1. GCSE Food Technology
Superlearning

2. Research Context: Chilling and Freezing
Design Theme: Fish Based Food Products

3. Research – Chilling
Cook-chill products are thought to be of a better quality than frozen products. They have a much shorter shelf-life (usually a few days) but do not need to be defrosted first.
Cook-chill products are prepared, cooked and chilled rapidly. They are stored at a temperature just above 0°C.
Refrigerators are used for the short-term storage of perishable foods and ready meals that have been prepared by the cook-chill process.

4. Research – Chilling cont’d
Chilling slows down:
The rate at which micro-organisms multiply
The rate of any chemical reactions which could affect the quality of food
They need to stay at or below this temperature until they are used. For this reason they are always sold from the chiller cabinets in shops.

5. Advantages of Chilling
There is very little change in flavour, colour, texture or shape
Fresh foods can be kept at maximum quality for a longer time
The consumer can be offered a much larger range of fresh and convenience foods
Nutrients are not destroyed

6. Exam Question
Seafood sandwich fillings are popular with many consumers.
(a) Why is seafood a high risk food?
(2 marks)
(b) At what temperature should high risk foods be stored in a refrigerator?
(1 mark)
(c) How do retailers ensure that chilled foods do not fall below the correct temperature?
(4 marks)

7. Answer from mark scheme
(a) Why is seafood a high risk food?
• Moist
• Protein
• Easily contaminated by bacteria
• Short shelf life
Qualified answer or two simplistic answers ( 2 marks )
Simplistic answer ( 1 mark )
( 2 marks )
(b) At what temperature should high risk foods be stored in a
refrigerator?
0 . 5 C°
( 1 mark )
(c) How do retailers ensure that chilled foods do not fall below the
correct temperature?
• Regular checks
• Monitoring by staff
• Train staff in food hygiene
• Alarms if electric supply cut or temperature lowered
• Checking doors are shut correctly
• Checking fill levels are correct
• Checking equipment / chillers are defrosted regularly
• Temperature logging
• Correct use of food probes
Qualified answers well explained or number of simplistic answers
( 4 marks )
Qualified answer or two simplistic answers ( marks )

8. Freezing
When the temperature of a food is reduced, the activities of most micro-organisms are slowed down, until they become dormant (inactive), and growth and multiplication cease.
Most foods can be frozen successfully and contain relatively large amounts of water. When a food is frozen, ice crystals are formed in it. Foods such as fruit and vegetables, which are made up of many cells, can be damaged by the ice crystals if they are too large. This is because the cells rupture if the ice crystal exceeds the size of the cell. Once the food is thawed, its structure will collapse, releasing most of the liquid in it, because the cells no longer form the framework of the food

9. Effect of Freezing on Food
Low temperatures do not significantly affect the nutritional value of food, but thiamin and vitamin C may be destroyed when vegetables are blanched (briefly immersed in boiling water) before freezing.
If fish is frozen too slowly, some of its cells may rupture and release nutrients into the liquid that drips from the fish when it thaws.
Some flavours become weaker and some become stronger when food is frozen.

10. Standard Components used in Fish Products
Standard components are pre-prepared items used in food production.They are made at a different time, and often at a different place by another company. Common examples are:
Pre-prepared mashed potatoes
Ready made batter
Ready made sauces
Breadcrumbs
Advantages Disadvantages
Saves time
Time must be allowed for ordering and supply
Quality is guaranteed
Can be more expensive
A wider range of products can be produced e.g. breadcrumbs can be used for a variety of fish products.
The manufacturer is relying on another company that could let them down

11. Exam Question
Manufacturers of food products often use standard components.
(a) Name two different ways flaky pastry is sold as a standard component.
(2 marks)
(b) What is the correct storage temperature for the following standard components?
(3 marks)
(i)a packet of frozen vol au vents
(ii)a tin of pie filling
(iii)a bag of grated cheese
(c) What are the advantages and disadvantages of using standard components?
Advantages
Disadvantages
(6 marks)

12. Answer from mark scheme
Manufacturers of food products often use standard components.
(a) Name two different ways flaky pastry is sold as a standard
component.
• Frozen
• Packet ready made dried
• Block ready made
• Vol au vents / pastry cases ready prepared
• Chilled
• Ready rolled
• Do not accept .fresh.
2 x 1 mark (2 marks)
(b) What is the correct storage temperature for the following standard
components?
• frozen vol au vents -18C domestic freezer or -28C if industrial
• tin of fruit pie filling 20-25C / ambient temp (accept any temp in
this range)
• cheese 0-8C refrigerator (accept any temp in this range)
Do not accept refrigerator, freezer or room temperature.
3 x 1 mark (3 marks)
(c) What are the advantages and disadvantages of using standard
Advantages:
• save time
• save on costs of workers
• saves on buying / storing raw ingredients
• saves on buying specialist equipment
• consistency.same sensory attributes each time.
• Fewer cookery skills needed.
Disadvantages:
• cannot guarantee quality unless reliable supplier
• storage space special conditions may be needed
• expensive
• supplier may let down
• allow time for ordering
• may not be same nutritive value as freshly made products.
• difficult to change specification
• may contain additives / preservatives
Answers cover both advantages and disadvantages 5-6marks
Detailed answers or mixture of detailed / simplistic answers 3-4marks
Simplistic answers or one detailed 1-2 marks
(6 marks)

