Republic of the Philippines
Province of Sorsogon
Region V
Donsol Community College
Tres Marias, Donsol, Sorsogon
MODULE 4
Common Problem Encountered/Risks Factors in Food
Processing
FOOD PROCESSING, PACKAGING AND LABELING
FSM 211: A.Y. 2020-2021
First Semester-Module 4: Common Problem Encountered/Risks Factors in
Food Processing
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MODULE DEVELOPMENT TEAM
WRITER: JOCELYN L. BORDARAIS, LPT
EDITOR: ROSELYN A. MANTES, LPT
REVIEWERS: JOAQUIN G. ATAYZA, MATEA
EDUARDO A. POLLARCA, MAED
RENE C. BAROLA, MAM
LINEL L. JACINTO, RL., LPT
VIRGIE C. MALAGUEÑO, LPT
LAYOUT ARTIST: JOCELYN L. BORDARAIS, LPT
INTRODUCTION
Module four will provide you with the basic knowledge and
orientation about the common problem
encountered/risks factors in food processing industry.
This will also give you a deep understanding on how food
being processed until it reaches our table and be ready to
consume despite of some inevitable circumstances may
come across before, during and after the food processing.
As you go along with this module, try to accomplish every phase in order to fully
understand the Types and Methods of Food Processing. Moreover, you have to
answer the Pre-Assessment, examine and comprehend the lesson in the Read
and Study, fill-out Activities 1, 2, and 3, and answer the Post- Assessment.
Finally, reflect and share your thoughts by answering Going Further. Good luck!
OBJECTIVES
At the end of this module, you must be able to:
1. Give the common problems encountered/risks factors in food
processing.
2. Display appreciation of the importance of familiarizing common
problems encountered in food processing through own interpretation
of quotation.
3. Identify the common problems encountered/risks factors in food
processing.
PRE-ASSESSMENT
Fact or Bluff
Directions: Write F if the statement is fact, and B if it is a Bluff.
1. Perishable food items must be shipped without proper packaging to avoid
breakages and damages during transportation.
2. Availability of raw materials may cause delays in production resulting in
low supply.
3. Manual inspection is time-consuming and is prone to human error than
computerized inspection.
4. Consumer do not change their behavior, preference, wants and buying
decisions.
5. The absence and inadequacy of infrastructure facilities to store raw
materials do not affect the quality and availability of the end product.
6. Food manufacturers need to be as efficient when it comes to developing
new recipes and getting products out to market.
7. The possible causes of leakage are, defective adjustment of the can sealer
during sealing operation and presence of food particles or meat tissue
around the borders of the containers during the canning operation.
8. Under-processing is the use of excess temperature during the canning
operation. It usually leads to the development of unpleasant taste, loss of
flavor, and poor texture.
9. The presence of high levels of filth in food indicates that at some point
the food has been subjected to insanitary handling.
10. Under processing will cause contamination, and consequence of careless
of handling canning equipment and food ingredients will not be corrected
even with sterilizing high temperature.
READ AND STUDY
INTRODUCTION
Common Problems Encountered/Risks factors in Food Processing
Food processing industry comprises a large spectrum of industrial units
producing foods and vegetables products, marine products, meat and meat base
products, cereal based products etc. It has to play a key role in stimulating
economic development. Food processing industry can also be useful instrument
for improving food supply through prevention of post harvests losses of durable
foods and perishable food and generating employment especially in rural areas.
Establishment of food processing industry can trigger improvement in
productivity of agriculture and improve income of farmer. food processing also
provide comfort and easiness to our day to day living specially people who is
having hard time to prepare foods that may undergo different methods before it
will be served and ready to eat; and just like other sector, food processing also
encountered some inevitable problems that may come across the line and the
following are stated below.
1. Availability of raw materials
Agricultural produce is an important factor for
sustaining food processing activities. Due to seasonal
availability of certain crops, the sector faces delays in
production resulting in low supply.
For oil production, the majority of oilseed producers are
small and marginal farmers with poor access to resource
bases such as fertilizers, manure, etc. Hence, oilseeds
grown by such farmers have low yield.
Rabi crops like wheat, barley and mustard are sown
around mid-November and harvested in April or May.
These food grains are dependent on forces of nature, which are rather
unpredictable.
Seasonal scarcity and high cost of raw materials constitutes one of the major
constraints affecting the growth of small-scale food processing enterprises. This
scenario results in scarcity and higher pricing of raw materials.
2. Storage Constraints
Many of these shortage or scarcity issues can be solved by following proper
storage norms for raw materials.
However, this is a major challenge faced by the small-scale food processing
industry. The absence and inadequacy of infrastructure facilities to store raw
materials lowers the quality and availability of the end product.
There are two ways for proper storage
Warehouses storage problems arise due to scarcity of space
and how commodities are optimally stored in that space.
