1. ERT 455 MANUFACTURING & PRODUCTION OF BIOLOGICAL PRODUCT 1

2. Topic Outline Introduction and Goals Introduction and Goals Food Spoilage and Foodborne Disease Food Spoilage and Foodborne Disease Product Formulations and Flow Charts Product Formulations and Flow Charts Units of Operations Units of Operations Processing and Preservation Techniques Processing and Preservation Techniques Packaging Packaging 2

3. 1.5 Processing and Preservation Techniques Several Methods Several Methods Heat application Heat application Cold preservation Cold preservation Evaporation and drying Evaporation and drying Food additives Food additives Fermentation Fermentation 3

4. 1.5 Processing and Preservation Techniques 1.5.4 Food Additives 1.5.4 Food Additives substances added substances added to food to preserve flavor or enhance its taste and appearance. Reason Maintain product consistency Improve nutritional value Maintain palatability & wholesome -ness Provide leavening Enhance flavor Impart desired color 4

5. To maintain product consistency. To maintain product consistency. Emulsifiers Emulsifiers – consistent texture and prevent from separating. Stabilizers Stabilizers – used to retain the physical characteristics of the food. Anticaking agents Anticaking agents – help substances such as salt to flow freely @ to prevent the formation of lumps, easing packaging, transport, and consumption. To improve nutritional value. To improve nutritional value. Added vitamins and minerals – milk, flour, cereal and margarine. 1.5 Processing and Preservation Techniques 5

6. To improve nutritional value. To improve nutritional value. Antioxidants – Antioxidants – prevent fats and oils in baked goods. - prevent cut fresh fruits from turning brown when exposed to air (apple). To provide leavening. To provide leavening. Leavening agents, release acids when heated – helps cakes, biscuits and etc to rise during baking. To enhance flavor. To enhance flavor. Spice and synthetic flavor – enhance taste of foods. Impart desired color. Impart desired color. Color – enhance the appearance. 1.5 Processing and Preservation Techniques 6

7. Two types. Two types. 1.5 Processing and Preservation Techniques 7 Direct Additive Substance is added to a food for a specific purpose in that food. Eg: sugar or salt.. Indirect additives Substances that may come into contact with food as part of packaging or processing equipment, but are not intended to be added directly to food.

8. Color Additive Color Additive Any dye, pigment or substance Any dye, pigment or substance that can impart color when added or applied to a food, drug/cosmetic or human body. Used in foods, drugs, cosmetics, and medical devices (contact lenses). Reason Reason. To offset color loss due to storage/processing. To correct natural variations in food color. Can derived from natural sources. Vegetables, minerals, or animals. Eg: caramel color – produced by heating sugar. 8

9. 1.5 Processing and Preservation Techniques 1.5.5 Fermentation 1.5.5 Fermentation Had been developed since ancient times. conversion of carbohydratesto alcohols and carbon dioxide or organic acids In food processing, fermentation typically is the conversion of carbohydrates to alcohols and carbon dioxide or organic acids using yeasts, bacteria, or a combination thereof, under anaerobic conditions. Prepared/derived from.. Dairies, grains, fruits, vegetables, muscle foods and etc. 9 Simple understanding.. Fermentation is the chemical conversion of sugars into ethanol.

10. 5 main purposes 5 main purposes Enrichment of the diet through development of a diversity of flavors, aromas, and textures in food substrates. Enrichment of the diet through development of a diversity of flavors, aromas, and textures in food substrates. Preservation of substantial amounts of food through lactic acid, alcohol, acetic acid and alkaline fermentations. Preservation of substantial amounts of food through lactic acid, alcohol, acetic acid and alkaline fermentations. Biological enrichment of food substrates with protein, essential amino acids, essential fatty acids, and vitamins. Biological enrichment of food substrates with protein, essential amino acids, essential fatty acids, and vitamins. Elimination of antinutrients. Elimination of antinutrients. Decrease in cooking times and fuel requirements. Decrease in cooking times and fuel requirements. 10 1.5 Processing and Preservation Techniques

11. Primary benefit – conversion of sugars and others carbohydrates. Examples: Primary benefit – conversion of sugars and others carbohydrates. Examples: Juice into wine Juice into wine Grain into beer Grain into beer carbohydrates into carbon dioxide to leaven bread carbohydrates into carbon dioxide to leaven bread Sugars in vegetables into preservatives organic acids. Sugars in vegetables into preservatives organic acids. 11 1.5 Processing and Preservation Techniques

12. PACKAGING 12

13. Generally, to protect the food so its elements will not be exposed until it is ready to be prepared and consumed. Generally, to protect the food so its elements will not be exposed until it is ready to be prepared and consumed. Prepared from different materials. Prepared from different materials. 13 1.6 Packaging Glass Paper based Metal can Plastic