13. Sensory Testing of Food Products
Sensory testing involves the scientific
measurement of the qualities of a food
product. There are a variety of tests which
can be done depending on what you
want to find out. It is important to select the
correct one for the purpose:
Difference tests – these are used to find out if there are any noticeable differences between 2 or more products. E.g. coca cola and diet coca cola
Ranking tests – a set of coded samples are given to the tester in a random order. The tester ranks the samples in order of a specific quality e.g. sweetness. This test is often used to screen one or two of the best samples in a group.
Descriptive tests or profiling – a set of sensory descriptors is given for the testers to use e.g. colourful, glossy, dry etc. and the tester gives a score for each descriptor

14. Exam Question Explain why manufacturers use sensory testing.
(4 marks)
5 (b) (ii) What are the advantages of using a computer to record the results of sensory testing?
(2 marks)

15. Answer from mark scheme
Explain why manufacturers use sensory testing.
• To inform decisions on future product
• Identify what needs improving
• To gather information about the product
• To gain information on consumer preferences
• To compare product against other existing products
• To decide the sensory characteristics of a product
• To evaluate the product against sensory characteristics
of specification
• To ensure a successful product in terms of sales/meets
consumer appeal
Some detailed or several simplistic answers 3-4 marks
One detailed answer or two simplistic answers 1-2 marks
(4 marks)
AQA GCSE Mark Scheme, 2008 June series – Food Technology Full Course Higher 15
(ii) What are the advantages of using a computer to record the
results of sensory testing?
• Fewer human errors/ efficient/accuracy.
• can share / show results more quickly and with more
people,
• range of graphics and methods of presentation,
• neater – easier to see, organise etc
• can be reproduced in the future/saved for use later/copies
made
• can be changed easily
• easy to make comparisons
One detailed or two simplistic responses (2 marks)
Total for question 16 marks

16. Packaging Why are foods packaged?
To protect the product – against physical damage, chemical contamination or micro-organisms, insects or rodents
To contain the product e.g. eggs, fruit and vegetables
To preserve the product e.g. tin cans and modified atmosphere packaging (where foods in a package are flushed with a mixture of gases to prolong their shelf life)
To identify and provide information on the product
To prevent tampering – tamperproof packaging techniques now make it easy to detect if a package has been opened, examples include plastic collars on bottle tops, paper strips across jar lids and aluminium foil seals on fruit juice cartons

17. Labelling
The 1996 Food Labelling regulations state that a food label must include the following information:
Name of the product clearly displayed
The name and address of the manufacturer
A list of all ingredients in descending order of weight (largest to smallest)
Storage instructions, giving specific details of the best conditions and temperatures for safe storage
Shelf-life of the product must be shown
Cooking instructions (if appropriate)
The country for where the product originated
The net weight of the product

18. Exam Question
Explain why the following materials are often used to package food products.
(i) Paperboard
(2 marks)
(ii) Polystyrene

19. Answer from mark Scheme
Explain why the following materials are often used to package food
products.
(i) Paperboard
• Flexible . can be folded
• Cheap
• Can be waxed to make water resistant
• Easy to print on
• Lightweight
• Environmental friendly
(ii) Polystyrene
• moulded to shape
• can be used for hot / cold food / insulation
• Sturdy- protects product
Detailed answers . different for each material 2 marks
Simplistic answers 1 mark
2 x 2 marks (4 marks)

20. Preparation and cooking of Fish – Fish can be used in many dishes but is most popular in the UK fried in batter and served with chips
Type of Fish
Uses
White
Steamed, poached, grilled, fried, baked. Serve in a roux sauce or in pastry, curry, with sweet and sour sauce etc
Oily
Bake, fry, grill, poach. Serve with a sharp sauce, e.g. tartare, fry in oatmeal; stuff with breadcrumbs/herbs and bake
Shell
Serve as a starter, e.g. prawn cocktail, or in soups, salads, fried in batter, with rice etc.

