FOOD PROCESSING

(Part 2)

BEVERAGES
Alcoholic Beverages
-

produced from sugar-containing liquids

by alcohol fermentation
most popular: beer, wine, brandy,
other alcoholic distillates

1. Beer
-

involves the use of germinated barley

(malt), hops, yeast and water
adjuncts may be added (cereals other
than barley such as rice and corn)

- properties:
invigorating property: ethanol
aroma, flavor and bitter taste: hops
nutritional value: unfermented solubilized
extracts
refreshing effect: carbon dioxide
- total world production: 8.73 x 109 liters/year
- raw materials
barley
-

provides ample quantities of extract

high starch content
high degree of germination
High germination vigor and good swelling ability

 adjuncts
- supplementary sources of starch,
unmalted cereals
- Wheat, corn and rice

hops
- contribute to bitter flavor and aroma of
beer
- clarifier
- active antibiotic properties
- composition: bitter cpds (18.3%);
essential oils (0.5%); protein (20%); fiber
(15%); ash(8%); CHO (34%)

 brewing water
- influence beer quality and character
- should be low in salt content
(biocarbonates, calcium and magnesium)
- treated in order to remove ions
brewing yeast
- strains of Saccharomyces cerevisiae (top
fermenting yeast) and S. cerlsbergensis
(bottom fermenting yeast)

Steps:

1. malt production
soaking of cereals in water
(steeping)
germination (15-20 C, 7 days)
drying (2-3 % MC)- formation
of color and roasted aroma

2. wort preparation (mashing)

dispersion of malt in water
combination of malted barley and
cereal adjuncts and mildly cook the
mixture
extract readily soluble materials and
gelatinize the starch (begins at 38 C
and gradually raised to 77 C)
filtration: liquid (wort) high in sugar

3. brewing
addition of hops to the wort and
boiled in a kettle for 2.5 hrs
after boiling, the hops is removed
from the wort

Hops

Importance:
- concentrates the wort
- nearly sterilizes the wort
- inactivate enzymes
- precipitates remaining proteins
- caramelizes sugar (flavor)
- extracts the flavor, preservative
and tannin-like products from hops

4. Fermentation
Bottom Fermentation
cooled wort is pumped into the tank
at 5-6 C; inoculation of yeast and
fermentation for 6-10 days at 6-10
C, filtration, aging (1.5 2 C for 2 4
months)
Top Fermentation
fermentation at higher temperatures
(18 25 C for 2 7 days)

 produced alcohol content of about 46% (9.2 proof)

lowers the pH of the wort to about
4.0 and produces carbon dioxide
(0.3%)

5. Finishing and Packaging

final polishing
addition of carbon dioxide (if
necessary)
pasteurized (60 C)

2. Wines
-

a beverage obtained by full or partial

alcoholic fermentation of fresh,
crushed grape or grape juice (must)
Steps in production
a. Must Production (extraction of juice,
pressing)
- with or without removal of skins
- treated with sulfur dioxide to avoid
discoloration and microbial activity
- pasteurize

b. Fermentation
- Saccharomyces cerevisiae var
ellipsoideus
- 21 days at 12-14 C (white wines) juice
fermentation
- 21 days at 20-24 C (red wines)- pulp
fermentation
c. Aging (3-9 months)
- to get rid of the sediments (racking)
- further build up of aroma and flavor
3. Alcohol distillate
-

lambanog, brandy, rhum, whisky, gin

Distilled fruit wine, 38% alc by wt.

Carbonated Non-alcoholic Beverages

- softdrinks
- sweetened, flavored, acidified, colored,
artificially carbonated and sometimes
chemically preserved
- raw materials
a. Sugar crystalline or sugar syrup or high
fructose syrup
Final sugar content is 8-14%
Imparts sweetness to soda, adds body and
mouth-feel
Reduced calorie and non-nutritive
sweeteners
b. Flavoring agents usually synthetic cmpds,
natural flavor extract & fruit juice concentrate
are used; whatever the source, it must be

c. Colors caramel (heated sugar)

- Synthetic food color is more stable than
natural food extracts
d. Acids
- added to enhance beverage flavors and acts
as a preservative against microbial growth
e. Water
- account for as much as 92-97% of the total
volume of the drink
f. Carbon dioxide
- gives sparkles and zest to carbonated
beverages
- improves flavor
- preservative action

The soft drink industry purchases carbon

dioxide in high pressure cylinders
Industry practice involves either carbonating
the entire beverage or only the water that
is subsequently mixed with the flavored
syrup