14. Functions of food packaging Functions of food packaging Physical protection – shock, temperature, compression. Physical protection – shock, temperature, compression. Barrier protection – water vapor, dust, oxygen. Some packaging have oxygen absorber to help extend shelf life. Barrier protection – water vapor, dust, oxygen. Some packaging have oxygen absorber to help extend shelf life. Containment – reason of efficiency (powders and granular materials need containment). Containment – reason of efficiency (powders and granular materials need containment). Information transmission. Information transmission. Marketing. Marketing. Convenience. Convenience. Portion control. Portion control. 14 1.6 Packaging

15. Food packaging types. Food packaging types. 15 1.6 Packaging TypeFood example CansCan of Tomato soup Plastic trayFish, meat BagsPotato chips Flexible packagingBagged salad CartonsEggs

16. 16 Bag in box -aluminum foil -paperboard Blister pack -aluminum foil -thermoformed plastic 1.6 Packaging Aluminum can -aluminum

17. Shelf-life Shelf-life Shelf-life of packaged foods is controlled by: Shelf-life of packaged foods is controlled by: 17 1.6 Packaging Food properties Water activitypH Sensitivity Microbiological deterioration Barrier properties The ability of a package to control the permeation and penetration of gasses

18. 18 1.6 Packaging Environment Adulteration Contamination Physical/ Chemical deterioration Temperature change

19. Factors affecting the selection of a packaging material. Factors affecting the selection of a packaging material. Light – deterioration by light = changes in color caused by loss of natural pigments Light – deterioration by light = changes in color caused by loss of natural pigments Temperature – low thermal conductivity materials = reduce conductive heat transfer. Temperature – low thermal conductivity materials = reduce conductive heat transfer. Mechanical strength – protect from damage. Mechanical strength – protect from damage. Grease resistance – leakage of oils and fats spoil the appearance of a pack. Grease resistance – leakage of oils and fats spoil the appearance of a pack. Micro-organisms, inserts, animals and soils – inadequate seals, tears = contamination Micro-organisms, inserts, animals and soils – inadequate seals, tears = contamination 19 1.6 Packaging

20. Packaging materials for selected foods. Packaging materials for selected foods. Short shelf-life 20 1.6 Packaging ProductGlassMetalPaper/paperboardPlastic Jar Bottle Can Tin Foil Tube Bag/wrap Pot Drum/tube Carton Bottle Pot Tray/overwrap Film Bakery productsXXXX Cooked meatsXX Dairy products (milk, yogurt) XXXXX Fresh fruit/ vegetables XXXX Fresh meat/ fishXX

21. Medium/ long shelf-life 21 1.6 Packaging ProductGlassMetalPaper/paperboardPlastic Jar Bottle Can Tin Foil Tube Bag/wrap Pot Drum/tube Carton Bottle Pot Tray/overwrap Film BeveragesXXXX Dried foodsXXXXXXXX Dairy products (butter, cheese) XXXXXX Heat sterilized foods XX Snack foodsXX

22. Medium/ long shelf-life 22 1.6 Packaging ProductGlassMetalPaper/paperboardPlastic Jar Bottle Can Tin Foil Tube Bag/wrap Pot Drum/tube Carton Bottle Pot Tray/overwrap Film Frozen foodsXXXX SugarXX Preserves (pickles, sauces) XXXXXX BiscuitsXXXXX Cooking oilXXX

23. Interactions between packaging and foods. Interactions between packaging and foods. 2 reasons 2 reasons May have toxicological effects on the consumer. May have toxicological effects on the consumer. Reduce the shelf-life or sensory quality of the food. Reduce the shelf-life or sensory quality of the food. Some types of packaging materials have volatile compounds that may be absorbed and cause tainting of foods. Some types of packaging materials have volatile compounds that may be absorbed and cause tainting of foods. In metal containers, interaction of food acids, anthocyanins, sulphur compounds and etc with steel, tin or aluminum are prevented by using lacquers and coatings for the metal. In metal containers, interaction of food acids, anthocyanins, sulphur compounds and etc with steel, tin or aluminum are prevented by using lacquers and coatings for the metal. 23 1.6 Packaging

24. Assignment Task Find issue in designing packaging for biological products. Find issue in designing packaging for biological products. Example: Example: Changing of the drinking glass bottle packaging into plastic bottle packaging. Changing of the drinking glass bottle packaging into plastic bottle packaging. Effect of drinking water in plastic bottle when exposed to the high temperature. Effect of drinking water in plastic bottle when exposed to the high temperature. Discusses, Discusses, Problems that occurred. Problems that occurred. Effects to the human life. Effects to the human life. Suggestion of the solutions, additions or improvements that can be done. Suggestion of the solutions, additions or improvements that can be done. 24

25. THANK YOU FOR YOUR ATTENTION… References : José M. Aguilera and Peter J. Lillford, Food Materials Science ¸ Springer Science+Business Media, LLC ¸2008 Hui., Y.H., Handbook of Food Products Manufacturing, Wiley & Sons, Inc., Hoboken, New Jersey, 2007 25