Chapter 5

Food Processing and Technology

Food processing has become an increasingly important component of the food

industry. There are many reasons due to which the farm produce does not get fully
utilized which leads to wastage. Moreover, farmers may not get a good price due to
excess produce.
Food processing is the answer to such problems, where fruits and vegetables are
processed into various products that can be preserved for a long time. This would
not only help to use the surplus and avoid wastage but would also help the farmer
to get a good price in the off season.
Moreover, with increasing urbanisation and ever increasing population, there is an
increasing demand for ready to eat manufactured foods or preserved foods which
can be dehydrated, canned, pickled and frozen for both domestic and foreign
markets.
Learning objectives
After learning this chapter students will be able to:
 define ‘ Food Science, Food Processing’ and ‘Food Technology’ and
‘Food manufacturing’
 explain the significance of food processing and technology;
 trace the history of food processing and technology processing
 identify the causes of spoilage of food;
 list the basic principles of food preservation
 identify the desirable skills of a food technologist
 Recognise the career avenues and for self and wage employment
opportunities in this field.
 FOOD SCIENCE
It is the science of studying nature of foods and the changes that occur
in them naturally and also during handling and processing.

( FOR EXAMPLE food science of tomatoes

 perishable food has high water content ,
 PH is acidic
 tomato has lycopene pigment, which does not dissolve in water .
 lycopene can be extracted at high heat hence color intensifies
when blanched .)

FOOD PROCESSING Fig 5.2)

Food processing is the first level of manufacturing where food passes
through number of processes. For example -Turning Raw tomatoes into
tomato paste –
Washing , blanching- cooling packing – selling in packs.
It is the set of methods and techniques used to transform raw ingredients
into finished and semi-finished products ( refer to fig )
PROCESSING includes variety of operations by which raw food
stuffs are made suitable for consumption , cooking, storage. It also
includes adding ingredients to food to extend shelf life

FOR EXAMPLE
Making potato chips from Raw potatoes-
Washing - Peeling – Cutting – Blanching –Drying – Frying De- oiling-
Seasoning –Packing ( fig 5.1)

Processing of potatoes into potato chips

 Washing and Cutting
peeling

Frying Dewater Blanching

z Seasoning Packing
deoiling
FOOD PRESERVATION

Concerned with prevention of food spoilage and prolong shelf life of food
It involves preserving processed or unprocessed raw material for future
use.
( for example make tomato pickle ) (Fig 5.2)
FOOD MANUFACTURING
Food manufacturing is the second level of manufacturing after food
processing .
It is the mass production of food products using principles of food technology
to meet the diverse needs of consumers.
Food manufacturing is the process of transforming edible raw materials into
shelf stable products that are more user friendly and ready for
consumption.
. Examples of manufactured foods are canned rajmah , frozen peas , sliced
pineapple, ready to fry cutlets, samosas, etc.
Food manufacturing is one of the largest manufacturing industries
(Using tomato paste for salsa sauce, tomato soup , tomato juice, tomato
powder , tomato chips .etc )
 Food Technology is a science which deals with the techniques and principles
involved in processing and preserving the food substances.
Food technology is the application of technology to retrieve, store ,
manufacture, preserve and transport food for human consumption.
It is the process of developing new products :
 First the need is identified, like new flavour of chips,
 Market research- gap analysis( what consumer wants vs what is
available flavours , consumer perception )
 Plan made to develop new product – understand the manufacturing
process , try new recipes and processes ,
 Product disassembly –understanding the raw material for making new
product
 Sensory evaluation – tasting done by trained panel of food evaluators
 Quality assurance – check nutritional component of product
 Packaging and labelling – appropriate licencing and packaging material
as per the laws .
 Product evaluation /market testing – improving the product on basis of
feedback if required.( refer to pic ---)

.
Food technology develops skills for
 Selection
 Storage
 Preservation
 Processing
 Packaging
 Distribution of safe Wholesome and nutritious foods
 Afforadable and Convenient foods
 Saving and utilising all the produce .

