Food processing

1. OVERVIEW OF THE FOOD INDUSTRY

2. FOOD INDUSTRY
• Commercial movement of food from field to fork
• Traditionally, food production was centered around
two activities:
Labor-intensive agricultural activities
Personal food preparation
• Modern food industry is the result of technological
& cultural changes that have occurred over the last 150 years

3. The components of the food
industry include:
• Regulation: local, regional, national and international
rules & regulations for food production & sale, including
food Quality & food safety, & industry lobbying activities
• Education: academic, vocational, consultancy
• R&D: food technology
• Financial services: insurance, credit
• Manufacturing: agrichemicals, seed, farm
•machinery & supplies, agricultural construction, etc.

4. The components of the food industry Cont.
• Agriculture: raising of crops and livestock, seafood
• Food processing: preparation of fresh products for
market, manufacture of prepared food products
• Marketing: promotion of generic products (e.g. milk
board), new products, public opinion, through advertising,
packaging, public relations, etc
• Wholesale & distribution: warehousing, transportation,
logistics
• Retail: supermarket chains and independent food stores,
direct-to-consumer, restaurant, food services

5. • Modern food industry is reliant on technology,
transportation, management & logistics for physical
fulfillment, and on marketing and government regulation for
maintaining an efficient consumer market Food is grown,
processed, & transported in a global manner
• Wide range of businesses and individuals are employed by
& profit from all aspects of this huge and complex system

6. Industry Size
• Processed food sales worldwide are approximately
US$3.2 trillion
• In the U.S., consumers spend approximately US$1trillion
annually for food, or nearly 10% of the GDP
• Over 16.5 million people are employed in the food industry
• India is the second largest producer of food next to China
• India has the potential of being the biggest with the
food and agricultural sector

7. • Accounts for less than 1.5 per cent of international food trade
• The Indian food industries sales turnover was Rs 140,000
crore annually at the start of year 2000
• The industry has the highest number of plants approved by the
US Food and Drug Administration (FDA) outside the USA

8. Sector Subsector
Fruit & vegetables, Meat & poultry
Milk & milk products, Alcoholic
beverages, Fisheries, Plantation,
Grain processing, Confectionery,
Soya-based products, Mineral
water, High protein foods
Soft-drink bottling, Confectionery
manufacture, Fishing, aquaculture,
Grain-milling & grain-based
products, Meat and poultry
processing, Alcoholic beverages,
Milk processing, Tomato paste,
Fast-food, Ready-to-eat breakfast
cereals, Food additives, flavors
Indian Food Processing

9. Food Processing
• The Indian food processing industry is presently growing at
14 % against 6-7 per cent growth in 2003-04
• The industry received foreign direct investments (FDI)
totaling US$ 143.80 million in 2007-08 against US$ 5.70
million in the previous fiscal year
• The size of the global processed-food market is estimated at
US$ 3.2 trillion

10. Food Processing
• Nearly 80 % of agricultural products in the developed
countries get processed and packaged
• The ministry of food processing is planning to set up
350 new food processing units
• The food and grocery market in India is the sixth
largest in the world
• Food and grocery retail contributes to 70 % of the
total retail sales

11. Indian food market
• The Indian food market is estimated at over US$ 182 billion
• According to consultancy firm McKinsey & Co, the retail
food sector in India was US$ 70 billion in 2008
• Despite a global slowdown, Indian spice exports are growing
India exported 470,520 tonnes of spices valued at
US$ 11.68 billion an all time high in 2008-09

12. • 99% of the food processing industry is unorganised
• Immense scope for growth for the organised sector
• The organised food retail sector is largely dominated by
restaurants, fast food outlets
Major investments
• Private investment has been one of the key drivers for
growth of the Indian food industry

13. Government Initiatives
• The new trade policy places increased focus on agro-based
industries
• Food processing industries in the list of priority sectors for
bank lending
• The government has started work on 10 Mega Food Parks,
& is planning to increase the number to 30 by 2016
• Fruit and vegetable processing units have been completely
exempted from paying excise duty

14. Food Safety Regulations in India
• Ministry of Food and Consumer Affairs main Government
agency dealing with product standards for consumption in
the domestic market
• The Bureau of Indian Standards (BIS) is the main Standard
Setting body in India for all domestic market requirements
• The Export Inspection Council (EIC) is the Chief
enforcement body for exports
• Policies and plans for the food processing industries is
coordinated by the Ministry of Food Processing Industries
formed in 2001

15. Ministry Legislation
Ministry of Agriculture Insecticide Act
Milk and Milk Product Control Order (MMPO)
Meat Food Product Order 1973
Ministry of Rural Development:
Directorate of Marketing and
Inspection (DMI)
Agricultural Produce (Grading and Marking)
Act
Ministry of Health & Family
Welfare
Prevention of Food Adulteration Act 1954
Ministry of Food Processing
Industries
Fruits & Vegetable Products (Control) Order
– FPO 1955
Ministry of Commerce Export (Quality Control & Inspections) Act
1963

