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Food technology

Food manufacture

Food manufacture - revise it

In the core strand, Food manufacture, you will have studied manufacturing processes and technologies used in the production of food products. The information below will help you revise parts of this section of the course. There are a couple of revision questions with sample answers.

Outcomes
This material addresses aspects of the following syllabus outcome:
H4.2 A student applies principles of food preservation to extend the life of food and maintain safety.

Source: Board of Studies NSW, Stage 6 Food Technology Syllabus, Preliminary and HSC Courses (1999)

Storage and transport

During manufacture, raw materials, semi-processed and processed foods need to be efficiently and hygienically stored and transported to:

• allow easy, cost-effective movement of food
• maintain the quality of the product
• prevent spoilage.

Storage

Storage conditions and distribution systems at various stages of food manufacture

• Raw produce is stored before it is manufactured into value-added foods.
• After manufacture, food that is shelf stable is packed into boxes and shrink-wrapped to increase both stability and protection of the cartons.
• Chilled food is kept between 2 and 4 C.
• Frozen food is kept at -18C.
• Food manufacturing plants are often located near sources of raw materials and transport networks.
• Freezers and coolrooms have large steel doors to maintain temperatures, and air conditioning fans blast cold air down from above the door to restrict the movement of warm air into cold environments.
• The wholesaler or retailer often pulls apart the cartons and reassembles them with a variety of products for individual supermarkets.
• Usually one of three environments is chosen: frozen, chilled or dry storage at room temperature.

Transportation

• The correct transport of food is crucial to maintaining its quality.
• Refrigerated trucks transport chilled products. For food that does not need special storage conditions, enclosed semi-trailers protect food from excess heat and from the weather. Such trucks are double walled and insulated.
• Liquids are transported in tankers and pumped out at the factory.
• Dry foods, such as flour, can also be transported in tankers and hydraulically unloaded by tipping the tray.
• Trucks used to carry food must be kept clean and be made of non-corrosive material. They cannot be used for transporting other substances.
• Cargo ships are especially fitted for raw or unprocessed items. Such foods are stored in special containers which are refrigerated and atmospherically controlled so that they reach their destination in peak condition.
• Airfreight is used for markets where the demand for fresh produce commands a premium price, for example, prawns or lobsters.
• Some refrigerated trucks have microchips inserted in the unit to ensure the refrigerator is maintaining a constant temperature, for example, for transporting yoghurt.

Question

Describe the functions of packaging in facilitating the storage and transport of food.

• There are many instances of wasteful, inefficient over-packaging, in addition to cases of packaging that has failed on its way to the consumer with the attendant loss of food.
• Efficient packaging is based on scientific principles which recognise the function of the package. The most appropriate materials are selected and, in order to minimise costs, the package should allow for efficient mechanised handling to eliminate high labour costs.
• Present-day packaging involves materials such as paper, steel cans, glass bottles etc. These in turn are packaged together into secondary packages, loaded onto pallets and secured by film, wrapping or some other means. Pallet loads can then be used for packing into containers for transport over long distances.
• The 3D configuration of packaging is of importance when ensuring maximum economy and efficiency of transport. The size and shape of the package influences its cost, strength and stability.
• Individual packs must also be easy to use, for example,
  - easy to pick up and carry
  - fit easily into cupboards, shelves, refrigerators.
  - easy to open and dispense from
  - easy to close, if they are multi use packs
  - easy to recycle, reuse or return
  - safe, with no hazards, such as broken glass or sharp edges.
• Good packaging minimises costs by using lightweight materials (recyclable if possible) and by preventing waste through loss, deterioration or contamination. It also facilitates mechanised handling and distribution, thus reducing high labour costs.
• Australia's success in exporting food is dependent on lightweight packaging to overcome our geographical location and high freight costs.

Question

Outline the role of value-adding during food manufacture.

Value adding:

• means adding steps to the manufacture of foodstuffs to increase their convenience to consumers, for example, ready-to-eat meals
• increases quality and variety of food, for example, different types of milk
• provides more profit for the manufacturer, because each step performed adds extra 'value' to the product, therefore more convenience for the consumer who can be they are charged appropriately
• offers the opportunity to sell food products at increased profits to overseas markets
• provides new products on the market to maintain consumer interest
• meets new consumer demands, for example, healthy food products
• requires new packaging developments because some value-added foods have specific storage needs; for example, food that has undergone UHT processing and packaging does not need refrigeration until open. Sous vide, microwave meals and frozen meals that can be cooked in their package also add value and convenience to the food.