Product damages are another problem faced in warehouse;
few damages are inevitable but can be reduced with a rack
safety netting and avoiding overload of shelves.
Cold storage for frozen food is a
massive sub-industry in and of itself. With ever-
evolving food trends there are growing varieties of
ready-to-eat food, beverages, processed frozen fruit and
vegetable products, marine and meat products and so
on – many of these items require specialized storage
environments.
The lack of availability of these types of facilities pose a major constraint for the
food processing sector.
3. Transportation Issues
Perishable food items must be shipped with proper
packaging to avoid breakages and damages during
transportation. Also, timely delivery is important to avoid
spoilage – certain food items do not last long even if stored
in climate-controlled facilities.
4. Technological equipment
In some country food processing sector, they stick
to traditional production processes where the quality of
agricultural and food products is being inspected by
human evaluators. This manual inspection is time-
consuming, labor intensive and prone to human error. To
lessen the impact of these issues, computerized inspection
of these products must be implemented.
5. High competition
This industry is highly competitive with many players in the organized, as
well as, unorganized sectors. In order to survive in a competitive environment,
the food processing industry can definitely develop through marketing channels,
improving food quality standards and strengthen manpower to face global
challenges.
6. Meeting consumer demands
Many of the challenges faced by food
manufacturers relate to meeting changing consumer
demands. Often this needs to happen quickly and with
costs kept to a minimum. Consumer change their
behavior all the time, with new preferences and
emerging fads dominating many buying decisions. This
happens often, meaning that food manufacturers must
develop products to meet these demands in ever-shorter
timeframes. Recent trends include high protein
products, Omega 3 supplements, on-the-go nutritional snacks over more
traditional meals, as well as a whole host of other food trends.
There is no doubt that we have moved into a world of more diverse
consumer needs where requirements are becoming increasingly personal. Food
manufacturers need to work more closely with customers to understand their
individual needs and goals. They also need to be as efficient when it comes to
developing new recipes and getting products out to market.
7. Climate change
There are numerous factors that challenge food
production. The climate, topography and soil
variations within biomes may be challenging for
growing food, but the way people change the
environment can also have an impact on food
production. Research shows changing and
unpredictable weather conditions are altering the
seasons and bringing change to biomes. For example, in Sudan droughts and
extreme floods are becoming more common and farmers have to cope with crop
losses, and adapt to these changes where they can.
In some countries, because the weather has become so volatile and
extreme, people have to gain new understandings of the weather, adapt their
farming techniques, and learn disaster management strategies to reduce the
risk of people and communities.
8. Rusting of tin plate
Rusting of tin plate is the common trouble encountered
in the cold
storage. Rusting disfigures the containers, destroys the
label, corrodes the containers, which will lead to
oxidation, leakage, and the ultimate spoilage of the
canned products.
Avoid rusting by utilizing cans which are reasonably
dry and free from rust development either inside or
outside. In the storage, proper ventilation is required to
induce evaporation of moisture.
9. Under-processing
In order to preserve meat, use the reasonably high temperature to
eliminate all the spore-bearing microorganism causing spoilage. Under
processing will cause contamination, and consequence of careless of handling
canning equipment and food ingredients will not be corrected even with
sterilizing high temperature.
Proper sterilization is a method of expelling gas from the cans under
process. It is also considered of efficient method of heat penetration into the
central area of the retort, especially when canned food is processed.
Under processing therefor must avoided. It is mainly due to the improper
use of exhaust which fail to alleviate the temperature of heat into central area of
the cans inside the retort sign of under processing is swelling of cans after
sterilizing without any presence of leakage.
10. Leakage
The possible causes of leakage are:
➢ Defective adjustment of the can sealer during sealing
operation
➢ Presence of food particles or meat tissue around the
borders of the containers during the canning operation
➢ Meat tissues protruding over the can or overfilling
➢ Defective cans or factory defect in the manufacture of
cans.
To avoid leakage, the most important thing to do is to check
the cans for defects, and to avoid overfilling of cans, as well as
to exercise care in the handling of food products and canning
equipment during the operation.
11. Discoloration
The most common cause of discoloration of meat in
cans is the use of ordinary tin cans in canning. Cans that
are not enameled can use stain development in the interior
side of the tin cans. The reaction of Sulphides from the
ingredients or meats on the inner side of tin cans can cause
the discoloration of meat in cans.
12. Over-processing
Over-processing is the use of excess temperature
during the canning operation. It usually leads to the
development of unpleasant taste, loss of flavor, and poor
texture. With all these known, it is moreover important
to know the right temperature and time processing of
every particular product, as well as the size of cans used
in canning in order to avoid over-processing or under-
processing. Another technique to avoid over-processing
is to cool the cans immediately after sterilization.
