruin the colour of the lollipop. The
laboratory also pulls samples of the candy batch from the cooker analyses the
moisture content, because higher sugar concentrations will make the candy too
malleable and it will melt in warmer weather. Flavours and colours are carefully
checked and tested, and measured precisely for inclusion in the batch.
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In the factory, operators ensure that the machinery is clean and running
properly. Some machines turn off the processes at certain temperatures or when
the batch reaches a certain weight, so these machine-tripping devices must be
carefully maintained as well.
VII. MANUFACTURING PROCESS FLOWCHART
HOT DOG
Introduction
Hot dogs are a processed meat product made by mixing chopped meat with
various curing ingredients, flavorants, and colorants. The meat is then stuffed in
casings, cooked, removed from the casing, and put in the final package. Although
the technology for hot dog making was developed thousands of years ago, these
meat products continue to be a popular summertime food.
The typical raw hot dog is a pink, cylindrical-shaped piece of meat. It is

about 1.6 oz (45.36 g) on average and contains anywhere from 0.175-0.245 oz (5-
7 g) of protein. It also contains about 0.455 oz (13 g) of fat, 450 mg of sodium and
150 calories. Since hot dogs are meat products, they are an excellent source of
nutrients including iron, zinc, niacin, riboflavin, and B vitamins. When hot dogs
are made using pork meat, they are good source of thiamin. Since they are a pre-
cooked food, they are less prone to spoilage than other types of meat products.
This makes them one of the safest meat products available.
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Brief History
The earliest record of a hot dog type product dates back to 1500 B.C. in
Babylonia. Sausages were mentioned in Homer's Odyssey written during the
ninth century B.C. These early forms of hot dogs were made by grinding up meat,
stuffing it in animal intestine and cooking it over a fire.
The exact origin of the product we call a hot dog is debated. Some claim
that it was first developed in Frankfurt, Germany, in 1484. Others claim that it
was developed in Vienna, Austria, and suggest that the term wiener reflects this
point. Still others suggest that it was not developed until the late 1600s when
Johann Georghehner (who was from Coburg, Germany) produced a sausage
product known as the dachshund sausage.
In 1852, a butchers' guild in Frankfurt produced a spiced, smoked sausage

product which they named frankfurter after their hometown. It was slightly
curved in shape and was often called the dachshund sausage. The product was
brought over to America by Charles Feltman and Antoine Feuchtwanger. Feltman
sold frankfurters and sauerkraut from a pushcart in New York's Coney Island. He
opened up the first Coney Island hot dog stand in 1871. Shortly thereafter, he
started selling the frankfurters with milk rolls, which were the precursors to hot
dog buns. The buns that we use today were probably first introduced in St. Louis
by Feuchtwanger in 1904. He was a sausage concessionaire who loaned white
gloves to his customers to hold the hot sausages. Since most of his customers did
not return his gloves he worked with a baker to develop a bun, which people
could use to hold their sausages.
In 1893, sausages became a popular food at baseball parks. They were first
introduced in the St. Louis Browns ballpark and then spread to the rest of
baseball. The term hot dog was coined in 1901 by a sports cartoonist named Tad
Dorgan. He was at the New York Polo Grounds, where he had heard some
vendors selling red hot dachshund sausages. This prompted him to draw a
cartoon of a real dachshund covered with mustard on a bun. Since he did not
know how to spell dachshund he wrote on the caption "get your hot dogs." The
cartoon was a hit and the name persisted.
Food Processing 434

MANUFACTURING COMPANIES IN THE PHILIPPINES
MEKENI FOOD CORPORATION

Location: Porac, Pampanga
The 1st ISO 22000 Certified Hotdog
and Marinated Meat Processing
Plant in the Philippines, First in
Asia and 2nd in the World
SAN MIGUEL PUREFOODS

COMPANY INC.
Location: Pasig City
Largest Filipino owned food
company
CDO FOODSPHERE, INC

Location: Paso de Blas,
Valenzuela City
Leading food manufacturing
company
RAW MATERIALS
MEAT
It is the primary ingredient in hot dogs.
While pork is most often used, other types
may be used such as beef, chicken or
turkey. Sometimes variety meats like livers
are used however, the hot dog producers
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must clearly label the product with the

statement "with
variety meats" or "with meat by-products." The proteins and fats of which meats
are composed are responsible for meat characteristics. For example myofibrillar
proteins give meat its texture and structure. Myoglobin and hemoglobin proteins
create the natural color of the meat. Fats in the meat give the characteristic
flavor.
SALT
It improves the taste and increase the shell
life. It is used in curing solution to make the
meat easier to work with, improve flavor, and
inhibit bacterial growth.
WATER
It helps create the necessary meat emulsion
and adding to the meat's juiciness.
SODIUM NITRITE
It retards the development of rancidity and

stabilize the meat color.
SODIUM ASCORBATE
Acts as a curing accelerators that preserve

