Food production systems A food production system has

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Food production systems

Food production systems

A food production system has three parts. 1. Input: The different ingredients, materials, machinery

A food production system has three parts. 1. Input: The different ingredients, materials, machinery and items which go into the system. 2. Process: The different things that happen to the Input which change it into the Output. 3. Output: The finished food product.

 • For example: when making cakes the food production system would be. .

• For example: when making cakes the food production system would be. . . Input: Process: Output: Eggs, Beating, Fairy sugar, baking cakes flour, etc. • Care must be taken at all stages of a food's development - from production through to consumption - to ensure that it is safe and of high quality.

Next slide shows you what precautions are taken during the food production process.

Next slide shows you what precautions are taken during the food production process.

Production: Raw materials must be of high quality. Storage: High-risk foods should be stored

Production: Raw materials must be of high quality. Storage: High-risk foods should be stored below 5 degrees Celsius. Preparation: Equipment and food handlers must comply with hygiene regulations.

Cooking: Food must be cooked thoroughly to prevent food poisoning. Transportation: Temperature control may

Cooking: Food must be cooked thoroughly to prevent food poisoning. Transportation: Temperature control may be necessary for high-risk foods. Serving: Food must be kept below 5 degrees Celsius or above 63 degrees Celsius.

Hazard Analysis and Critical Control Point (HACCP) • If a food manufacturer wishes to

Hazard Analysis and Critical Control Point (HACCP) • If a food manufacturer wishes to produce products which are of high and consistent quality s/he will need to identify areas of production where inaccuracies (hazards) could occur. These inaccuracies are known as hazards. • The food manufacturer must then design checks to be put into place to prevent hazards from occurring.

For example. • If a packet of cookies is to contain biscuits which are

For example. • If a packet of cookies is to contain biscuits which are identical in weight, shape and appearance, regular checks will be needed throughout the production process. Variations would not only be unacceptable to the consumer, but may actually break the law (for instance, if weights were not as stated on the packaging).

For example cont. . . • The first stage will be to write a

For example cont. . . • The first stage will be to write a product specification, which will lay down the exact details of a product - for example, its size, shape, colour, storage life and packaging. • The manufacturer will then carry out a risk assessment that will identify what could go wrong and then specify how the problem will be dealt with.

 • This whole process is usually known as H. A. C. C. Ps

• This whole process is usually known as H. A. C. C. Ps • A team of people will identify the hazards, which could be from micro-organisms, chemicals, people or machinery. • A CCP (Critical Control Point) could be any part of the production process, which could affect the finished quality of the product.

 • H – Hazard • A – Analysis • C – Critical •

• H – Hazard • A – Analysis • C – Critical • C – Control • P – Points

www. foodreg. com 7 Principles in HACCP

www. foodreg. com 7 Principles in HACCP

HACCP Structure www. foodreg. com

HACCP Structure www. foodreg. com

What does 7 Principles mean? www. foodreg. com

What does 7 Principles mean? www. foodreg. com

1. Conduct Hazard Analysis www. foodreg. com

1. Conduct Hazard Analysis www. foodreg. com

2. Determine CCP www. foodreg. com

2. Determine CCP www. foodreg. com

3. Establish Critical Limit(s) www. foodreg. com

3. Establish Critical Limit(s) www. foodreg. com

4. Establish Monitoring System www. foodreg. com

4. Establish Monitoring System www. foodreg. com

5. Establish Corrective Action(s) www. foodreg. com

5. Establish Corrective Action(s) www. foodreg. com

6. Establish Verification Procedures www. foodreg. com

6. Establish Verification Procedures www. foodreg. com

7. Establish Record-Keeping Procedures www. foodreg. com

7. Establish Record-Keeping Procedures www. foodreg. com

For example Weighing of ingredients Time Shaping Temperature Consistency of mixtures Hygiene Before and

For example Weighing of ingredients Time Shaping Temperature Consistency of mixtures Hygiene Before and after preparation/cooking. Of cooking, chilling, mixing, etc. Of mixtures, division of dough, etc. Storage of foods, cooking and chilling. During making and when cooked/chilled or stored. Of raw ingredients, food handlers, machinery and the finished dish.

