Underline U-4 FBT
Underline U-4 FBT
Dharmalingam K
B.Tech., M.Tech., PGDIS, PhD.
Food Biotechnology
Assistant Professor
Department of Biotechnology
Chaitanya Bharathi Institute of
Unit - 4
Technology
Hyderabad – 500075
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UNIT- IV
Food Processing Applications: Principles and methods of food processing
(freezing, heating, dehydration, canning, additives, fermentation, irradiation,
extrusion cooking, dielectric heating). Enzymes and chemicals used in food
processing for flavor development; Processing of meat, fisheries, vegetables, and
dairy products. Food adulteration and food safety
Food Processing
Freezing is the home food preservation method that best preserves nutrients, flavors and
colors. Freezing has many advantages:
• It is widely used throughout the food industry and is frequently employed as a CCP in
various HACCP plans.
• In this regard is it used to extend shelf life by several days e.g. milk or bottled fruit.
✓ Batch (holding) Method: In this method every particle (e.g. milk) must be heated to at least
63°C and held for at least 30 minutes, however this is not used commercially nowadays.
✓ Heat treatment of such products must be severe enough to inactivate/kill the most heat
resistant bacterial microorganisms, which are the spores of Bacillus and Clostridium.
✓ Food products filled in sealed containers are exposed to temperatures above 100°C in
pressure cookers.
✓ Temperatures above 100°C, usually ranging from 110-121°C depending on the type of
product, must be reached inside the product.
✓ Products are kept for a defined period of time at temperature levels required for the
sterilization depending on type of product and size of container.
• If spores are not completely inactivated, vegetative microorganisms will grow from
the spores as soon as conditions are favourable again.
• Favourable conditions will exist when the heat treatment is completed, and the products
are stored under ambient temperatures.
• The surviving microorganisms can either spoil preserved food or produce toxins which
cause food poisoning.
• Temperatures of 110°C will kill most Bacillus spores within a short time.
• In the case of Clostridium temperatures of up to 121°C are needed to kill the spores
within a relatively short time.
Canning: The process of canning for extending the shelf life of foodstuffs was discovered
by Nicolas Appert, a French confectioner in early nineteenth century.
• The process involves cooking of the food, and thereafter sealing it in sterilized jars
or cans, and boiling the containers for sterilization.
• The process could not be popular until 1864 when Louis Pasteur showed the relationship
between the food spoilage and microbes, and subsequently illness
✓ It has been shown that different foodstuffs have natural protection against spoilage
✓ High acid foodstuffs such as strawberries do not need any preservative for canning
and only boiling for a little time is sufficient.
✓ On the other hand, many other foodstuffs such as carrots need longer boiling and
one has to add acidic preservative such as citric acid.
✓ Foodstuffs with low acid constituents such as vegetables and meats need pressure
canning.
✓ However, canned foodstuffs are spoiled within a short span of time after opening the can
or bottle.
• Sometimes, can with canned food gets swollen or bursts due to gas production inside
since canned foods are prone to entrance of water or microbes which help in
decomposition of food.
• There are reports that canned food contained anaerobic microbe, Clostridium
botulinum which produces a toxin capable of causing food poisoning or even sometimes
death upon consumption by humans.
• The contamination of this microbe is generally not visible by naked eye, however, its
toxin can be denatured by proper cooking.
• This microbe also produces a toxin, however unlike toxin produced by Clostridium
botulinum, this is not inactivated by heating the canned food
• Food additives are chemicals added to foods to keep them fresh or to enhance their
colour, flavour or texture.
• They may include food colourings (such as tartrazine ), flavour enhancers (such as MSG)
or a range of preservatives.
Chemical preservatives
• Antimicrobial chemical agents are added for the long-term preservation of foods.
• These chemical agents are added in small quantities, where large amounts can be
toxic.
• For example, acid and benzoates are used for food preservation in acidic foods, such
as jams, salad dressings, juices, pickles, carbonated drinks, and soy sauce.
• Sorbic acids and sorbates are used for cheese, wine, baked foods, and others.
• In the case of meats, nitrates and nitrites are used to prevent the botulism toxin .
• For fruits and vegetables, sulfur dioxide and sulfites are used, whereas propionic
acid and propionates are used for baked foods.