the flavour of the meat during storage.
MANUFACTURING PROCESS
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GROUNDING
The production of hot dogs begins with the preparation of meat. After it passes
inspection, the incoming meat is cut into small pieces and placed in a stainless
steel mixing container. The container is equipped with high-speed choppers,
which can reduce the size of the meat pieces even further.
MIXING
The other raw materials including the curing ingredients (salt, sodium nitrite,
sodium ascorbate),flavorings and ice chips are blended in the steel mixing
container until a fine emulsion, or batter, is produced. More water is then added
to disperse the ingredients evenly and to make hot dogs juicy. This batter has a
smooth paste-like consistency, which makes further processing easier.
LINKING
After the batter passes quality control checks, it is pumped into an automatic
stuffer/linker machine. In this machine, batter is put into tube-shaped, cellulose
casings. These casing are then twisted at precise points to produce a long linked
strand of equally sized hot dogs. Most casing are removed later in the process
however, some manufacturers continue to use natural casings, which remain on
and are eaten along with the hot dog. This more traditional method of hot dog
making is done by smaller manufacturers and tends to cost more.
COOKING
The linked hot dog strands are then conveyed to a large smokehouse. Here, they
are thoroughly cooked under controlled conditions. The manufacturer has the
opportunity at this point to impart a different flavor on the hot dogs by using a
variety of smoke sources. The cooking times vary depending on the recipe
however, typically it takes about an hour.
CHILLING
Hot dogs are chilled by showering it with water to equalize the internal
temperature. When it is done, the hot dog links are moved via a conveyor to an
automatic peeler
PEELING
After passing through the smole and cook cycle, and being showered in cool
water, the hot dog goes into the peler. Here, the protective, air and smoke-
Food Processing 437

permeable cellulose casing “skin” is stripped away and individual links are
conveyed to the packaging line.
PACKAGING
From the peeler, the individual hot dogs are transported to the packaging
machinery. Here, they are lined up and placed on a plastic film. The films are
folded and vacuum-sealed to preserve the hot dog's flavor and increase shelf life.
Printed on the films are all of the graphics and required text needed for
marketing. The sealed packages are moved to a stamping machine, which prints
on a freshness date. They are next transported to boxing devices, put on pallets
and shipped in refrigerated trucks to local supermarkets. The entire process of
hot dog making from receiving the meat to boxing up the hot dog takes only a few
hours.
QUALITY CONTROL
Quality control is an extremely important factor in any food processing facility.
For health and safety reasons, the government regulates all of the raw materials
that are used in the hot dog making process. The meat in particular is heavily
regulated because the use of poor quality meat represents a significant health
risk. Most manufacturers use only high quality meats to assure that their hot
dogs are of similar quality. Upon receipt of the raw materials, they are checked
for things such as pH, % moisture, odor, taste, and appearance to ensure they
meet the previously set specifications. Additionally, the processing equipment is
sterilized and checked before any processing can begin. During manufacture, the
meat emulsion is continuously checked to assure that all the ingredients are put
in at proper proportions. Since hot dogs are eaten, steps must be taken to ensure
that they will have an appealing taste and be free from contamination. For this
reason, tests similar to the ones run on the initial raw materials are performed on
the final product.
Microbial Examination of Meat

Microorganisms play an important role in the quality of meat before, during, and
after processing, by initiating undesirable biological changes in the meat. In
addition, the age of the animal, ration content, method of slaughter, chilling of
the carcasses, storage conditions of the meat and the sanitary conditions after
slaughter materiallt influence the quality of the end product.
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Microbial Examination of Equipment

Equipment sanitation tests are applicable to surfaces of all types of equipment
coming in contact with food. The swab-contact technique may be applied to large
or small areas on flat or curved surfaces.
Hazard Analysis Critical Control Point (HACCP)

It is the current preventive system for Food Safety mandated and implemented in
food manufacturing companies in the United States, Europe and various
exporting Asian countries, including Philippines.
KETCHUP
A. INTRODUCTION
Ketchup, or catsup, is a table sauce. It is a sweet

and tangy sauce, typically made from tomatoes, a
sweetener, vinegar, and assorted seasonings and spices.
The sweetener is most commonly sugar or high fructose
corn syrup. Seasonings vary by recipe, but commonly
include onions, all spice, cloves, cinnamon, garlic, and
sometimes celery.
Tomato ketchup is often used as a condiment.

Ketchup is sometimes used as a basis or ingredient for
other sauces and dressings. It is also used as a flavoring for some things.
B. HISTORY AND BACKGROUND
The word ketchup is derived from the Chinese ke-tsiap, a pickled fish sauce. It
made its way to Malaysia, where it became kechapand and ketjap in Indonesia.
In 1711, it is said to be from Malay’s kichap, but probably not original to Malay.
Ketchup might have come from Chinese koechiap "brine of fish," which, perhaps is from
the Chinese community in northern Vietnam.
Originally a fish sauce, the word came to be used in English for a wide variety of
spiced gravies and sauces. Tomato ketchup emerged in the year 1800 in U.S. and
predominated from early 20th century.
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In seventeenth century, English sailors first discovered the delights of this

