GROUP 10

Magat, Roderick Jr.

Padilla, Ely France, E.
Pantaleon, Stephen, D.

Food and Beverage Processing

When wandering the grocery store aisles, it’s easy to forget that for every colorful package that
sits on the shelves, a myriad of processes go into preparing the foods inside. Whether it’s
cereal, breakfast pastries, cookies or canned peaches, everything must be either steamed,
dehydrated, pulverized, pasteurized or otherwise treated to fit into the cans, boxes and
cellophane packages.

STANDARDS
Because safety is involved, many regulations and standards are in place around the world. Yet
there are few specific guidelines and none that are accepted worldwide to manage the quality
and purity of the steam that comes into direct contact with the food or processing that food. In
the U.S., there are basically three mentions in current regulations: Accepted Practices for a
Method of Producing Culinary Steam, the FDA Code of Federal Regulations and a National
Organic Standards Board review.

GRADES OF STEAM
Several grades of steam are used in food processing and each has its own level of
contamination risk. Each also presents its own challenges for the equipment in process control.

 PLANT STEAM
Industrial or plant steam is the lowest grade of steam. It is the starting point for all steam used in
food and beverage processing, but it’s the steam that doesn’t come into direct contract with the
food or drink product. In other words, it’s used in heat exchangers or used for hot water
generation, in boiling pans and other areas. Softened water, reverse osmosis-treated or de-
alkalized water is generally used for plant steam.

 FILTERED OR CULINARY STEAM

The next level of steam is filtered or culinary steam. Culinary steam is used in applications used
to sanitize the processing system. These are called “Clean in Place” (CIP) procedures, and they
are employed to ensure the proper level of hygiene in pipes, valves, fittings and related
components in the food processing systems themselves.
  CLEAN STEAM
The highest grade of steam is clean steam, and it is typically raised from purified water in a
dedicated clean steam generator. This is the area in which the foods or beverages are in direct
contact with the steam. To create clean steam, a secondary generator with a controlled feed
water system is used. Clean steam requires the use of stainless-steel pipework and
components that eliminate the potential for corrosion of steam traps, valves and pipeline
equipment.

Methods, Processes, And Equipment in Processing Food and Beverages

The food and beverage processing sector covers a wide range of products. Many process
steps are common to the manufacture activities of different products. Food and beverage
processing plants vary in size and location, and are ideally located in close proximity to fresh
water resources. Plant operation is often seasonal reflecting the harvesting of the raw materials,
however product lines are unaffected by seasonal variations and take place throughout the year.
Product processing
Food and beverages can be processed as a single operation or in a combination of several
operations. The most common processing methods are through heat application and heat
removal. The heat application methods include blanching, pasteurization, heat sterilization,
evaporation, and dehydration including heat processing by baking or cooking in oils. Heat removal
processing includes chilling, controlled or modified storage and packaging (to reduce the rate of
respiration), freezing, and freeze-drying. Other preservation and processing methods include the
use of sodium chloride and sugar, food additives, and irradiation.
Heat application processes

 Blanching- is a cooking process wherein a food, usually a vegetable or fruit, is scalded in

boiling water, removed after a brief, timed interval, and finally plunged into iced water or placed
under cold running water (shocking or refreshing) to halt the cooking process. Blanching foods
will help reduce quality loss over time.
 Pasteurization- is the process of heat processing a liquid or a food to kill pathogenic bacteria
to make the food safe to eat. The use of pasteurization to kill pathogenic bacteria has helped
reduce the transmission of diseases, such as typhoid fever, tuberculosis, scarlet fever, polio,
and dysentery.
 Heat sterilization
Dry heat sterilization process is accomplished by conduction; that is where heat is absorbed
by the exterior surface of an item and then passed inward to the next layer. Eventually, the
entire item reaches the proper temperature needed to achieve sterilization.
Moist heat sterilization describes sterilization techniques that utilize hot air that is heavily
laden with water vapor and where this moisture plays the most important role in the
sterilization.
 Evaporation- is the partial removal of water from liquid food by boiling. For instance, liquid
products can be concentrated from 5% dry solids to 72%, or even higher, depending on the
viscosity of the concentrates. Evaporation is used to pre-concentrate food, to increase the
 solid content of food, to change the colour of food and to reduce the water content of a liquid
product almost completely, e.g. as in edible oil drying.
 Dehydration- In food processing , means by which many types of food can be preserved for
indefinite periods by extracting the moisture, thereby inhibiting the growth of microorganisms.
Dehydration is one of the oldest methods of food preservation and was used by prehistoric
peoples in sun-drying seeds.
 Distillation-is the process of separating the components or substances from a liquid mixture
by selective boiling and condensation.