Types of food additives
The different types of food additive and their uses include:
• Anti-caking agents – stop ingredients from becoming lumpy.
• Antioxidants – prevent foods from oxidising, or going rancid.
• Artificial sweeteners – increase the sweetness.
• Emulsifiers – stop fats from clotting together.
• Food acids – maintain the right acid level.
• Colours – enhance or add colour.
• Humectants – keep foods moist.
• Flavours – add flavour.
• Flavour enhancers – increase the power of a flavour.
• Foaming agents – maintain uniform aeration of gases in foods.
• Mineral salts – enhance texture and flavour.
• Preservatives – stop microbes from multiplying and spoiling the food.
• Thickeners and vegetable gums – enhance texture and consistency.
• Stabilisers and firming agents – maintain even food dispersion.
• Flour treatment – improves baking quality.
• Glazing agent – improves appearance and can protect food.
• Gelling agents – alter the texture of foods through gel formation.
• Propellants – help propel food from a container.
• Raising agents – increase the volume of food through the use of gases.
• Bulking agents – increase the volume of food without major changes to its available energy.
DEHYDRATION
• The technique of drying is the oldest method of food preservation practiced by mankind.
• The removal of moisture, which is actually dehydration or drying, prevents the growth
and reproduction of microorganisms causing decay and minimizes many of the
moisture mediated deterioration reactions.
• Further, removal of moisture brings about substantial reduction in weight and volume,
thus minimizing packing, storage and transportation costs and enable storability of
the product under ambient temperatures
Theory/Principle of Drying
• Drying can be defined as the application of heat under controlled conditions to remove
the majority of the water normally present in a food by evaporation.
• The main purpose of dehydration is to extend the shelf life of foods by a reduction in
water activity (aw).
• This inhibits microbial growth; however the processing temperature is not normally be
sufficient to cause inactivation, thus care is to be taken with the product on subsequent
rehydration.
• Drying does cause deterioration in the eating quality and nutritive value of the food.
• The role of the food engineer is to design a plant that will minimize such detrimental
effects while obtaining efficient drying rates.
• Typical foods that are important commercially include; sugar, coffee, milk, potato, flour,
beans, pulses, grains, nuts, breakfast cereals, tea and spices.
Mechanism of Drying
When hot air is blown over a wet food, heat is transferred to the surface, and the latent heat of
vaporization causes water to evaporate. Water vapour diffuses through a boundary film of air
and is carried away by the moving air. This creates a region of lower water vapour pressure at
the surface of the food, and a water vapour pressure gradient is established from the moist
interior of the food to the dry air. This gradient provides the driving force for the removal of
water from the food. Water moves to the surface by the following mechanisms:
Four main factors affect the rate and total drying time, which include:
• The properties of the products (the moisture content, surface area to volume ratio, surface
temperature and rate of moisture), loss especially particle size and geometry;
• The geometrical arrangement of the products in relation to heat transfer medium (drying air);
• The characteristics of the drying equipment/drier (the dry bulb temperature, relative
humidity).
Common dryer types used for liquid and solid foods
• These fermentative microbes protect the foodstuff against other pathogenic microbes by
producing an acid or alcohol which is toxic to other pathogenic microbes.
• During fermentation, controlled conditions such as salt, temperature, oxygen level and other
parameters are maintained which help the fermentative microbe to produce the food product
good enough for human consumption
Irradiation
• Foodstuff is exposed to ionizing radiation either as β- particles or γ- rays.
• The radiation is capable of killing bacteria, molds and pests among others.
• The irradiation is also capable of decreasing the ripening of fruits and stops spoilage.
• Although, World Health Organization (WHO) and Food and Agricultural Organization
(FAO) have affirmed food irradiation, but there are controversies in this technique.
• Some people have a misconception that upon irradiation, food may become radioactive.
• Others oppose this technique by saying that irradiation may sterilize contaminated food.
• This technique has been mostly used for spices, condiments and fresh fruits.
Irradiation
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Extrusion cooking
• It has advantages of low cost, sustainability, and versatility for production of a wide variety
of food products.
• For formulation of functional foods, bioactive compounds are added to base mixtures, the
main sources being fruits, vegetables, cereals, oleaginous plants, legumes, and industrial
food by-product such as pomace.