Chinese condiment and brought it west. Ketchup was first mentioned in print around
1690.
The Chinese version is actually more similar to a soy or Worcestershire sauce. It

gradually went through various changes, particularly with the addition of tomatoes in
the 1700s. By the nineteenth century, ketchup was also known as tomato soy.
Early tomato versions were much thinner with a consistency more like a soy or
Worcestershire sauce.
F. & J. Heinz Company began selling tomato ketchup in 1876. By the end of the
nineteenth century, tomato ketchup was the primary type of ketchup in the United
States, and the descriptor of tomato was gradually dropped.
C. MANUFACTURING COMPANY OF KETCHUP IN THE PHILIPPINES
NutriAsia
Plant Location: Cabuyao, Laguna
Products: UFC Banana Catsup, Jufran Banana Catsup, Papa Banana Catsup, etc.
Distributor of (in the Philippines): Heinz Tomato Ketchup
D. RAW MATERIALS
The main ingredients of ketchup are tomatoes,

sweeteners, vinegar, salt, spices, flavorings, onion, and/or
garlic. The types of sweetener used are usually granulated
cane sugar or beet sugar. Other sweeteners include dextrose or
liquid sugar in the form of corn or glucose syrup. The white vinegar, commonly 100-grain
Food Processing 440

distilled, helps to preserve the ketchup. The spices commonly used to enhance the flavor
of the tomatoes are allspice, cassia, cinnamon, cayenne, cloves, pepper, ginger, mustard,
and paprika. Some manufacturers believe that whole spices produce a superior, milder
flavor than ground spices or spice oils. More modern processes use premixed or
encapsulated spices, which are easier to use but more expensive.
E. MANUFACTURING PROCESS
I. Developing quality tomatoes
Ketchup manufacturers must seek out the best quality tomatoes for their product.
Tomato varieties are developed which are superior in color, flavor, texture, and yield.
Consistency is an important factor, as slight variations in tomato characteristics could
alter the flavor and color of the finished product.
II. Harvesting and Preparing tomatoes
Tomatoes are harvested mechanically between June and July. The fruit is
commonly conveyed by water from the trucks into a flume, or an inclined channel. The
water method washes the tomatoes and protects them from bruising while they pass
from the truck to the factory. The tomatoes are sorted, washed, and chopped. Next,
precooking, or scaling, in stainless steel vats preserves the tomatoes and destroys
bacteria.
Equipment used:
Mechanical Harvester
III. Pulping
The chopped and precooked tomatoes (often times, tomato paste are used) are
pumped into pulping machines, or cyclones, which separate seeds, skins, and stems
from the pulp. The pulp and juice are filtered through screens and processed further into
ketchup, though some may be stored in a paste for use later in the year.
Food Processing 441

Equipment used:
Pulping Machine
IV. Mixing and Cooking
The pulp is pumped into cooking tanks or kettles and heated to boiling. Foaming
may occur if fresh tomato pulp is used, but can be corrected with anti-foaming
compounds or compressed air. Precise amounts of sweeteners, vinegar, salt, spices, and
flavorings are added to the tomato pulp. Most spices are added early in the cooking
process. To avoid excessive evaporation, volatile spice oils and vinegar must be mixed in
later. Onions and garlic can be mixed in with the spices, placed in a separate bag, or
chopped and added to the pulp. Salt and sugar may be added at any stage of cooking
though it is better to add sugar later to prevent burning. The mixture cooks for 30-45
minutes and is circulated by rotating blades installed in the cookers. The temperature
must be carefully regulated to insure absorption of the ingredients without overcooking,
which creates a flat body.
Equipment used:
Pasteurizer/ Mixing Tank
V. Finishing
Once the cooking is complete, the ketchup mixture passes through a finishing
machine. Finishers remove excess fiber and particles through screens, creating a
smoother consistency. The ketchup passes to a holding tank before further processing.
The ketchup may be milled at higher temperatures and pressures to achieve a smoother
consistency.
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Equipment used:
Storage Tank
VI. De-aeration
The ketchup must be de-aerated to prevent discoloration and growth of bacteria.

Excess air might also create unattractive air pockets and impede the closure process.
Equipment used:
Vacuum Deaerator
VII. Filling
To prevent contamination, the ketchup passes from the receiving tanks to the
filling machines at a temperature not lower than 190°F (88°C). The containers are filled
with the ketchup and immediately sealed to retain the freshness of the product. Ketchup
containers come in various sizes and shapes, including 14-oz. bottles, No. 10 cans,
pouch packs, room-service sizes, and single-serve packets.
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Equipment used:
Receiving Tank
VIII. Cooling
The containers must be cooled to prevent flavor loss through stack burning, which
occurs when ketchup stays at high temperatures after cooking is complete. Containers of
ketchup may be cooled in cold air or cold water.
Equipment used:
Cooking Vessel
IX. Labeling and Packing
The ketchup containers are labeled and coded with product information, including
ingredients, date and location of manufacture, and shelf-life. The bottled ketchup may be
inspected again before shipping. The entire process of ketchup manufacturing generally
takes two to three hours.
Food Processing 444