Heat removal proceseses

 Chilling- refers to the rapid cooling of a food product from its manufacturing temperature
down to refrigerated or cold temperatures, usually from 2 to 4°C.
 Controlled or modified storage and packaging (to reduce the rate of respiration)-
Modified Atmosphere Packaging is an optimal blend of pure oxygen, carbon dioxide and
nitrogen within a high barrier or permeable package. A finely adjusted and carefully
controlled gas blend is developed to meet the specific respiration needs for each
packaged food product.

 Freezing- In the food industry , freezing usually refers to deep freezing, or lowering the
temperature of product below -18°C.
 Freeze-drying- also known as lyophilisation or cryodesiccation , is a low temperature
dehydration process which involves freezing the product, lowering pressure, then
removing the ice by sublimation . This is in contrast to dehydration by most conventional
methods that evaporate water using heat.

Other preservation and processing methods include the use of preservatives, food
additives, irradiation etc.
Food coloring - added to food to replace colors lost during preparation, or to make food look
more attractive. May be natural or artificial, the latter are much cheaper to use. Unfortunately,
artificial food colorings, such as Yellow 5 have been linked to behavioral problems in children.
Some food colorings approved for use in the US have been banned in Europe and Japan.
Flavors - natural and artificial - while natural sounds healthier, this may not always be the case
(see poison mushrooms). Flavors are added to foods to enhance their aroma and entice you to
buy them and then eat them.
Humectants - prevent foods from drying up. Glycerine is an example.
Preservatives - prevent food from spoiling due to mold, bacteria and other microorganisms.
Three natural preservatives are salt , sugar , and vinegar . But there are many more artificial
preservatives in use today, such as nitrates and nitrites found in meats. Home baked bread
goes stale after 36 hours, and starts to develop mold within 4 days, but a loaf from the
supermarket will keep for more than a week due to propionates which prevent mold.
Food irradiation is the process of exposing food and food packaging to ionizing radiation .
Ionizing radiation, such as from gamma rays, x-rays or electron beams, is energy that can be
transmitted without direct contact to the source of the energy (radiation ) capable of freeing
electrons from their atomic bonds (ionization) in the targeted food.
Equipment
 Detector*
A  Dicer
 Accumulation Table  Dryer*
 Agitator  Dumper
 Aspirator  Dust Collector*

B E
 Bin  Encruster
 Blancher  Evaporator*
 Blender*  Expeller
 Blower  Extractor
 Boiler*  Extructor*
 Box Taper  Extruder
 Bucket Elevator
F
C  Feeder*
 Can Closer  Fermenter
 Cap Sorter  Filler*
 Capper  Filling Line
 Carbo Cooler  Filter*
 Cartoner  Flaker
 Case Sealer & Gluer  Freezer
 Case Taper  Fryer
 Caser
 Centrifuge* G
 Chiller  Generator
 Chocolate Equipment  Grinder*
 Chopper
 CIP System H
 Coater  Heat Exchanger*
 Coating Pan  Homogenizer
 Compressor*  Hopper
 Conveyor*
 Cooker K
 Cooler  Kettle*
 Cooling Tower
 Corker
 Counter L
 Crimper  Labeler*
 Cutter  Lab Equipment
 Lidder
 Liquifier
D
 De-Duster
 Depositor M
 Destemmer  Metal Detector
  Mill*  Sheeter
 Mixer*  Silo
 Slicer
O  Stainless Steel Tank
 Oven  Stuffer

P T
 Pasteurizer  Table*
 Peeler  Tank*
 Press*  Tenderizer
 Printer  Tunnel
 Pulper
 Pump* U
 Unloader
R  Unscrambler
 Refrigeration
 Ribbon Mixer V
 Roaster  Valve
 Votator
S
 Scale* W
 Screen  Washer
 Screw Press  Water Treatment
 Seasoner  Winery Equipment
 Seasoning Drum  Wrapper*

RISK
The Food & Beverage Industry is one of the most dynamic industries around. Just as in the world of
fashion, the food sector too experiences constant

evolution. The changing industrial climate makes this industry particularly challenging for
manufacturers, suppliers and retailers alike.

Risks are aplenty and managers need to ready themselves and their teams to withstand the force of this
change. Having a comprehensive risk management system in place will enable manufacturers to
recognize risks and counter them effectively. It is important for companies to build physical and
intellectual capabilities that can protect them from the risks associated with a dynamic market.

The Food & Beverage Industry faces multiple risks, such as:

 Changes in consumer tastes

 Changes in national and regional
 statutory regulations
 Evolving demographic trends
 Compromised quality of ingredients and materials
 Contamination and poisoning of ingredients and end products
 Development of incorrect product design
 Unnecessary and unhealthy practices and processes in place
 Mismatch in technological capabilities and market requirements
 Manhandling of product and materials and resulting damage
 Financial risks associated with various processes and practices
 Third party risks related to transport agencies, middlemen, financiers, retailers and so on
 Risks associated with sharing intellectual property
 Risks associated with product information misrepresentation
 Consumer safety risks
 Loss mitigation risks and inability to manage risk