13. Machine malfunction
Machines fail for a variety of reasons. Likewise, not all
failures are the same. The term "machinery failure" or
"malfunction" usually implies that the machine has stopped
functioning the way in which it was intended or designed. This is
referred to as “loss of usefulness” of the machine or component.
14. Lack of Leadership
Supervisors are often pulled in different directions, strained for time, and
focused on meeting the most immediate demands. As a result, they may not be
leading in an optimal way.
15. Pressures on Cost, Quality, And Meeting Customer Demands
The manufacturing environment is fast-paced, and supervisors are faced with
multiple demands, all vying for their attention. These constantly changing
demands force us into firefighting mode, which is not an efficient long-term
strategy.
16. Contamination with filth
Filth in food comes from the pests that contaminate
food--insects, mites, birds, and rodents. Although the
presence of minute quantities of filth in food is
inevitable, the Federal Food, Drug, and Cosmetic Act
prohibits food contamination by filth. The Food and
Drug Administration has taken a pragmatic approach
in establishing Defect Action Levels which represent
current industry standards for food purity. Even though
much of the food industry conforms to high standards,
incidents of gross adulteration continue to occur. Some
contaminants, however, are not altogether harmless to
the consumer. The presence of high levels of filth in food indicates that at some
point the food has been subjected to insanitary handling. Depending on whether
the contamination occurred before or after the last heat-processing (sterilizing)
step in manufacture or preparation, the significance of filth in food ranges from
merely aesthetically unappealing to allergenic, toxic, injurious, or pathogenic.
ACTIVITY 1: Fill in the blanks
Directions: Fill in the missing word to form a word or group of words. Write
your answer in the given space.
1. _ I _C _ L _ R _ T _ O _
2. L _ _ K _ _ E
3. U _ D _ R _ R _ C _ S _I _ G
4. _ U _ T _ N _
5. _ _ E _ P _ _ C _ _ S _ _ G
6. M _ _ _ I _ E M _ _ F _ _ _ T _ _ N
7. C _ _ _ _ T E _ H _ _ G _
8. H _ G _ _ O _ _ E _ _ T _ _ N
9. _ _ _ _ _ _ _ _ _ _ _ I O N I _ _ U _ S
10. S _ O _ A _ E C _ N _ T _ A _ N_ S
ACTIVITY 2: 3-2-1 Prompt
Directions: Write Three things you have learned from the lesson, Two questions
from the lesson, One aspect of class or the text you enjoyed.
Three things I have learned from the lesson…
1. _________________________________________________________
2. _________________________________________________________
3. _________________________________________________________
Two questions I want to ask from the lesson…
1. _________________________________________________________
2. _________________________________________________________
One text I’ve enjoyed and why…
1. _________________________________________________________
_________________________________________________________
_________________________________________________________
ACTIVITY 3: Matching type
Directions: Match column A to column B. Write the letter only.
1. Problem encountered where in a. Lack of leadership
supervisors are often pulled in
different directions, strained b. Rusting of tin plate
for time, and focused on
meeting the most immediate c. Over-processing
demands. As a result, they
may not be leading in an d. Leakage
optimal way.
2. It is the use of excess e. Machine malfunction
temperature during the
canning operation. It usually f. Under-processing
leads to the development of
unpleasant taste, loss of flavor, g. Contamination with filth
and poor texture.
3. One of the common food
processing trouble
encountered in which usually
implies the machine has
stopped functioning the way in
which it was intended or
designed. This is referred to as
“loss of usefulness” of the
machine or component.
4. Food processing risks factors
which can cause
contamination, and
consequence of careless of
handling canning equipment
and food ingredients will not
be corrected even with
sterilizing high temperature.
5. This risks factors in food
processing disfigures the
containers, destroys the label,
corrodes the containers, which
will lead to oxidation, leakage,
and the ultimate spoilage of
the canned products.
POINTS TO RMEMBER
Take note of the following important points in Module 1
1. Read and understand the lesson. Reread if you must.
2. Do not leave the activities unanswered.
3. Scoring rubrics for all essay questions:
Scoring rubrics
Criteria percentage
Content 50%
Originality 25%
Mechanics (grammar, spelling, 15%
format}
Timeliness of submission 10%
TOTAL 100%
POST-ASSESSMENT
Identification
Directions: Write the answers of the following questions.
1-4. The possible causes of leakage.
5-6. two ways for proper storage
7-10. list down common problems encountered in food processing.
GOING FURTHER
In your own understanding discuss the given quotation and cite the importance
of knowing the common problems encountered in food processing.
“Food availability is not really the issue. The quality of
the food is what we recognize is the problem”.
Catherine Bertini
References:
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KEY TO CORRECTION
Pre-assessment
1. B
2. F
3. F
4. B
5. B
6. F
7. F
8. B
9. F
10. F