Equipment used:
Wine Bottle Filling Machine
F. SEVEN STEPS IN DETERMING THE SHELF LIFE OF A PRODUCT
Shelf life studies are conducted on various types of products to determine the length
of time the product will retain certain qualities including acceptablemicrobial counts,
taste, appearance, vitamin levels, and odor. They are typically performed as customer
requirements. The shelf life study will determine the “Best By Date” for your product.
1. Identify what may cause the food to spoil

o Product: raw materials, formulation, water activity, pH, oxygen availability,
preservatives
o Process: Processing activities, packaging, storage conditions
2. Decide which tests to use
o Sensory: odor, appearance, flavor texture
o Microbiological: spoilage and pathogenic organisms
o Chemical: pH, free fatty acids, headspace analysis, etc.
o Physical: product abuse storage and handling
3. Plan the shelf-life requirements
o What tests need to be done
o How long will the studies be run
o How many samples for each test, for each study
o What are the storage conditions
o When will the study be run
4. Run the Shelf Life study
o At time intervals established in step 3
o Run the appropriate tests in step 2
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5. Determine the shelf life

o Eventually a point is reached when the product no longer meets
requirements for quality or safety, which is the shelf life
o Usually a pre determined point is established to end the study if quality
and safety are not affected
6. Establish working shelf life
o Working shelf life will be less than actual shelf life due to real world factors
such as storage conditions and potential product abuse
7. Once product is released to the market -> Monitor Shelf Life
o Investigate any customer complaints or failures
o Evaluate samples from production and distribution to validate study
results
The duration of a shelf life study is dependent on the individual product. Client
may have an anticipated or desired shelf life. Shelf life studies cannot be open ended, but
they can be extended or shortened based on the results.
G. EQUIPMENT LAYOUT
Food Processing 446

KIMCHI
Definition of Kimchi
Kimchi, also spelled kimchee or gimchi, is a traditional fermented Korean

side dish made of vegetables with a variety of seasonings. It is often described as
spicy and sour. In traditional preparation kimchi is often allowed to ferment
underground in jars for months.
It is Korea's national dish, with hundreds of varieties made from napa
cabbage, radish, scallion, or cucumber as a main ingredient. Kimchi also has
many different kinds depending on the main ingredients.
History of Kimchi
The Three Kingdoms Period (57 B.C.E. – 668 C.E.)

The Chinese history book Sanguozhi (Records of the Three Kingdoms),
written in the 3rd century C.E., says the following, “The people of Koguryeo are
very good at making fermented foods such as wine, soybean paste, and chotkal
(salted and fermented fish).” The early kimchis were a lot different than they are
now. There was no red pepper (as no one had gone to the Americas to retrieve it),
and cabbage was not used often. Early kimchis were mainly radishes dipped in
paste or salted in brine
Koryeo Period (918-1392)

During this period, more vegetables were being brought in, including pine
mushrooms, large radishes, and the famous Chinese cabbage. The first known
written record about kimchi itself was in the middle of the Koryeo Dynasty. Poet
Lee Kyu-bo wrote the following: Preserved in soybean paste, kimchi tastes good in
the summer. Whereas kimchi pickled in brine is served as a good side dish
during the winter. When the root of the Chinese cabbage grows larger in the
ground, it tastes like a pear, especially after the first frost in the autumn harvest
season. The types of vegetables used in kimchi diversified during the Koryeo
Dynasty. Cucumbers, wild leeks, Indian mustard leaf, and bamboo shoots found
their way into kimchi pots. The “juicy” style of kimchis also came into being. This
is also the time that garlic and spices were introduced.
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The Joseon Dynasty (1392-1910) and Outside Influence

Kimchi diversified more during Korea’s longest and most stable dynasty.
Salt was no longer the sole preservative. Kimchis were also being preserved in soy
sauce.
The average king’s table would have baechu kimchi (white cabbage kimchi,
similar to sauerkraut), water kimchi, and Ggakdugi (tiny cubed radish kimchi). It
was around this time that chile peppers were introduced into kimchi.
Japan’s Toyotomi Hideyoshi attempted a few failed invasions of Korea from
1592-1598. It is at this time, I believe, that both Japan and Korea went through
major culinary changes.
Korea, at the time, was closed off to the world except China. It had little to
do with Japan and absolutely nothing to do with European traders. Yet Japan
had been doing trade with the Portuguese. The Portuguese introduced foods from
the Americas, including potatoes, sweet potatoes, corn, and chile peppers.
The Japanese didn’t take too well to the chile peppers, but they did like the
sweet potatoes. Some special varieties of sweet potato are sold as souvenirs in
Japan today.
Despite the horrors of the Hideyoshi invasions, including Hideyoshi
bringing home his own souvenirs of 38,000 Korean ears (and I don’t mean corn),
some major cultural exchanges took place.
The Japanese took home methods for making celadon pottery, ideas about
Buddhism, and art.
By 1827, there were 92 different types of kimchi. Today there are over 200.
Kinds of Kimchi
Baechu Kimchi
Baechu kimchi s made by fermenting brined Korean cabbage with Korean radish,
vegetables, salt-fermented seafood, ground red pepper and various seasonings.
White Kimchi (Baekkimchi)

This is the kimchi that proves wrong the assumption that they’re all red and
spicy. As baekkimchi doesn’t use a single red pepper flake, it’s palatable for kids,
the elderly, patients with stomach problems, and even grouchy foreign
barbarians. While baekkimchi may be the wallflower at the kimchi party, it’s
chock full of vitamins and is good for taking down a stubborn cold.
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Green Onion Kimchi (pa gimchi)

Long, slender green onions (not the bulbous yellow variety) are the basis for this
kimchi variant, most frequently prepared down south in Jeolla and Gyeongsang.
Aside from the great taste, the green onions here can rid fish of toxins, aid
stomach function, and restore energy. Snack on this one with a bowl of
makgeolli.
Geotjeori
While the majority of kimchi is left to rot, er, ferment for months and possibly
years, geotjeori is a notable exception as it can be eaten right away. It’s briefly
dipped in salt and sometimes drizzled with soy sauce instead. Diners who prefer
a milder, fresher kimchi will enjoy this unfermented but still flavorful dish.
Radish Cube Kimchi (kkakdugi)