Significance of food processing and technology

The main aims and purposes of food processing are to :
1. maintain quality of foods ( sensory quality and nutritional quality)
2. improve the shelf life of foods ( Increase in shelf stable products).
3. make foods consumer friendly (especially for working women ,
- cost effective , convenient to use, shelf stable , safe and
nutritive )
4. Increase variety in the diet :Due to globalisation , there is an
increase awareness and demand for fortified foods ;wheat flour
( folic acid) oils and fats ( Vitamin A ) , salt ( Iron and Iodine),
etc. Also change in lifestyle has increased the demand for
 alternation in foods with decreased calories, decreased
saturated fat, no trans fatty acids, reduced cholesterol, reduced
salt, reduced sugar, artificial sweeteners , increased dietary
fiber, no pesticides, no artificial colours, etc.
5. Prevent wastage and utilize excess agricultural and
horticultural produce. (Several Mega food processing parks
have been set up in various states by government of India to
improve the infrastructure for storage, transportation and
processing capacity. )
6. Rural employment and value addition of agricultural produce.
Agro processing links agricultural production to the industry(
market) which are two vital pillars of the economy. It creates
employment opportunities as farmers also get value addition
for their produce . For example, normally potatoes for which a
farmer gets 5 to 10 rupees a kilo , when processed into chips would
fetch Rs 400 to 600 per kilo .
All this has increased the importance of food processing and
technology as a discipline and there is a huge demand for food
technologists.

Development of Food Processing and Technology

Food Processing& food preservation methods

used in Prehistoric Times

• Sun drying
• Controlled Fermentation
• Salting
• pickling,
• candying,
• roasting,
• smoking,
• baking and
• using spices as preservatives.
 In 1810, Hermetic bottling Technique

 Nicolas Appert developed

 Peter Durand Canning

In 1864,  Pasteurization of
 milk.( the process of
 Luis Pasteur treating milk at high and
low temperatures, to
destroy disease producing
organisms.)
 Pasteurization of vinegar,
wine, alcohol
 Souring of milk

World War II, In 20th century growth of food processing and technology
( because of exploration of space and the
rising consumer society)

• Mid 20th century • rise in food processing,

 convenience foods/ready to use food
frozen foods, (instant soup mixes)

• freeze drying ( food frozen , ice

changes directly to vapours- sublimes
- under vacuum)
Freeze dried noodles • juices concentrates,
• artificial sweeteners
• colouring agents
• preservatives

21st century Rise in demand for processed foods

Production of foods suitable for

health
 Prehistoric Middle New methods
 Pickling & Bottling
 Canning

Drying,  Antimicrobial preservatives  Irradiation

Salting,  Antioxidants  vacuum seal
packing .
Pickling,  Refrigeration
 Spray drying
Smoking,  Freezing  freeze drying
Sugaring,  blast chilling
Preservatives  High pressure
food
preservation (
HPP)( food
packed and sealed
subjected to high
pressure )

FOOD SPOILAGE / FOOD DETERIORATION

When a food undergoes some unwanted chemical changes which makes the
food unhealthy for human consumption it is termed as spoiled food or
deteriorated food and the process is called food deterioration.
Signs of food spoilage / food deterioration

Food deterioration is associated with spoilage, development of off-flavors,

deterioration of textures, discoloration and loss of nutritional value in varying
degrees, reducing aesthetic appeal and rendering it unfit/unsafe for
consumption. ( refer table --)

Appearanc Flavour/ deteriorati discoloration Change in Loss of

e/ spoilage developmen on of Consisten nutritiona
t of off- texture s cy l value
flavors
reduced ▪ off Discolourati thin sauce loss of
aesthetic flavour ferment on nutrition
appeal ▪ foul decay Browning al value
moisture smell soggy
loss- limp ▪ Stale slimy
wrinkled ▪ Rancid(oi
shrink ls )
▪ Rotten
▪ taste bad
▪
A number of factors can lead to food spoilage/ deterioration

1. Pests and infestation by insects.

2. Inappropriate temperatures used for processing and/or storage
3. Excessive exposure to light and other radiations
4. Excessive use of chemicals(pesticides)
5. Excessive drying/ loss of moisture
6. Oxygen( oxidation )
7. Moisture ( humidity )
8. micro organisms [bacteria, fungus and moulds)
9. enzymes

Reasons of food spoilage

the above factors of food spoilage can be classified as three types of spoilage/
deterioration.