 • Each of the CCPs will have a tolerance level for example, food

• Each of the CCPs will have a tolerance level for example, food could be cooked for between 20 and 22 minutes. These may also be known as critical limits. • Once these CCPs have been identified, checks can be put in place that will monitor a product's progress through the production process.

 • These checks could be: a) Visual: Checking decorations on cakes, or the

• These checks could be: a) Visual: Checking decorations on cakes, or the colour of a mixture. b) Electronic: Fridge/freezer thermometers, timing devices. c) Scientific: Carrying out microbe checks on equipment.

 • Many of these checks can be monitored by computer and require very

• Many of these checks can be monitored by computer and require very little intervention from food production workers. • Continuous monitoring will give feedback on all stages of production and action can be taken quickly to remedy any problems. • Early detection of problems can prevent waste of ingredients and reduce the need to shut down the whole production line, which would be both costly and time consuming.

Sensory

Sensory

Sensory Evaluation • Food manufacturers and retailers often use sensory evaluation in order to

Sensory Evaluation • Food manufacturers and retailers often use sensory evaluation in order to help them to know what consumers think of their products. • They may also carry it out to ensure that all the food produced by a production line is identical.

 • This testing may take place at various stages of the production process

• This testing may take place at various stages of the production process and may involve testing raw ingredients, after developing new dishes, after they have been modified or after they have been stored. • The food will be tested using organoleptic factors, meaning that they are using our different sense organs.

 • • • Such as: Texture (mouthfeel) Taste or flavour Appearance or colour

• • • Such as: Texture (mouthfeel) Taste or flavour Appearance or colour Smell or aroma • In order to ensure that sensory testing is considered to be 'fair', it is important that conditions are carefully controlled.

 • This will involve: 1. Sipping water between each sample to remove the

• This will involve: 1. Sipping water between each sample to remove the taste of the previous food. 2. Using separate booths so that testers are not influenced by each other. 3. Labelling food with numbers or letters so that the tester does not recognise a brand name. 4. Having a well-lit room with the minimum of noise and smells.

5. Using clean cutlery and utensils for each sample. 6. Sometimes using blindfolds (blind-testing)

5. Using clean cutlery and utensils for each sample. 6. Sometimes using blindfolds (blind-testing) so that the tester if not influenced by the appearance of the food. 7. Each sample of food being the same size. 8. Having a minimum of 6 testers.

 • Testers must not be: • Suffering from a condition, which would affect

• Testers must not be: • Suffering from a condition, which would affect their taste (for example, smoking, a heavy cold, or taking strong medication). • Allergic to foods or ingredients.

Different types of sensory tests 1. Difference or Discrimination Tests • Two or more

Different types of sensory tests 1. Difference or Discrimination Tests • Two or more samples are compared at a time in order to find out if there is a difference between them. • Paired comparison tests: Pairs of food samples are tested and testers are asked to say if there is a difference between them in relation to a particular characteristic, such as saltiness or crunchiness.

 • Triangle tests: Three samples are presented to testers, but two of them

• Triangle tests: Three samples are presented to testers, but two of them are identical. The testers are asked to identify the 'odd one out'. This test is useful for comparing different brands of the same product (for example, tomato ketchup) or for ensuring that all batches from a production run are identical.

2. Grading Tests • Food samples will be tasted and then placed in order

2. Grading Tests • Food samples will be tasted and then placed in order to reflect a particular characteristic for example, sweetness, or a personal preference. • A Hedonic Scale is a very simple way of recording what a tester thinks of a product?

 • Testers are asked to tick underneath the face which best describes how

• Testers are asked to tick underneath the face which best describes how they feel about the product. • Rating tests: Testers rate a product using either a 5, 7 or 9 point scale.

 • • • For example: 1. Extremely wet 2. Very wet 3. Moderately

• • • For example: 1. Extremely wet 2. Very wet 3. Moderately wet 4. Slightly wet 5. Neither wet or dry 6. Slightly dry 7. Moderately dry 8. Very dry 9. Extremely dry

 • Ranking tests: Samples that are coded are given to a tester in

• Ranking tests: Samples that are coded are given to a tester in a random order. Testers are asked to rank the samples in order of preference using codes or symbols rather than numbers. A minimum of 10 testers are needed to produce results, which are both reliable and informative.