Unlike its tamer cousin danmuji (pickled yellow radish), kkakdugi is one radical
radish. It’s prepared by cubing a radish and then pickling it with the standard
combination of kimchi preservatives. If you find kkakdugi tough to snag with
chopsticks, just use a spoon. It’s sharp flavor makes it a great pairing with
comparatively bland dishes like seolleongtang and kalguksu.
Young Radish Kimchi (Yeolmukimchi)

The radishes used in yeolmukimchi are much smaller than those that go into
other kimchi dishes, which puts the focus on the stem rather than the vegetable
itself. The radishes are dunked into a flour porridge with red pepper flakes, garlic,
and other ingredients and then put in the fridge to pickle. The chilled but spicy
broth is a favorite in the summer months.
Nabak Kimchi
Nabak kimchi gets its name from the Korean expression nabaknabak, which
means dicing up vegetables very fine. This refers to the radish and Chinese
cabbage which are cut into thin squares and soaked in a water bath with a bit of
chili powder thrown in to spice things up. This one is generally eaten in the
spring and summer, whereas a similarly soupy kimchi called dongchimi is served
up in the winter, minus the spice.
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Chive Kimchi (buchu kimchi)

Chives go into this classic Gyeongsang Province kimchi. Unlike other varieties,
buchu kimchi should be eaten before it gets sour, as too much fermentation will
ruin the flavor. Since it’s easy to make, this is a good choice for budding kimchi
cooks to start out with.
Philippine Manufacturing Company of Kimchi

Kimchi Best
Located at 2311 Royal Plaza Remedios St. Malate, Manila, Philippines
Production of Baechu Kimchi By Lactic Acid Fermentation
Raw Materials
Raw Material Structure Function
Contains the
bacteria
lactobacillus for
lactic acid
Napa Cabbage fermentation
Preserves the
napa cabbage and
acts as a yeast in
the fermentation
of napa cabbage
Salt
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Red, pepper, The ingredients

salted shrimp, needed to make
garlic, ginger, the kimchi sauce.
green onion, Adds flavour to
turni, fish sauce the kimchi
Process of Making Kimchi Sauce
1. Size Reduction
First the Garlic, Ginger, and Ginger are minced into bits. The turnip
should be cut into 2 inch long. The Salted Shrimp should also be minced
into bits. We need 6 tablespoons garlic, ½ tablespoon ginger, 6-10 finely
chopped green onion, ¼ of the cut turnip, 1 ½ cups red pepper, 3
tablespoons sugar and 3 tablespoons fish sauce in making a fish sauce in
one napa cabbage.
2. Mixing
The minced salted shrimp, 6 tablespoons garlic, ½ tablespoon ginger,
6-10 finely chopped green onion, ¼ of the cut turnip, 1 ½ cups red pepper,
3 tablespoons sugar and 3 tablespoons fish sauce are now mixed in a bowl.
Manufacturing Process of Baechu Kimchi
A. Preparation of Raw Materials

1. Washing
The cabbages should be washed in three different washing tab. Each
cabbage should be washed and some part that are not suitable for
kimchi making will be thrown away.
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Three-Tab Washer
B. Conditioning of Raw Materials

1. Pickling
Pickling is the process of of preserving food by anaerobic
fermentation in brine or vinegar. The resulting food is called a pickle.
This procedure gives the food a salty or sour taste. The next step is to
put the napa cabbage into a vessel with brine solution in it. The solution
should have the ratio of water to sea salt used is 5:1. Let the napa
cabbage stay for 12-16 hours. In this process, the fermentation of napa
cabbage begins. Different sets of bacteria are active depending on the
temperature of the process. That is, there will be a different mix at
household temperature than in the fridge. If you leave Kimchi out too
long, the vegetables will lose their crunch and get mushy. Traditionally,
Kimchi is made out on the porch or buried in the earth, where the
temperature is about 50 F degrees. If you use traditional Kimchi spices,
with lots of garlic, your Kimchi will really smell up the house if your
container isn’t closed. The Korean Kimchi pots aren’t closed really, so
they usually make it out on the porch, and it is pungent.
Fermentation Vessel
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Chemical Reaction:
C6H12O6 → 2 CH3CHOHCOOH
C. Heart of the Process

1. Mixing
After pickling napa cabbage, we set is aside to put sauce into it. We
delicately put sauce in the capa cabbage because if it would crack, the
napa cabbage would mold when in the process of fermentation.
D. Refining
1. Packaging
The kimchi should be packaged in an air-tight polyethylene bottle. It
must be stored in a cool environment.
Polyethylene Containers
Food Processing 453