21. Examples of the different types of fish:
Type of Fish
Examples
White
Plaice, halibut, sole, cod, coley, haddock, sea bass, whiting, monkfish, hake, hoki, red snapper
Oily
Anchovy, eel, kipper, mackerel, pilchard, salmon, sardine, tuna, trout
Shell
Cockles, winkles, mussels, scallops, oysters, lobster, prawns, crabs, crayfish

22. Exam question
Control checks are made on different batches of salmon and prawn filo parcels.
Problems found during the checks are listed below.
(i) Give one cause of each problem. (5 marks)
(ii) Explain how the problem may be prevented. (5 marks)
Filo pastry is dry and breaks up when handled.
The filling leaks out of the parcel during cooking.
Pieces of fish shell are found in the filling.
Creamy sauce is thin and runny.
The final product is pale and lacks colour.

23. Answer from Mark scheme
Problem
Cause
(5 x 1 mark)
Prevention
Pastry is dry and
breaks
• Incorrect
proportions of
ingredients
• Over handling
• Overcooking /
time / temp
• Not used in time
• Weigh accurately
• Monitor working
temp / keep cool /
moist
• Training staff
• Quality control
checks
• Cover before use
Filling leaks out
• Incorrect seal
Not used water to seal edges
Too much filling/insufficient pastry
Pastry too thin/torn
Steam vent needed
Accurate weighing of filling
Quality control checks
Training of staff
Sealing of edges

24. Answer cont’d Shell in the filling Lack of visual checks Poor supplier
Quality control checks not completed
Poor quality shellfish
Check on suppliers
Clear specification
Quality control checks
Visual checks
Regular monitoring
Sauce is thin and
runny
Insufficient cooking time/temp
inaccurate proportions
Too much liquid
Not enough sauce to thicken
Weigh accurately
Monitor working temp
Training staff
Pale product
Incorrect choice of fat in pastry
Not finished with egg/milk glaze
Not cooked long enough/hot enough
Cook for longer/higher temp
Add finishing technique
Change to butter/margarine instead of white fats

25. A mass production line in a milk-bottling plant
Manufacturing methods and equipment
There are different types of manufacturing system, each one suitable for different scales of production:
One-off production is when a single product is made to the individual needs of a customer, for example a designer wedding cake. This is classed as a luxury food item.
Batch production involves the making of a set number of identical products (large or small). Typically batch production is used in a bakery, where a certain number of several different types of bun, loaf, cake etc, will be made every morning.
Mass production is used to make foods on a large scale, either wholly or partially using machines. The production line involves individual tasks that will be carried out repetitively. This is time-efficient and helps to keep the costing of the product low.
Continuous-flow production is a method of high-volume production, used in foods such as milk and packet pizzas. Production lines run 24 hours a day. Where production line machines are controlled by computers this is called Computer-Aided Manufacture (CAM).
                                                                                          
A mass production line in a milk-bottling plant

26. Quality Assurance of Food Products
.Factory equipment
There are different types of specialised machinery used in food manufacture.
Computerised scales weigh food more accurately.
Centrifuge machines separate liquids from solids.
Date-stamping machines will label many packaged foods with a date stamp on the production line.
Depositors add an exact amount of food into a number of containers at the same time.
Mandolins slice or cut food products so portions are consistently the same size.
Bench or floor-standing mixers are used in bakeries to add and mix exact quantities of ingredients to the food, maintaining consistency.
Boiling vats are huge drums used for cooking foods, such as soups.
Deck ovens are computer-controlled ovens that cook a batch of several products at the same time.

27. Special Dietary needs of Consumers
Coeliacs Disease – allergic to gluten therefore cannot eat anything made from wheat e.g. flour
Lactose intolerant – allergic to lactose (found in milk) therefore cannot eat any dairy produce
Vegans – vegetarians who do not eat any foods associated with animals
Ovo-lacto vegetarian – vegetarians who do not eat meat but will eat eggs and milk
Allergies – the most common food allergy is a nut allergy
Pregnant women – needs lots of protein rich foods, vitamins and minerals. She should avoid soft cheeses and pate due to bacteria that might be present.
Children – needs plenty of protein and calcium. Reduce the amount of sugar and fat.

28. Control Checks During Food Manfacture
Visual checks to cartons to see if they have been tampered with/damaged. Ones damaged should be removed.
Visual check date rotation first in first used.
Weighing and measuring use digital scales for accuracy.
Automatic mixing for computer controlled amount of time.
Fixed cooking period using timer
Visual check – are they the correct colour?
Correct amount in each packet
Detector for foreign objects e.g. metal, jewellery
Weight check
Temperature of sealing
Temperature of storage/distribution area

29. Exam Question
Using notes, sketches or flowcharts describe the processes and control checks needed to make your chosen design idea in a test kitchen. (10 marks)