16. Ministry Legislation
Ministry of Civil
Supplies, Consumer
Affairs & Public
Distribution
Standards of Weights & Measures Act
Standards of Weights & Measures (Enforcement) Act
Solvent Extracted Oils, De-oiled Meal &
Edible Flour Control Order, 1967
Vegetable Products Control Order, 1976
Bureau of Indian Standards (BIS) Act 1986
Ministry of Environment
& Forests
Aquaculture Authority Notification 1997 & 2002
Environment (Protection) Act1986,
Environment (Protection) Third Amendment Rules,
2002
Coastal Regulation Zone – Notification 21 May 2002
Aquaculture Authority - Notification

17. CHEMICAL CHANGES DURING
PROCESSING -
LOSS OF NUTRITIVE VALUE & FLAVOUR

18. EFFECT OF PROCESSING ON
NUTRIENT CONTENT OF
FOODS

19. Food processing
• Set of methods and techniques
used to transform raw ingredients
into food or to transform food into
other forms for consumption by
humans or animals either in the
home or by the food processing
industry.
• Takes clean, harvested crops or
slaughtered & butchered animal
products & uses these to produce
attractive, marketable & often long-
life food products. Similar processes
are used to produce animal feed.

20. Food processing methods
• Removal of unwanted outer
layers
Ex. Potato peeling or the
skinning of peaches.
De-husking, milling & polishing
of cereals.
Chopping or slicing, Ex. Diced
carrots.
• Mincing & macerating
• Liquefaction, Ex. Fruit juice
• Fermentation, Ex. Beer
breweries

21. •Emulsification
•Cooking, such as
boiling, broiling, frying,
steaming or grilling
•Deep frying,
Baking ,Mixing
•Addition of gas, Ex.
Bread, Soft drinks

22. Food
processing
methods
•Proofing
•Spray drying
•Pasteurization
•Packaging

23. Factors influencing losses due to processing :
•Genetic make-up of the plant or animal
•Soil in which it is grown
•Use of fertilizer
•Prevailing weather
•Maturity at harvest
•Packaging
•Storage conditions
•Method of preparation for processing
•The storage conditions and handling after processing

24. The effect of food processing on nutrient content
will depend on:
•Characteristics of the food being processed,
•Concentration of the nutrient in the food
•The sensitivity of the nutrient to conditions such as heat, oxygen,
pH and light
Ex. Sensitivity of vitamin C to heat varies with pH

25. The effects of processing on nutrient content
•Food has to be a good source of a particular nutrient, Ex. The losses
of protein (amino acids) during blanching of legumes, more
significant than of vitamin C
•Processing to be done within the recommended guidelines, Ex. For
heat and pH over-processing will destroy nutrient content, taste &
appearance

26. Nutrient Effect of Processing
Fat Oxidation accelerated by light
Protein Denatured by heat (improves digestion)
Amino Acids Some are sensitive to light. Lysine bio – availability reduced
by non - enzymatic browning
Vitamin C
(Ascorbic acid)
Decreases during storage, drying, heating, oxidation
Cell damage (e.g. chopping or slicing)
Losses due to oxidation catalyzed by copper, iron
Stable to heat under acidic conditions
Ex. Pasteurization of orange juice
Effect of Processing on Nutrient Foods

27. Nutrient Effect of Processing
Vitamin B1
(Thiamine)
Destroyed by high temperatures, neutral and alkaline
(e.g. baking soda, baking powder) conditions
Lost in cooking water
Vitamin B2
(Riboflavin)
Sensitive to light at neutral and alkaline conditions
Moderately heat stable under neutral conditions
Sensitive to heat under alkaline conditions
Vitamin B3
(Niacin,
Nicotinamide)
The most stable vitamin
Stable to heat and light
Leaches into cooking water

28. Nutrient Effect of Processing
Folate Decreases with storage, or prolonged heating
Lost in cooking water
Vitamin B6
(Pyridoxine)
Heat stable in alkaline and acidic conditions
Pyridoxal is heat labile
Vitamin B12 Destroyed by light and high pH
Carotenes Easily destroyed by heat
Oxidises and isomerises when exposed to heat and light
Vitamin A Very heat labile
Easily oxidised

29. Nutrient Effect of Processing
Vitamin D Oxidises when exposed to heat and light
Vitamin E Oxidises readily

30. Heat Processes
• Heating can be both beneficial &
detrimental to nutrient content of foods
• Generally improves the digestibility of
foods, making some nutrients more
available Ex. Protein in legumes

31. Heat Processes
Reduction in protein quality
of the food
• Lysine content most often
affected
• Vitamin C destroyed by
heating
• Losses of other labile
nutrients depend on the
extent of heating and other
prevailing conditions, such
as pH

32. Dehydration
•Two processes occur during
drying:
Addition of heat
Removal of moisture from the
food
• Nutritional losses during
drying are more due to the
application of heat than to the
removal of moisture,
Exception is thiamine

33. Losses during the drying
process depend on
• Preparation procedures
before drying, Ex. Slicing,
Blanching
• Drying temperature
• Drying time
• Storage conditions