FISH PROCESSING: CANNED SARDINES
I. Introduction
Fish refers to cold blooded vertebrate animals living in water. They provide
a very good balance of nutrients and have a low calorie, low fat edge that is
naturally light compared with other protein-rich foods. There are more than
20,000 different species of fish in the world, but less than 200 of them are
commercial significant like the commonly used sardines. Fish can be processed
in a very careful and clean manner. The processing technology includes different
processes and techniques employed in the post-harvest handling, processing and
marketing of aquatic products from the time of harvesting to the final utilization.
Sardines are small, silvery, elongated fishes with a single short dorsal fin,
no lateral line, and no scales on the head. They range in length from about 15 to
30 cm (6 to 12 inches) and live in dense schools, migrating along the coast and
feeding on plankton, of which they consume vast quantities. They spawn mainly
in spring, with the eggs and, a few days later, the larvae drifting passively until
they metamorphose into free-swimming fish.
Sardines of any species are commercially fished for a variety of uses: for
bait; for fresh fish markets; for drying, salting, or smoking; and for reduction
into fish meal or oil. The most important catching apparatus is an encircling net,
particularly the variety known as the purse seine. Many other modifications of
encircling nets are used, including traps or weirs, the latter being stationary
enclosures composed of stakes into which schools of sardines are diverted as they
swim along the coast. The fish are caught mainly at night, when they rise to the
surface to feed on plankton. After catching, the fish are submerged in brine while
they are transported to shore. Sardines are canned in many different ways. At the
cannery the fish are washed, their heads are removed, and the fish are cooked,
either by deep-frying or by steam-cooking, after which they are dried.
In Spain, Portugal, and many other countries the fish are then packed in
either olive or soybean oil, while in Scandinavian countries they may alternatively
be smoked. They may also be packed in a tomato or mustard sauce.
The chief use of sardines is for human consumption, but fish meal made
from sardines is used as animal feed, while sardine oil has many uses, including
the manufacture of paint, varnish, linoleum, and, in Europe, margarine.
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II. History of Canned Sardines

The canning process dates back to the late 18th century in France when
the Emperor Napoleon Bonaparte, concerned about keeping his armies fed,
offered a cash prize to whoever could develop a reliable method of food
preservation. Extremely popular in the United States in the 20th century,
sardines are now making a comeback as people realize that they are an incredibly
rich source of omega-3 fatty acids and vitamin D and that, because they are
small fish at the bottom of the food chain, they are not as likely to contain
concentrated amounts of contaminants such as mercury and PCBs. Nicholas
Appert conceived the idea of preserving food in bottles, like wine. After 15 years of
experimentation, he realized if food is sufficiently heated and sealed in an airtight
container, it will not spoil.
An Englishman, Peter Durand, took the process one step farther and
developed a method of sealing food into unbreakable tin containers, which was
perfected by Bryan Dorkin and John Hall, who set up the first commercial
canning factory in England in 1813. As more and more of the world was explored,
and as provisioning armies took on greater importance, the demand for canned
foods grew. Thomas Kensett, who immigrated to the United States, established
the first U.S. canning facility for oysters, meats, fruits and vegetables in New York
in 1812. More than 50 years later, Louis Pasteur provided the explanation for
canning's effectiveness when he was able to demonstrate that the growth of
microorganisms is the cause of food spoilage.
Canned sardines were, for a while in the middle of the 1800s, an exotic and
high status food, with their very own serving dish and a role at the table during
the soup course. Sardines were among some of the earliest canned foods
produced in America, and they were also imported from France, and carried an
exotic aura. Besides they were a bit pricey. As a result, a homemaker was proud
to present them at table, and in the later 1860s, silver and glass makers created
little baskets or dishes that actually held an opened sardine can for formal
presentation on a properly set table. Additionally, silver forks and tongs, even
named “sardine forks” appeared during the last quarter of the 19th century.
Recipes for the elegant presentation of sardine salads, sardine sandwiches fit for
ladies luncheons, and of course, simple sardines as a side dish crop up in
cookbooks from 1870 through the early 1900s. Sardines had a proletarian side as
well. They were offered at saloons as a snack.
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III. Raw Materials

Sardine Fish
Sardines of any species are commercially fished for a

variety of uses; any of certain food fishes of the herring
family, Clupeidae, especially members of the genera
Sardina,Sardinops, and Sardinella.
Tomato Sauce
Tomato sauce should be made from sound raw
materials without any decomposition by mould, yeast
or bacteria. The canned tomato sauce should not
contain microbes which can develop at a normal
storage temperature. The color should be red, even
with a faint tinge of yellow, but never brownish. Odor
and taste should be pure and natural. The tomato
sauce should be heterogeneous and not contain too
much seeds or skin.
Salt
Salt used for making brine or other purposes should be
pure and not contain appreciable quantities of
magnesium chloride, a common contaminant of
unrefined salt.
IV. MANUFACTURING PROCESS:

A. Descaling
EQUIPMENT FUNCTION MECHANISM
Equipped with Fish will

rotating drum with submerge in
internal helicoids a brine tank
that facilitates the to remove the
forward of the fish. scales.
Descaling Machine
Food Processing 456

B. Sorting
The fish then move to conveyor for size sorting.
Used to sort sardine Segregate the fish into four

and sardine-like fish different grades, with
into regular sizes. thicknesses ranging from
between 5 mm and 33 mm.
The fish pass; tail first,
down inclined oscillating
Grading Machine tracks which are separated
by gradually widening gaps.
C. Nobbing
The fish can be cut The pre-sorted fish

in two different are then place in a
ways: removal of conveyor belt where a
head only or nobbing machine
removal of head and automatically cuts
Nobbing Machine
tail. the fish head and tail.
D. Fish Filling
The cut fish are then filled into cans. These cans are sterilized at 85
degrees centigrade.
Food Processing 457