30. Answer from Mark Scheme
Using notes, sketches or flowcharts describe the processes needed to make your chosen idea in a test kitchen.
Marks awarded for prototype made in test kitchen not large scale production. N.B. answers do not need to cover all aspects in order to gain full marks.
Look for candidate showing awareness of different aspects e.g. at least one reference to time/temperatures, named process, control checks…
• Logical sequence shown through the main stages of the flow chart/notes/stages/steps
Preparations
Kitchen hygiene
Personal hygiene
Weighing ingredients
Equipment e.g. pre heating oven
Production
Preparing product
Preparing filling/ topping/coating/decorations as relevant
Dovetailing of tasks
Named processes e.g. baking, rubbing in, creaming, melting, grating, piping etc
Finishing techniques
Control checks:
timings
temperatures
food safety
portion control/ use of cutters/templates
safety precautions e.g. use of oven gloves
checks on size, shape etc
Feedback
Detailed answer showing logical plans 8-10 marks
Detailed answer showing logical plans but with minor omissions 5-7 marks
Some parts of the answer may not be logical or be omitted 3-4 marks
Simplistic answer giving some relevant planning 1-2 marks
(10 marks)

31. Decorations and Finishes
A decoration is something you apply to a product AFTER it has been made e.g. melted chocolate, icing, piped cream
A finish is something that you do to the actual product to change its appearance during the making of the product e.g. glaze with egg, glaze with sugar and water, flute pastry edges, put nuts on top

32. Safe Storage of Food
Low risk foods: this means foods with high acid or sugar content, raw vegetables, edible oils and fats
Medium risk foods: this means dried or frozen products, freshly processed products and those with a high fat content
High risk foods: this means unprocessed meat, fish, eggs and dairy products

33. How hazards are controlled during food production
HACCP:
HACCP stands for Hazard Analysis and
Critical Control point. It involves:
Identifying possible risks before, during and after production of a product
The risks are analysed in terms of how likely they are to happen and how serious they are
For each hazard preventative measures and testing/checking is planned in to ensure that the hazard (Critical control point) is reduced.

34. How do manufacturers obtain consistent products?
Consistency means:
Same quantities of ingredients used
Same amount of filling, coating, casing
Same colour
Same shape
Same texture
Same strength of flavour
Same size
Same nutritional content
Human error means that hand produced food products are not as accurate and consistent as those made by machinery. Automated equipment can repeat tasks many times without getting tired or risking workers’ health and safety

35. CAD (Computer Aided Design)
Designing a new food product with the aid of
a computer is known as computer aided
Design. CAD can be used to:
Calculate the nutritional value of the food product
Work out the sizes and costs of different batch production runs
Work out the shelf life of a product
Present the product’s sensory profile
Predict what will happen if ingredients or methods are changed
Plan how a product will be manufactured
Present ideas for the packaging

36. CAM (Computer Aided Manufacture)
CAM is using computers to control pre-
programmed equipment to make products.
CAM has many uses in food production
including:
Automated production processes
Data logging e.g. recording pH values, temperatures
Responding to monitoring feedback e.g. reducing or increasing temperature of environment as needed
Control of designated tolerances e.g. weight, dimensions, moisture content, flavour colour, shape

37. Exam Question Food manufacturers often use CAD and CAM.
(a) (i) What is meant by the term CAD?
(1 mark)
(ii) What is meant by the term CAM?
(b) Give examples of how CAD and CAM may be used in bread production.
(4 marks)

38. Answer from Mark Scheme
(a) (i) What is meant by the term CAD?
CAD means computer aided design ( 1 mark )
(ii) What is meant by the term CAM?
CAM means computer aided manufacture ( 1 mark )
(b) Give examples of how CAD and CAM may be used in bread production.
CAD Examples may give one detailed answer or two simplistic examples.
• Designing the appearance of product, calculating nutrient content, model portion sizes, cost / profit, calculating shelf life, analysis of sensory data, presenting information for labelling, showing assembly procedures, packaging design.
CAM Examples may give one detailed answer or several simplistic answers.
• Monitoring production process, e.g. temperature changes, controlling changes, feedback from monitoring, use of computer controlled equipment, e.g. breadmaker, microwave oven, electronic scales
• Must give example of CAD and CAM for full marks ( 4 marks )
Total for question 6 marks

39. Sketching in your exam – examples of good practice:
Draw in pencil
Colour in if possible
Label all parts of your design

40. Choosing your final design:
You will have to give detailed reasons for
your choice of final design. Remember look
at the specification they gave you and relate
back to that e.g. if the specification asks for
the product to be colourful and you have put
a range of different coloured vegetables in
then use that as a reason for choice

41. Explain Expand upon (knowledge) Show you understand (apply to case)
Give an example

42. Recommend Make a choice Give reasons for choice and
Make relevant to your design

43. Discuss Put forward both sides of the case then, Reach a conclusion.
Give reasons for the conclusion.

44. And finally………
Good luck to you all, don’t
panic and do your very
best!!