1.Physical,
2.Chemical
3 Biological

physical chemical biological

a)Infestation by a)Food enzymes Growth and activities of
pests & insects  Browning/ microorganisms,
infestation oxidation  Bacteria
 b) damages  ripening  yeasts
▪ C)Loss of  moulds
moisture
▪ D) oxygen
/moisture

1. PHYSICAL : Exposure of food to some external factors like pests , physical damage
, exposure to air , moisture and temperature can cause food spoilage.
a) Damage by pests and insect infestation : Foods often get spoilt due to
insects and pests; sign of which are visible by holes, powder , hair ,
droppings ,etc.
b) Mechanical /Physical damages such as bruising of food tissues may occur
due to improper handling while plucking, transporting, drying, preserving,
etc. Food may also get spoiled when handled excessively.
c) Moisture
▪ Gain of Moisture : One of the major undesirable physical changes in food
powders is caking due to absorption of moisture from the atmosphere.
▪ Loss of moisture :After harvesting, due to loss of moisture, skin of the fruits
and vegetables shrink in size and become limp.

CHEMICAL SPOILAGE :It can be caused by enzymic spoilage , enzymic

browning or over ripening .

Enzymic spoilage
A special class of proteins molecules , called enzymes are chemicals which are
present in all food . They act as biological catalysts to accelerate chemical
reactions.
Action of enzymes start after death of animals or plants . They start
decomposition process called enzymic spoilage .

Enzymic Browning due to oxidation

Enzymes cause browning in certain foods the moment they are exposed to air.
When a fruit is cut or bruised, the exposed surface gets discoloured and turn
brownish due to the activity of enzymes(called enzymic browning) This leads to
destruction of vitamin C, Thiamine and Carotene, and reduces the shelf life .

ii) Ripening due to enzymes :

Enzymes are involved in the process that causes ripening in fruits and vegetables.
After harvesting of fruits , enzymes continue ripening process
which leads to rotting as can be observed in bananas. Its skin colour
changes to dark brown and after a while may no longer be fit to be
consumed.Fig --
3.BIOLOGICAL
The main micro-organisms responsible for the contamination of food are bacteria,
moulds and yeasts. These micro-organisms are invisible and can be seen under a
microscope. They are capable of multiplying very rapidly in the correct moisture,
food and temperature conditions. These conditions must be avoided if the risk of
food spoilage is to be reduced.
Factors affecting growth of Micro-organisms/ biological spoilage flow chart

1. Nutrient availability
2. Moisture
3. PH
4. Temperature
5. Availability of oxygen
6. Presence or absence of inhibiting substance

1. Nutrient availability: all microorganisms need food to grow

Bacteria Mould Yeast

Bacteria prefer protein Mould grow on variety of Yeast spoilage occurs in
rich food. For example- foods, particularly meat, syrups, fruits, fruits juices
meat fish poultry, eggs cheese, fruit and bread. and jam
and diary products.
These are known as HIGH
RISK FOODS.

2.Moisture availability - All microorganisms require some level of water.

High level of humidity promote microbial growth Perishable food with high
water content .
. Perishable foods spoil faster as they have higher level of moisture than semi
perishable and non perishable foods .

Perishable food Semi Perishable food Non Perishable food

FOOD HAS HIGH MEDIUM MOISTURE NEGLIGIBLE MOISTURE
MOISTURE CONTENT CONTENT.
Lasts for 1- 2 days Lasts for 1-2 weeks Lasts for one year( in dry
storage )
 Examples Examples- Examples

milk, potato Wheat

curd, ,onion pulses,

fish, ginger, jaggery,

meat, garlic, nuts

green leafy vegetables citrus fruits, oil

etc.
apple rice .

eggs . spices

3.PH LEVEL .
Most bacteria grow at low acid or near neutral pH level. Yeast and mold thrive
on high acid foods .

Bacteria Mould Yeast

grow at near neutral pH level and low Grow on high acid foods
acid foods.
4.Temperature
Temperature is an important factor for microbial growth. Lower temperature inhibits
microbial growth . Bacteria can grow on wide range of temperatures bacteria-
between 50 to 600 C . This temperature range is referred as danger zone.
 5.Availability of Oxygen – Aerobic micro-organisms require oxygen for their
growth whereas Anaerobic micro-organisms can grow in absence of oxygen
.yeast can grow without the presence of oxygen

 6 .Presence or absence of inhibiting substance-

Microbial growth can be reduced by

Increasing microbial inhibiting substances present naturally in
turmeric,neem, garlic etc or commercially available preservatives
 reducing access to oxygen by adding another chemical like vinegar and oil
in pickles .
 Reducing moisture eg,.dehydration /sundrying like in papads
 By adding sugar and salt that locks up the water molecules and reduce its
availability for microbes as in case of jams for example Niprosin (produced by
the lactic acid ) is a natural food preservative as it inhibits certain strains
of the food pathogen, such as Clostridium botulinum, Staphylococcus
aureus, etc .