E. Pre-Cooking

Flash Cooker
The flash cooker is used for After the can had
pre-cooking and drying of been filled it will pass
sardines before exhausting on flash cooker for
and closing the cans. pre-cooking at 85
degrees centigrade.
F. De-Watering
Separate the pre-cooked The pre-cooked

sardines from remaining cans will move on
water in slurry and decanter for de-
therefore plays an watering.
important role in food
processing industries.
Decanter
G. Sauce-Filling
Use to fill sauce and The cans passed

other ingredients to on the sauce filling
cans. tank where tomato
sauce and pre-mix
ingredients are
poured into the
cans.
Sauce-Filling Tank
Food Processing 458

H. Sealing
Cans are sealed with a maximum of 300 cans per minute per line.
I. Retort Sterilization
Sterilize all types of
Autoclave conserved foods in The filled cans place in
sealed cans, with a busie basket for
temperature and sterilization. The busie
pressure control. basket are then push
Steam sterilization inside the retort for
with water spray sterilization with a
heads with over- preset temperature of
pressure. 117 degrees Centigrade.
J. Labeling and Packaging

Each can is carefully labeled and ready for selling.
CORNED BEEF
Introduction
Meat processing, preparation

of meat for human consumption.Meat is
the common term used to describe the
edible portion of animal tissues and any
processed or manufactured products
prepared from these tissues. Meats are
often classified by the type of animal from
which they are taken. Red meatrefers to the meat taken from mammals, white
meat refers to the meat taken from fowl, seafoodrefers to the meat taken from fish
Food Processing 459

and shellfish, and game refers to meat taken from animals that are not commonly
domesticated. In addition, most commonly consumed meats are specifically
identified by the live animal from which they come. Beef refers to the meat from
cattle, veal from calves, pork from hogs, lamb from young sheep,
and mutton from sheep older than two years. It is with these latter types of red
meat that this section is concerned.
Brief History
The industrial production of beef is believed to have started in the British
Industrial Revolution. The product was also traded to the French for use in
Caribbean sugar plantations as sustenance for the colonists and the slave
laborers.
Corned beef and cabbage, Minnesota
In the United States and Canada, consumption of
corned beef is often associated with Saint Patrick's Day.
Corned beef is not considered an Irish national dish, and
the connection with Saint Patrick's Day specifically
originates as part of Irish-American culture, and is often
part of their celebrations in North America.
Corned beef was used as a substitute for bacon by
Irish-American immigrants in the late 19th century. Corned beef and cabbage is
the Irish-American variant of the Irish dish of bacon and cabbage.
In the United Kingdom, corned beef refers to the variety made from finely
minced corned beef in a small amount of gelatin (bully beef; from the French
bouilli "boiled"), and is sold in distinctive, oblong cans, just as in the United
States and Canada, or in slices from supermarkets.
It is a widely known staple among Filipinos most especially in urban areas.
Due to US influence and possibly a product of surplus trade during and after
occupation, corned beef is considered as a favorite complement to rice at any time
of the day most especially during breakfast. As such, being a perennial
commodity among Filipino groceries and homes due also to its affordability, it has
also become an offshoot of tapsilog, a popular modern Filipino dish, being coined
as cornsilog from corned of the original name and suffix -silog which is a
portmanteau of sinangag (a type of garlic fried rice) and itlog or egg in Tagalog.
Nowadays, corned beef in the form of cornsilog is served (particularly during
breakfast hours) even in fast food chains and other restaurants across the
Philippines such as in Jollibee, Chowking and McDonald's.
Food Processing 460

Raw Materials
A. Salt
Table salt is one of the most common preservative used in meat
preservation. The addition of salt in the form of brine allows the process of
osmosis to take place. Osmosis is the tendency of liquids to move across a semi-
permeable barrier from areas of low salt concentration to high. Once the liquid
has exited the beef, it would form a highly concentrated brine by dissolve the salt
on the beef's surface. Doing this draws water out of the microorganisms,
preventing their growth and it also slows down oxidation process thus
preventing the beef from going rancid.
The texture of the meat processed depends on the concentration of the
brine solution. High concentration is desired since the salt weakens muscle fiber
making the meat tender and at the same time dehydration makes it denser.
B. Sugar
Refined sugar cane is preferably used compared to brown sugar since
brown sugar caramelizes at a lower temperature and leads to the darkening of the
meat on cooking. The sugar counter acts the astringent quality of the salt,
enhances the flavor of the product and aids in lowering the pH of the cure. It also
contributes to the growth of beneficial bacteria such as Lactobacillus, by feeding
them.
C. Nitrates and Nitrites
“Saltpeter, also known as nitrate of potash or chemically known as
Potassium nitrate is responsible for the development of proper color in cured
meat. Salt-friendly bacteria will transform nitrates into nitrites. These nitrites
then not only destroy the very bacteria that created them, they also that provide
flavor advantages to meat. The function of saltpeter is that it serves as a powerful
antioxidant. It also prevents the growth of clostridium. These days synthesized
nitrites is more widely used than saltpeter because it is hard to control potassium
nitrates conversion to nitrite. It is believed that one of the by - products of this
reaction is a cancer producing substance called nitrosamines.
We all know that meat turns from red to brown as the main muscle
pigment myoglobin oxidizes and turns into metmyoglobin, a reaction catalyzed by
free iron atoms in the meat. Well when nitrites react with meat, they form nitric
oxide, which in turn bonds with the iron, thus preventing the reaction that
transforms myoglobin into metmyoglobin, allowing beef (or ham) to retain its deep
Food Processing 461