• During the extrusion cooking process, ingredients are mixed, conditioned, and
transformed to a melt fluid, thus causing degradation or a release of functional
compounds because of structural and chemical changes caused by the effects of some
process variables such as temperature, moisture content, screw speed, and inherent
factors such as geometrical configuration of the extruder.
• The easy operation at much less time, maintaining the proper quality of food, happens to be
the best reason for microwave heating being a step ahead of conventional treatments of food.
• The frequency of microwave heating is maintained between 300 MHz and 300 GHz.
• Sterilization of food occurs with no change in quality of the food at a very short time.
• Microwave heating, in recent days, has become a prevailing process of inhibiting microbial
contamination in food industries.
✓ Microwave and RF energy are transmitted as electromagnetic waves and the depth to
which these penetrate foods is determined by both their frequency and the characteristics
of the food.
✓ Microwave energy has a range of frequencies from 300 MHz to 300 GHz whereas RF
energy has lower frequencies, from 1 to 200 MHz.
✓ However, because these frequencies are also used for communications and navigation, an
international agreement has allocated the following bands for industrial, scientific and
medical use:
• Microwaves: 915 MHz (range 902–928 MHz) and 2450 MHz (range 2400–2500 MHz).
• Radio frequency: 13.560 MHz (range 13.553–13.567 MHz), 27.120 MHz (range 26.957–
27.283 MHz) and the seldom used 40.68 MHz (range 40.66–40.70 MHz).
Continuous microwave finish drying equipment.
• Fringe-field electrodes: is also composed of a series of rod electrodes or narrow plate electrodes, but the
electrodes with opposite polarity are alternately arranged either all above or all below the sample
https://doi.org/10.1016/j.jfoodeng.2023.111609
• The ‘through-field’ design is the simplest and consists of two electrodes at different
voltages that form a parallel plate capacitor, supplied by a high-voltage generator.
Food is placed or conveyed between the plates, and this design is used for relatively
thick pieces of food.
• In the ‘fringe-field (or ‘stray-field’) design, a thin layer of material passes over
bars, rods or plates that are connected to either side of the voltage generator and have
alternating polarity. The product makes complete contact with the electrodes which
ensures that there is a constant electric field in the product between the bars.
• The ‘staggered through-field’ design has bars arranged above and below the
product, and is used for foods of intermediate thickness (e.g. biscuits)
The advantages of dielectric over conventional heating can be summarized as:
• rapid heating throughout the food without localized overheating or hot surfaces, which
results in minimum heat damage and no surface browning;
• heat transfer is not limited by boundary films and energy conversion efficiencies are high;
• For centuries, human beings have exploited the impressive catalytic efficiency of
these ubiquitous biomolecules for food processing, especially in the preparation of
beer, wine, cheese and bread.
• Enzymes are generally extracted from edible plants and the tissues of animals.
• Certain enzymes also are produced by microorganisms like bacteria, yeasts, and fungi
Some of the enzymes generally employed in food industry are listed below:
3. Lipase: Used to shorten the time for cheese ripening. It is employed in the production of
enzyme-modified cheese/butter from cheese curd or butterfat.
• Those which break the terminal amino acids from the protein chain are called
exopeptidases (Eg: carboxypeptidase A) whereas, those which attack internal peptide
bonds of a protein are called endopeptidases (Eg: trypsin).
• Certain proteases - Rennet (mainly chymosin), obtained from the stomach of calves, has
been used traditionally in the production of cheese.
• Similarly, papain from the leaves and unripe fruit of Carica papaya has been used to
tenderise meat.
Rennet and Milk Coagulation
• Rennet involves the hydrolysis of a specific peptide linkage, between phenylalanine and
methionine residues (-Phe105-Met106-) in the kappa-casein protein present in milk.
• There are four major types of casein molecules in milk, viz., alpha-s1, alpha-s2, beta and
kappa.
• The alpha and beta caseins are hydrophobic proteins that are readily precipitated by
calcium but kappa casein is not calcium-precipitable.
• The caseins self-associate into micelles in which the alpha and beta caseins are kept from
precipitating by their interactions with kappa casein.