3. Profile • A star with 8 points is labelled with words which describe

3. Profile • A star with 8 points is labelled with words which describe some sensory characteristics of a product. A tester is then asked to place the food sample on a scale of 1 to 5 for each characteristic. These results are then plotted onto the star. It is possible to compare similar products - for instance, two types of biscuits or fruits - by plotting them on the same star profile.

Producing a New Product

Producing a New Product

Design specification • This specification is written early on in the development of a

Design specification • This specification is written early on in the development of a product and is quite general and wide. • For example: • "My product will have an edible casing. " • "My product will contain a savoury filling. " • "My product will cost under RM 10. "

Product specification • This is a more detailed specification, usually written when the final

Product specification • This is a more detailed specification, usually written when the final product has been decided upon. • It may be given to a chef in a test kitchen and then will undergo sensory testing before the decision is made to produce it on a large scale.

 • For example: • "The pastry will be rolled out to 15 cm

• For example: • "The pastry will be rolled out to 15 cm squares. " • "It will contain mushrooms, sweetcorn, cheese sauce and chicken. " • "It will cost between RM 10 and RM 15. "

Manufacturing specification (Higher tier) • This is a very detailed specification, which would be

Manufacturing specification (Higher tier) • This is a very detailed specification, which would be given to the food manufacturer so that identical products can be produced on a large scale. • This specification may also include sensory characteristics of the product - for instance, "it will be golden brown with a crisp, flaky texture. "

 • For example: • "The pastry will be rolled out to 15 cm

• For example: • "The pastry will be rolled out to 15 cm squares. " • "The mushrooms will be cut into 5 mm slices. " • "The cost will be RM 12. "

Design a manufacturing specification. • Here are some ideas of what to include to

Design a manufacturing specification. • Here are some ideas of what to include to produce a successful specification. – Specific dimensions (with a sketch) - for instance, weight, size, shape. – Specific qualities of ingredients - for example, percentage of fat in meat, size of cherries. – Names of ingredients with weights and proportions to use - for example, "200 g butter, 450 g flaked haddock. "

– Specific tolerances - for example, thickness of pastry, viscosity (runniness) of sauce. –

– Specific tolerances - for example, thickness of pastry, viscosity (runniness) of sauce. – The size to which ingredients must be cut for example, the exact shape and size of pieces of fruit and vegetables, the nozzle size for mincing meat, the slicing grade for carrots, the grating size for cheese. – Types of cooking methods and cooking temperatures with critical control points. – Cooling times and methods.

 • Finishing techniques - for example, "Brush with whole egg glaze before baking",

• Finishing techniques - for example, "Brush with whole egg glaze before baking", "Fill centre of cake with fresh whipped cream to a thickness of 2 cm", "Decorate with six slices of tomato and one teaspoonful of mixed herbs before cooking", "Cover surface of biscuit with white rolled icing to a thickness of 0. 5 cm. " • Specific details of packaging requirements - for example, microwavable dish with sealed film covering in crushproof sleeve. "

 • Wording for the label, which will provide information for the consumer about

• Wording for the label, which will provide information for the consumer about ingredients, nutrition, the name of the product, storage and cooking/reheating instructions, shelf life, etc. • Sometimes a photograph is used to help a manufacturer to meet that specification. This would normally still need additional written information, but is useful in large-scale catering where a meal is being assembled on a plate from bought components.

Development of a new product • Food companies develop many food products each year

Development of a new product • Food companies develop many food products each year in order to help them remain competitive and to increase sales. If a new food product is to be successful it is important that it is tested and evaluated throughout its development in order to make sure that it is what the customer really wants.

Stages in product development Identify target group i. e. vegetarians Market research Write a

Stages in product development Identify target group i. e. vegetarians Market research Write a design specification Generate some ideas Sensory evaluation of these ideas Select some of the ideas for further development Consumer testing Further modification Test if product can be produced on a large scale Design packaging Final product specification Large scale production Advertising Launch of product

The end Thank you

The end Thank you