pink color, even when fully cooked, like in the photo below, taken by our very
own dbcurrie for her blog cookistry.
D. Ascorbic acid/ Ascorbate/ Erythorbate
They speed up the curing reaction, preserves the meat’s original color thus
giving the product a longer shelf life.
E. Phosphates
Phosphates are dissolved in the water first since they do not easily dissolve
in a brine solution. They increase the water holding and binding capacity of the
meat which also in turn increases the product yield.
F. Vinegar
It has some antiseptic value which prolongs the shelf- life of the product.
The advisable acid content must only be between 4.5% - 5%.
G. Spices
These are “aromatic vegetable substances” used for seasoning of food which
consist of leaves, flowers buds and other rhizomes which has been dried and
grinded before addition.
H. Binders, Fillers, Emulsifiers
These improves the characteristics such as texture, appearance and
plumpness.
Binder is the one that holds the meat particles and moisture together
during processing.
Fillers are not soluble nor do they have any water soluble proteins.
They serve as fillers added for additional weight. Examples are cereals.
Emulsifieers contains water soluble proteins to improve the volume
and texture of the product.
I. Coloring agent
It may be natural or synthetic. Example is anatto (achuete).
Processing
Technical Processes:
Unit
Function Machine Mechanism
Operation
Beef precooking is
A. Beef pre
Cooking line. done in acooking
cooking
line.
To reduce machine used to
B. Shredding the size of force meat or meat
the meet in trimmings by
Food Processing 462

small means of a feeding

desirable worm (auger)
process. under pressure
through a
horizontally
mounted cylinder
(barrel)
Bowl cutter
Addition of Injects the brine

C. Curing brine solution to the
solution meat.
Brine injector
Mixers are used to
blend meat and
spices, or coarse
and finely chopped
meat. The machine
generally consists
of a rectangular or
Addition of round bottom
D. Mixing,
additives vessel through
tumbling
and spices which two parallel
shafts operate (Fig.
51). Various
paddles are
mounted on those
Mixer/ blender shafts to mix the
meat.
Food Processing 463

To achieve a
E. Addition of juicy soft
liquid or texture for
jelly the final
product.
The corned beef is

placed in a
F. Canning
sterilized with the
juicy liquid.
Canning Machine
Food Processing 464

Fruit Yoghurt Manufacturing Process

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Fruit Yoghurt Manufacturing Process

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Pamantasan ng Lungsod ng Maynila

College of Engineering and Technology

Yoghurt is a milk product obtained by the fermentation of milk by the

II. Types of Yoghurt

Drinking Yoghurt (Yoghurt Drink)

III. Brief History

Food Processing 380

IV. MANUFACTURING COMPANIES IN THE PHILIPPINES

AB PASCUAL FOODS INC.

HACIENDA MACALAUAN INC.

Food Processing 381

Streptococcus thermophilus is an essential

Lactobacillus delbrueckii Subsp.

 FRUCTOSE & SUCROSE

Common Fruits Used in Yoghurt Production

Food Processing 382

VI. MANUFACTURING PROCESS

FRUIT FLAVORING PREPARATION

Food Processing 383

The raw milk is pumped through the plate heat

Food Processing 384

Food Processing 385

HEAT SEALING COLUMN

Food Processing 386

production process. Before the production of yogurt, manufacturers conduct a

Food Processing 387

MANUFACTURING PROCESS FLOWCHART

Food Processing 388

DIFFERENT TYPES OF FRUIT JUICES

 Aguamiel Aguamiel is the sweet juice or sap

Apple Juice Apple Juice is the juice extracted from

Food Processing 389

cider, apples are pressed to extract

Bug Juice Bug Juice is a beverage. Exactly what

Cranberry Juice Cranberry Juice is a bright red fruit

Grape Juice Grape Juice can be red or white. To

Lemon Juice Lemons are primarily used for their

Food Processing 390

Nectar Nectar is a marketing term that came

Food Processing 391

frozen concentrate or as a powder.

Tomato Juice To make Tomato Juice, tomatoes are

Manufacturing Companies of Fruit Juices in the Philippines

Zest-O Corporation is one of the largest beverage companies in

Food Processing 392

2. Green Choice Selection Inc.

Greenchoice Selections, Inc. X It is started by a group of health-conscious

3. Dole Philippines Inc.,

Food Processing 393

4. Profood International Corporation

Profood International Corporation is the largest Philippine-based dried mango

MANUFACTURING PROCESS OF APPLE JUICE

Food Processing 394

Food Processing 395

Fruit are then spray washed and

To prepare them for juicing, a disintegrator,

Extraction may be accomplished through

1. The hydraulic cider press is one of the

Food Processing 396

2. The bladder press is an effective batch system. The Willmes Pressor is a

3. Continuous screw presses can be used successfully with slippery apple

Food Processing 397