Ways to prevent Food spoilage /Principles of Food Preservation

 Ways to prevent Examples of preservation methods
spoilage
Application of heat blanching ,
(use of high temperature cooking,
pasteurization,
canning
Lowering temperature Refrigeration (run at 4.7 -7°C.)
during storage (inhibits Freezing 0oF or -18oC colder
the growth of Chilling (temperature between –1°C and
microorganisms ) 8°C.
AIR FREEZING –

Removal of water/ High concentration of salt /sugar

moisture sun drying
dehydration
freeze drying
spray drying
Reduction of pH Addition of acids – acetic acid ( vinegar)
Citric acid( lemon)
sodium benzoate

Controlling oxygen nitrogen packing cryogenic freezing

/carbon dioxide controlled atmosphere
vacuum packing to keep out oxygen
modified-atmosphere packaging

CLASSIFICATION OF FOOD ON THE BASIS OF EXTENT AND TYPES OF

FOOD PROCESSING
Processed foods can be classified into three groups according to the
extent and purpose of the processing used in their production.

These are classified on the basis of nutrients lost

Minimally Processed Ultra processed

processed foods

20 % nutrient loss 50 – 60% nutrient More than 60%

loss nutrient loss

contains no added Contains 2 to 3 Contains 5 added

ingredients , no salt ingredients ingredients

Examples
Carrot Carrot juice Carrot cake

Wheat Wheat flour Biscuits

Corn Canned corn Corn chips

Apple Apple juice Apple pie

1)Unprocessed and minimally processed foods.

Minimally processed foods are whole foods in which

most of the nutrients are intact . The food is in it near
natural state as they contain no added ingredients.
 This stage of processing is done to ensure good quality
food is fresh, suitable to store and safe to consume.
These foods may be minimally altered by removing inedible
parts ( cleaning, trimming, shelling ) cutting, drying
,roasting, pasteurizing and packing , chilling, freezing etc
.

They include frozen fruits and vegetables, pasteurised milk,

unsalted peanuts , bottled water , spices and dried herbs.

2)Processed foods

This processing changes the nature of the original foods and

makes the food more complex .

They are made by adding two or three ingredients such as salt, oil,
sugar , enzymes , additives and other substances.

This includes physical and also chemical processes such as pressure,

milling, refining, hydrogenation and hydrolysis, etc. to make culinary
ingredients .vegetable oils, wheat flour, pastes , cream, canned vegetables
in syrup, juices ,etc .

3)Ultra-processed food products:

Ultra high processed foods have many( five ) added ingredients.

Such as sugars, salt, fats, additives ( flavors ,artificial color &
stabilizers )and chemical preservatives.
Ultra high processed foods are mostly made from substances
extracted from foods.
Processes include salting, sugaring, baking, frying and also use
preservatives, additives, synthetic vitamins / minerals.
Examples are cold cuts, cakes , pastries ,biscuits ,salty snacks , cookies, ice-
creams soft drinks , etc
It is important to check the label for the following information
 It is important to be aware of different types of processed foods available in
the market

a) Preserved foods - in For example frozen peas ,

this the character of food dried tomatoes , dehydrated
does not change . The vegetables , etc
purpose is to keep the food
edible and prolong its shelf
life

Manufactured foods: the original Examples :

characteristics of raw product are
lost. jams, marmalades
,squashes, pickles, papads,
Various ingredients such as salt, sugar, wadis, etc.
oil , chemical preservatives, enzymes are
added .

a. Food derivatives these are derived from Examples :

naturally occurring foods .
b. In industry, constituents of foods may be Sugar from sugarcane
obtained from the raw product through wheat flour from wheat
purification oil from oil seeds
c. In some cases, the derivative may be processed Conversion of oil to vanaspati
further. ghee ( by hydrogenation )

d. Formulated foods : Products Examples :

that are prepared by mixing
and processing exact ratio e.
of ingredients to produce f. Infant foods like cerelac , stevia, protein bars,
foods that are shelf-stable . ice cream, kulfi and bakery products like
bread, cakes, biscuits etc

Functional foods are natural or Oatmilk ,

processed foods that contain Almond milk for protein
biologically active compounds and Probiotics help in improving gut
are clinically proven to benefit health
health spinach cracker for iron
Functional food have specific role - they deficiency
help in preventing nutrition related
.
diseases and also improve health .
Is this picture correct for medicinal
foods ?
 Medical foods are also functional foods ▪ Low sodium salt for
hypertension
Medical foods are foods that are ▪ Artificial sweetner for
specially formulated and diabetes
intended for the dietary ▪ lactose–free milk for
management of a disease that lactose intolerance.
has distinctive nutritional needs that
cannot be met by normal diet alone.