• In essence, kappa casein normally keeps the majority of milk protein soluble and
prevents it from spontaneously coagulating.
• Chymosin proteolytically cuts and inactivates kappa casein.
• Calf rennet, consisting of mainly chymosin with a small but variable
proportion of pepsin, is a relatively expensive enzyme and various attempts
have been made to find cheaper alternatives from microbial sources.
DOI: 10.1021/bk-2022-1433.ch001
• Hydrocarbons are only used in small quantities for fragrance and taste. Simple aliphatic
molecules, acyclic and cyclic terpenes, and benzene rings are all examples of hydrocarbons
• Essential oils are mostly made up of terpenoids, which are commonly employed as
flavoring agents or as a starting point for the discovery of new flavoring compounds.
• n-Amyl alcohol is found in the flavors of fruits, baked, dairy, meat, alcoholic, and roasted
foods
• Acetaldehyde is prominent in fruit flavour, despite the fact that its volatility makes it
difficult and risky to handle as a pure fragrance component.
What Is Food Adulteration?
• Food Adulteration can be defined as the practice of adulterating food or contamination of
food materials by adding a few substances, which are collectively called adulterants.
• Adulterants are the substance or poor-quality products added to food items for economic
and technical benefits.
• Addition of these adulterants reduces the value of nutrients in food and also contaminates the
food, which is not fit for consumption.
• These adulterants can be available in all food products which we consume daily, including
dairy products, cereals, pulses, grains, meat, vegetables, fruits, oils, beverages, etc.
Why is Food Adulteration done?
The process of contaminating food or adding to the food components is a common
phenomenon in developing countries.
For instance: Milk can be diluted by adding water to increase its quantity and starch
powder is often added to increase its solid content.
Listed below are the main reasons for adulterating food products:
• Practiced as a part of the business strategy.
• An imitation of some other food substance.
• Lack of knowledge of proper food consumption.
• To increase the quantity of food production and sales.
• Increased food demand for a rapidly growing population.
• To make maximum profit from food items by fewer investments.
Methods of Food Adulteration
➢ Access to enough safe and nutritious food is key to sustaining life and promoting good
health.
➢ Unsafe food containing harmful bacteria, viruses, parasites or chemical substances can
cause more than 200 different diseases, ranging from diarrhoea to cancers.
➢ Around the world, an estimated 600 million – almost 1 in 10 people – fall ill after eating
contaminated food each year, resulting in 420 000 deaths and the loss of 33 million
healthy life years.
➢ WHO aims to enhance the capacity to prevent, detect and respond to public health threats
associated with unsafe food at the global and country levels
The Codex Alimentarius Commission(CAC) is an international food standards body
established jointly by the Food and Agriculture organization (FAO) and the World Health
Organization (WHO) in May 1963 with the objective of protecting consumer's health and
ensuring fair practices in food trade.
Schematic representation
of regulations governing
infant formula in United
States.
HACCP stands for Hazard Analysis and Critical Control Point. It helps food businesses
ensure food safety by identifying and controlling potential problems before they occur.
The HACCP system is based on scientific and technical principles. To create an HACCP plan,
food businesses must:
•Identify hazards that need to be avoided, removed, or reduced
•Identify critical control points (CCPs) where hazards need to be prevented, removed, or
reduced
•Set limits for CCPs
•Monitor CCPs
•Correct problems with CCPs
•Put checks in place to ensure the plan is working
•Keep records
The HACCP system was developed in the early 1960s by NASA, the Pillsbury Company, and
the U.S. Army Laboratories to ensure safe food for space expeditions
• HARPC stands for Hazard Analysis and Risk-based Preventive Controls. It is a food
safety standard developed by the US Food and Drug Administration (FDA) under the Food
Safety Modernization Act (FSMA). HARPC is a science-based system that helps food
producers identify and control potential hazards that could make consumers sick.
• HARPC is a more comprehensive regulation than the previous standard, HACCP (Hazard
Analysis and Critical Control Points). HARPC focuses on preventive controls that are
science- or risk-based.
To identify hazards, companies must consider:
• Biological hazards, Chemical hazards, Physical hazards, Natural toxins, Pesticides, Drug
residues, Decomposition, Parasites, Allergens, and Unapproved food and color additives.