Water treatment
precipitation of minerals
Deionization
Activated charcoal to remove colors, flavors
and residual chlorine

 Final filtration to remove traces of

unwanted substances that may
have passed through the carbon
filter

Deaeration to remove oxygen

Coffee
- seeds of coffee fruit from which the
outer pericarp is completely removed
and the silver skin is occasionally
removed
- seed may be raw or roasted, whole or
ground and should be from the
botanical genus Caffea
- three species: C. arabica, C.
canephora, C. liberica
- world production: 5.9 x 10 6 tons

Structure of coffee berry and beans

a. Harvesting and processing

-

hand picking of mature berries

processing: removal of fleshy part
dry process: sun drying of whole fruit,
dehulling of dried husks and silver skin
wet process: squeeze the fruit using
rotating cylinders, carried into water
stream, 12-48 hrs fermentation,
removal of mucilagenous layer and
drying at 65-85 C

Product: green coffee

Composition
protein (8.7 12.2%)
lipids (8.3 17%)
fiber (10 11.7%)
sugar (2 9%)
caffeine (0.9 2.6%)
minerals (3 5.4%)

b. Roasting
-

done in order to release the truly

delightful aroma of coffee
200 250 C
Changes: increase in volume (5080%)
changes in color green to brown
loss in weight (13-20%)
builds up of typical roasted flavor of
the beans

4 Major Phases
drying at or above 50 C (proteins
denature, water evaporates)
development above 100 C (browning,
swelling and release of volatiles
decomposition 180 200 C (beans pop
and burst releasing aroma)
full roasting- optimum caramelization;
decrease in MC to 1.5-3.5%

c. Storing and packaging

- 8 to 10 weeks
- 6 to 10 months (vacuum packaging)
Caffeine
- one of the best known N-containing
compounds
- physiological effects (stimulation of
central nervous system, increased
blood circulation and respiration)
- mildly bitter in taste

Brewed coffee
- the coffee extract is made by
boiling the coffee for 10 min with
water and filtering
- with high content of flavoring and
stimulant constituent

g. Coffee products
i. Instant coffee
- soluble coffee
- obtained by extraction of
roasted coffee under pressure
- water temp can reach 200 C,
the extract will be concentrated
(35 70% total solids) and then
dired
- hygroscopic and unstable

ii. Decaffeinated coffee

- treatment of green coffee with
superheated steam at high pressure
- swollen beans are then extracted
with various organic solvents
(dichloromethane, acetic acid,
esters)
- drying

Tea / Tea Blends

- young tender shoots of tea
shrubs, consisting of young leaves
and the bud, processed in a way
traditional to country of origin
- China and Japan
- world production: 2.6 x 106 tons

1. Black Tea
Process:
- Withering leaves in trays (20 35 C for 4-18
hr) or drying racks or drum dried
moisture reduction, 75% to 55-65% (flaccid)
- conditioning step
leaves are fed into roller without pressure
(for uniform distribution of PPO enzyme)
- fermentation
enzymatic rather than microbial
stopped when leaves are bright and
coppery red and has odor like sour apples
- firing step (87-93 C, 20-22 mins)
heating in large oven or firing machine
copper red color turns black

2. Green Tea
- avoids oxidative processes
- the fresher the tea leaves, the
better the tea produced
- Enzymes are inactivated
- no withering step and fermentation
- Methods:
Japanese: steaming of fresh leaves
at 95 C followed by cooling and
drying, high temp rolling (75-80 C)
Chinese: roasting, rolling and firing

- tannin, chlorophyll, vitamin C and

organic acids decreases only
slightly as a consequence of
enzyme inactivation
- very light, clear, bitter tasting
beverage

Reactions Involve in Tea Processing:

1. Withering step
- start of changes in tea constituents
- hydrolysis of proteins to amino acids
- chlorophyll degradation
- increases cell permeability
2. Conditioning
- more uniform distribution of PPO

3. Rolling
-

substrates and enzymes are brought together

4. Fermentation
-

enzymatic oxidative processes

pigments are formed
aroma production

5. Firing
-

enzyme inactivation
conversion of chlorophyll to pheophytin

Packaging, storage and brewing

- cleaning (to remove coarse impurities)
- graded according to leaf size
- packed in standard plywood chest lined
with aluminum foils
- foils are sealed
- glass in metal containers
- should be protected from light, heat and
moisture
- brewing: hot water is added to leaves, left
for 3-5 minutes with occasional stirring
:4-6 g of tea leaves per liter

DRINKING WATER/ BOTTLED WATER

Drinking water
- should be clear, colorless and
odorless
- free from pathogens, perfect with
regards to taste and contains
minerals
- treatments:
filtration thru gravel and sand
layers of different grain size
aeration (to remove iron and
manganese)

 deacidification: carbonate salt

disinfection: chlorination
- analysis: microbiological, limits for
certain minerals

Bottled Water
- any potable water that is manufactured,
distributed or offered for sale, which is
sealed in food-grade bottles or other
containers and is intended for human
consumption (FDA, 1995)
- or water obtained from an approved
source that has undergone minimum
treatment (filtration and ozonation or
equivalent disinfection process).