Synthetic foods : these are g. For example

manufactured through microbial or Vinegar ,soya sauce , mono
chemical synthesis sodium glutamate enzymes ,
Synthetic foods are developed from food cholecalciferol or D3
substances that have been chemically
synthesized.( and are not from animal or
plant )

Food Industry is involved in-

 Manufacturing and processing
 Research and Development(modifying existing products, researching
consumer markets and developing new technologies)
 Ensuring food safety and monitoring food quality
  Improving quality control procedures
 Costing to ensure profitable production

Professionals involved in food processing and technology need to have a wide

range of knowledge and skills in each of the three stages of food production

1) Food science / Food as a material

 Nature and properties of food,
 Nutritional content
 Food hygiene and Food Safety ,
 Cost
 quality production of food
2) Food Product Development
 specifications of product
 cooking methods
 Labelling and packaging
 HACCP(Hazard Analysis and Critical Control Point)
 quality control
 sensory evaluation of dishes
 by testing and tasting products
 Industrial practices
3) Recipe Development
 Uses of ingredients
 measuring and weighing
 Adapting and Innovating recipes according to consumer needs
 cooking skills
 handling tools and equipment
 Adopting hygiene and safety norms
 use information technology to support product design.
 Industrial practices, , distribution channels, consumer purchase patterns

Preparation for Career

 Craft and
Short term*
After 10 +2 diploma
certificate
courses**

work in small
Employment Entrepreneurship
scale units

Bsc*** Msc.*** Research and

training

Beverages Stabiizers/Pr
Specializaion in Meat , Fat and oil eservatives /
any branch of Dairy poultry,sea
Food grains colors/
food tech products food
additives.

* Food craft Institutes

** Colleges of applied sciences
*** Central Food Technological Research Institute , Mysore

Central Food
Hindustan Technological
•Short term
institute of Research
10+2 certificate
•Diploma
Bsc. technology and MSc. Institute
science [CFTRI],
Mysore
 Food
Industries
Breweries/
hotels
Distilleries

flour
mills hospitals
process
ing
scope
fruit
&vegetable soft drinks
processing

fish/meat
dairy
processing
confect
ionery

Self employment opportunities

 Open Small scale or cottage industry for preserves, bakery goods,

minimally processing – cutting /cleaning /shelling etc
 Entrepreneur- government is providing incentives and support facilities (
finances, training, infrastructure and marketing) to the start ups and
women entrepreneurs. Financial support is being provided by banks.
Wage employment opportunities
 Purchaser
 Storekeeper /store manager
 Production manager
 Sensory evaluator
 worker in Processing and Manufacturing plant
 Quality control manager / quality assurance manager ( is it same ?)
 Researcher
 Sales and marketing personal
 self wage
employme employme
nt Purchaser nt Open Small scale
Storekeeper or cottage
/store manager industry

worker in
Processing and
Manufacturing
plant
Quality assurance
manager

Production
manager

Sensory evaluator

Entrepreneur-
Researcher

Sales and
marketing
personal
QUESTIONS
1. Explain the following terms:(A) Food Science (B) Food Processing (C)
Food Technology (D) Food Manufacturing and (E) Food Spoilage
2. Explain briefly the significance of Food Technology. How has it affected the
life of modern housewives, specially working women?
3.List some of the old methods of food preservation followed at home giving
examples and their viability in present times.
4. Give a brief account of development of food preservation to its present
status.
5. As a prospective food technologist what knowledge and skills does the
industry require you to have?
6. Keeping the concept of health and wellness in mind, explain with examples
how food scientists are trying to enhance the food values in processed and
packaged foods.

7. Explain the following briefly:

i. Why do we need to process and preserve food?
ii. What causes food spoilage and renders it unfit for human consumption?
iii. Food spoilage is generally caused by bacteria. What are the four conditions
that bacteria need to grow and multiply?
iv. What is done in food processing to extend shelf life?
v. As a food manufacturer it is a legal requirement to label the product. List the
advice and information that should be given to the consumers on these
labels.
vi. How is the information on nutritional values given on the label useful?

8 After the completion of 10+2 examination what is the professional scope in

the field of Food Processing and Technology?
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