TOPIC: Food Manufacture

Question 1

what is food manufacture

Answer 1

 Food Manufacture is the process of the conversion of raw materials into a final product that uses physical and chemical products

Question 2

• quality and quantity control in the selection of raw materials for food processing
What is this generally?

Answer 2

 Extensive time and effort is undertaken to ensure raw materials are of high standards
 Research will be conducted to choose suppliers to ensure correct quality and type is applied to the manufactured product

Question 3

When suppliers / manufacturers choose raw materials - what is expected of these ingredients?

Answer 3

1. free from contaminants
2. meet specific criterial characteristic for the specific manufacturing process - this may be:
    colour
    size
    moisture content
    nutritional value / density

Question 4

Describe the process of specification for raw materials

Answer 4

1. description/characteristics of material:
    moisture content e.g. pH level
    physical e.g. shape/size
    sensory e.g. aroma, colour
    chemical / microbiological e.g. bacterial load
2. Sampling Method for material:
    the number for samples for quality assurance, testing for specific characteristics
    these depend on the processed product - they will differ from product to product
3. Test for each specified characteristic:
    There is no value in a specific characteristic unless it can be tested
    this may include tests like pH for alkalinity or acidity, moisture tests, bacterial load tests, visual tests for colour/abnormality
4. Action after test shows result:
    action will include either accepting or rejecting the raw material as well as starting a method of controlling the problem if the material shows to be outside the standard

Question 5

• role of food additives in the manufacturing
process

What are food additives

Answer 5

Food additives are substances added to food that are not normally consumed by themselves.

Question 6

Why do manufacturers use food additives?

Answer 6

1. improve taste and appearance
2. improve quality and stability
3. preserves food by extending storage life
4. to supplement special dietary needs e.g. artificial sweeteners in sugar free

Question 7

describe 2 common food additives & their role in specific food products

Answer 7

1. Colours - used to add or restore colour to foods E.G. icing mixture is coloured to make it more attractive on cakes
2. Artificial Sweeteners - used to replace the sweetness normally provided by sugars in foods without contributing significantly to their available energy E.G. Diet Coke

Question 8

•characteristics of equipment used in different types of production and the factors influencing their selection

Generally Describe

Answer 8

Food is produced by manual methods as well as highly computerized production areas

AUTOMATION AND COMPUTERIZATION:
	Reduce labour
	Save energy
	Ensure consistent product quality
	Waste less materials
	Provide more consistent production levels

Question 9

•characteristics of equipment used in different types of production and the factors influencing their selection

Identify the different processes

Answer 9

	Separation
	Grinding and milling 
	Mixing 
	Heating 
	Cooling 
	Freezing 
	Evaporation 
	Dehydration

Question 10

SEPARATION

Describe Filtration: its purpose, equipment used & food example

Answer 10

Filtration is the passing of liquid through a filter so solid particles are removed

Equipment used to carry this out may be filtering systems

E.G. separation of cheese curd through filtration systems

Question 11

SEPARATION

Describe Sedimentation: its purpose, equipment used & food example

Answer 11

The use of gravitational or centrifugal forces to remove solids from liquids

Equipment used to carry this out is a centrifuge

E.G. separation of cream from whole milk

Question 12

SEPARATION

Describe Centrifuging: its purpose, equipment used & food example

Answer 12

Process used to separate food particles of different densities

Equipment used to carry out may be a centrifuge

E.G. skimming of milk

Question 13

Describe grinding & milling: its purpose, equipment used & food example

Answer 13

The process of reducing raw material size which may be required to:
 Make raw material easier to handle
 Make raw materials suitable for final product
 Make a completely new product

Equipment used to carry out may be computerised mills

E.G. grinding salt to make it easier to handle OR making flour from wheat

Question 14

Describe mixing: its purpose, equipment used & food example

Answer 14

Process used to evenly distribute ingredients through product batch

Equipment used may be a high pressure mixer

E.G. large scale production of baked goods in a factory

Question 15

Describe heating equipment: its purpose, equipment used & food example

Answer 15

Process used to heat raw material.

equipment used to carry out may be an industrial oven or tubular plate exchanger

E.G. tubular plate exchanger used to produce sauces

Question 16

Describe cooling: its purpose, equipment used & food example

Answer 16

Reduce temperature of a product to slow down or stop activity of enzymes

Equipment used may be an industrial fridge

E.G. used for fruit and veggies

Question 17

Describe freezing: its purpose, equipment used & food example

Answer 17

Used to change water into ice. Stopping or pausing enzyme activity

equipment used may be immersion freezers

E.G. Immersion freezers used to freeze poultry + beef

Question 18

Describe evaporation: its purpose, equipment used & food example

Answer 18

Used to increase solids concentration of liquid form

equipment used may be a industrial evaporator

E.G. the conversion of tomato juice to tomato paste

Question 19

Describe dehydration: its purpose, equipment used & food example

Answer 19

Reduce water content - limits microbial growth

equipment used may be spray dryers

E.G. cows milk powdered milk uses spray dryer to reduce moisture content

Question 20

• characteristics of equipment used in different types of production and the factors influencing their selection

What are the factors influencing equipment selection for processing?

Answer 20

1. Is it Effective, durable & sturdy?

2. Does it align with safety & hygiene standards?

Question 21

• production systems used in the manufacture of food, eg small scale, large scale, manual, automated, computerised

LARGE SCALE

Answer 21

Used in large production operations where there may be production lines, large scale production has the advantage of producing large volumes of product over short periods.

E.G. Arnott biscuits

Question 22

• production systems used in the manufacture of food, eg small scale, large scale, manual, automated, computerised

SMALL SCALE

Answer 22

 Used at the household / domestic level of production
 They are much less complex to operate E.G. a piping bag to pipe cream into eclairs or a domestic food processor or kitchen aid mixer to make dough

Question 23

• production systems used in the manufacture of food, eg small scale, large scale, manual, automated, computerised

MANUAL

Answer 23

 This involves an employee physically adding ingredients or performing certain operations by hand
 Usually found in small scale operations, the organisation relies heavily on the skill and judgement of its staff
 The costs associated with this operation are usually high and efficiency and consistency is often reduced
 As its name suggests, this level of production is labour intensive
E.G. hand dipping chocolate truffles

Question 24

• production systems used in the manufacture of food, eg small scale, large scale, manual, automated, computerised

AUTOMATED

Answer 24

 Refers to when machines handle and control the processing of food from the receipt of raw materials through to the finished product
 Automated systems have pre-set and predetermined specifications for operation, mixing times and speed, temperature control, cooking or cooling times, cleaning and sterilisation
E.G. automated production line to process fresh milk

Question 25

• production systems used in the manufacture of food, eg small scale, large scale, manual, automated, computerised

COMPUTERISED

Answer 25

 In highly sophisticated manufacturing organisations, the automated equipment and machinery are operated by computerised sensors that are capable of keeping complex operations running 24/7
 These computerised systems have the ability to store complex data, keep records of batch numbers, pH levels, production conditions, dates and time.
 E.G. cheese making production uses computerisation

Question 26

What are flow diagrams?

Answer 26

FLOW DIAGRAMS:
It is a method used of representing a food production process through a flow diagram
Features of diagram include:
Five basic symbols
Symbols written vertically down the page
Joined by vertical lines
Used separately or joined