Classification:
Spring water comes from the
surface just above the bedrocks
- water taken from a natural spring
- from water that flows naturally or
is self-flowing
- contains calcium, trace minerals
like fluoride

Mineral water comes from a

containment rock covered with clay
to prevent contamination of surface
water
- may be plain or carbonated
- contains mineral salts (BFAD)

Distilled water undergoes reverse

osmosis filtration
- does not necessarily remove all
heavy metals
- mineral content has been reduced
(<10 ppm) thru either distillation,
deionization, or reverse osmosis

COCOA AND CHOCOLATE

- consumed as a suspension
- world production: 2.95 x 106
Harvesting and processing of cacao
- cacao (Theobroma cacao)
- cut open and the beans scooped out
- fermentation:
fermentation beans are transferred to
fermentation tanks and left for 2-8 days
: mixing of beans from time to time
: rise in tem; decrease in pH

- washing and drying (6-8%

moisture)
- roasting: to further develop
flavor and color
- dehulling: to produce the nibs
- milling: heat of grinding melts
the fat, liquid in consistency

Composition of cacao beans

5 % moisture; 54 % fat; 0.2% caffeine;
1-2% theobromine; 11.5% protein;
8.5% CHON; 9% fiber; 2.6% ash

Changes during processing:

-

conversion of sugar to CO2 and ethanol

degradation of polysaccharides
oxidation of ethanol to acetic acid
termination of oxidation reaction (MC
<8%)

Products:
a. Chocolate liquor
- the liquid discharge from the mill,
high in fat (55%)
- solidifies on cooling and it is the
familiar bitter chocolate used in
baking and other applications
- can be processed with sugar
(sweet chocolate) or with milk and
sugar (milk chocolate)

b. Cocoa butter
- the fat removed from the chocolate
liquor

c. Cocoa
- the remaining press cake as raw
material
- ground to very fine powder to have a
smooth mouthfeel

d. Chocolate
- types depend on chocolate liquor, cocoa
butter, sugar, milk
- sweet chocolate: at least 15 %
chocolate liquor
- milk chocolate: at least 10% chocolate
liquor
- bitter chocolate: at 35% chocolate liquor
Process:
combining the mixture
fine grinding

 kneading in heated mixing

tanks (60 C for 96-120 hours)
tempering (controlled
crystallization, heating at 54
C and cooling to about 32 C
and continued stirring for 1
hour or more)
molding

FISH AND FISH PRODUCTS

1. Composition and characteristics
- depend on season of the year and
maturity
- edible portion is less than in warm
blooded animals
- waste is close to 50%

 Composition
- crude protein, 17-20%; minerals, 11.8%; MC, 65-82%; fat vary widely
(0.1-20%)
ex. Fat content: 0.1-0.4% (cod)
16-20% (tuna herring)

- easily digested as compare to warm

blooded animal meat
- fish proteins are highly digestible
and at least as good as red meat
with respect to essential amino acids
- fats of fish are readily digestible and
rich in unsaturated fatty acids, a
good source of vitamins A and D
- fish muscle is a good source of
vitamin B

2. Classification based on:

a. Environment the fish lives
seawater fish
pelagic fish: 20% fat; mackerel, tuna,
anchovies
demersal fish: <5%fat (many have
<1%) cod; flat fish, shrimp, oyster,
clams, crabs

fresh water fish

pike, carp
can live in both environments
salmon, eels
b. body form: flat or round

3. Spoilage factors
- fish tissue is more perishable than
any other animal tissue
- reasons why fish spoil rapidly:
microbiological: large no. of microorgs
in the surface and digestive tract
physiological: fish struggle when
caught
chemical: fat of fish is very rich in
trimethylamine

4. Fish products
a. dried fish
- sun/mechanical
- usually they are salted
- MC: <18%
b. smoked fish
- exposed to freshly generating sawdust
smoke
- cold smoking (1-3 days at 18-26 C)
- hot smoking (1-4 hrs; 70-90C)
c. canned fish
- good sources of calcium and phosphorus

The End
Keep Smiling!