34. Nutrient losses during
drying
• Losses during preparation
are greater than losses during
drying
• Nutrient losses during drying
can be decreased by drying at
a low temperature and
shortening drying time
• Storing under dry conditions
and at low oxygen levels

35. Sulphites
• Anti-oxidant to prevent browning
& preservation of fruits ,seafood
& meat
• Increased loss of thiamine from
food.
Blanching
• Destruction or inactivation of
enzymes that affect the colour,
texture, flavour and nutritive value
of foods during storage
• Results in significant nutrient
losses from fruits & vegetables

36. The nutrient losses during
blanching will depend on
several factors:
• The food item
• Surface area exposed
• The method used (steam
blanching or hot water
blanching)
• Contact time
• Amount of agitation

37. Food Item Nutrient Losses in Steam
Blanching (%)
Losses in Water
Blanching (%)
Peas Vit. C 12 26
Peas Amino acids 13 25
Spinach Amino acids 60 80
Losses in Nutrients
During Blanching

38. • Nutrient losses in blanching result
from: Thermal degradation, oxidation
& leaching
• Hot water blanching results in more
losses due to leaching of water-
soluble vitamins, minerals and amino
acids
• Addition of sodium bicarbonate (or
other alkali) to the blanching water
for preserving the colour softens the
texture of the vegetable and increases
destruction of vitamin C and
thiamine

39. Salting
• Commonly used for meat
and fish
• Loss of fluid & some of
the water-soluble proteins,
vitamins & minerals
• Some proteins are also
denatured by the salt

40. Smoking
• Usually follows salting or
curing
• Bactericidal & anti-
oxidative function
• Reduces oxidative changes
in fats, proteins and vitamins
• Nutrient losses due to heat,
flow of gases & interaction
of the smoke components
with proteins

41. Smoking
• The heat and flow of gases
cause drying of the food item
• Increase in the protein and fat
concentration of the food
• Increased concentration of
curing agent in cured foods
• Denaturation of proteins, but
the amino acid content retained
• Carcinogenic substances
deposited & absorbed on foods

42. Concentration
Nutrient changes depend on:
Contents of the mixture
Temperature
• Decreased water content &
increase in other nutrients

43. Concentration
Sugars in solution with water
will crystallize out if the water
content becomes too low or on
refrigeration
• Will not affect the sugar
content, only the appearance &
texture of the food
• Heat & high concentration of
salt & minerals, can denature
proteins, resulting in gelling

44. EFFECT OF PROCESSING ON
FLAVOUR CONTENT OF FOODS

45. Functional Group Flavour compound
Alcohols Eugenol (Clove)
Menthol (Peppermint)
Aldehydes Citral (Lemon grass)
Vanillin (Vanilla)
Amines Indole (Jasmine)
Trimethylamine (Fish)
Esters Isoamyl acetate (Banana)
Octyl acetate (Orange)
Ethers Anisole (Anise)
Eugenol (Clove)

46. Functional Gp. Flavour compound
Ketones Dihydrojasmone (Fruity woody floral)
2-Acetyl-1- pyrroline (Fresh bread)
Lactones gamma-Delactone (Peach)
Jasmine lactone (Peach & apricot)
Terpenes Citronellol (Rose)
Limonene (Orange)
Thiols Ethane thiol (Leek)
Grapefruit mercaptan (Grape fruit)
Miscellaneous
compounds
Nerolin (Garlic)
Methylphosphene (Orange flower)

47. • Several processing methods
involve application of heat
Heat affects flavour:
• Heat is both the enemy of
flavour ingredients & essential to
the development of many desired
flavour components in food
On the plus side
• Heat helps to develop flavours
& colour
• Needed for foods to obtain their
expected flavour profile, Ex.
Maillard browning
Caramelization of sugar

48. On the minus side
Volatilization of flavour:
• There is a “Flash off” of some flavour
components when heated in an open
processing system
Various flavor components affected
differently :
• Volatilization/co-distillation can reduce
overall flavour impact
• It can also throw the flavour system off
balance

49. Heat accelerates chemical
reaction among flavour
components & other
ingredients:
Ex. Interaction of protein &
starch with flavour
components affecting taste/aroma
• Many flavor components
disappear into these matrices
depending on the chemical nature
of the protein &/or starch matrix

50. Alternative processing
methods won’t always develop
flavours in the same way:
• Difference in processing can
cause the same flavour
precursors to undergo different
reactions & produce different
flavours, Ex: Peanuts, corn:
boiled, roasted

51. • Products with reduced fat levels
especially are particularly
susceptible to these interactions
due to presence of starch or protein
based fat mimetics
• Even if flavour components don’t
react directly with other
ingredients, the latter may serve to
destabilize an otherwise heat
stable flavour system

52. Degradation of flavour
components:
• Occur in open/closed processing
systems
• Depending on the pH of the food &
the type of food the flavour system
varies Ex: foods like tomato sauces
- the low pH will affect the flavour
profile & degradation reactions
• Moisture is also a factor that
determines how degradation
reactions proceed