CORE COMPETENCIES

UNIT OF COMPETENCY : PROCESS FOODS BY SALTING, CURING AND

SMOKING
UNIT CODE : PFB751330
UNIT DESCRIPTOR : This unit deals with the knowledge, skills and attitudes
required to process foods by salting, curing and smoking. Include packaging
using plastic bags only.

Prepare equipment tools, materials and utensils

(Day 1)

WHAT IS THIS LESSON ABOUT?

This lesson deals on how to prepare equipment, tools, materials and utensils needed in salting, curing
and smoking. This includes lessons on Waste management, Occupational Safety and Health Standards
(OSHS), Current Good Manufacturing Practices

Learning Objectives:

At the end of the lesson, you should be able to:

1. Define the terms hazard and control point.

2. Understand the importance of HACCP

3. Create awareness on basic concepts of 7S of good housekeeping

4. Implement and apply the 7S program in the workplace

5. Value the Occupational Safety and Health Standards (OSHS)

Introduction:

7S of Good Housekeeping is the most basic and fundamental approach for productivity and quality
improvement in all types of business. It is intended to optimize the physical workspace for efficiency and
effectiveness by identifying and storing the items used, maintaining orderliness and cleanliness in the
area and sustaining the new order to ensure safety of the workers in the most efficient manner. 7S of
Good Housekeeping is an expanded version of 5S of Good Housekeeping.

7S stands for

 Sort
 Systematize
 Sweep
 Standardize
 Safety
  Self-discipline
 Sustain.
Techniques that provide a methodology for organizing, cleaning, developing, and sustaining a productive
work environment.

S:1 - Sort This is the most important step. Take out unnecessary items and dispose them. Separating
things in terms of what is necessary from those that are not.

 NO POTENTIAL USE
 THINGS NOT NEEDED
 IMMEDIATE DISPOSAL
 POTENTIALLY USEFUL OR VALUABLE
 CONSIDER WHERE USEFUL & MOVE
 REQUIRING SPECIAL DISPOSAL
 ARRANGE RESPONSIBLE, INEXPENSIVE DISPOSAL
 Flow of Sorting Process Make a list of all items found within the Workplace
 Verify to ensure the list
 Classify the needed and not needed

S:2 - Systematize ARRANGING NECESSARY ITEMS IN GOOD ORDER FOR USE FUNCTIONAL STORAGE

 ORGANIZING
 THINGS USED CONSTANTLY
 THINGS NEEDED
 ELIMINATING TIME WASTED IN SEARCHING FOR THINGS WE NEED.
 THINGS USED OCCASIONALLY SELDOM USED
 PLACE A LITTLE NEARER PLACE A LITTLE FARTHER ENCLOSE IN A
SEPARATE, DESIGNATED PLACE

S:3 - Shine Cleaning your workplace and eliminating the root cause. Creating a spotless workplace.
Removing everything from the work that should not be there.

S:4 - Standardize Maintaining high standard of housekeeping It involves the development of a clear
system for maintaining cleanliness and orderliness Standardization can be achieved through “visual
control” system. Standardize using Visual Control Visual Control is a TECHNIQUE to enable people to
make rules easy to follow, differentiate normal and abnormal situations and act accordingly, with the
use of visual acts.

S:5 – Self Discipline Doing things spontaneously without being told or ordered. Developing habits you
won’t forget.

S:6 – Safety Freedom from unacceptable risk of harm brought about by clean and orderly environment 
Poor housekeeping can be a cause of accidents  A workplace must maintain order throughout the
workplace
S:7 – Sustain CONTINUOUSLY PERFORM THE 7S ACTIVITIES AND SEEK FURTHER IMPROVEMENT

What is the purpose of WORKPLACE HOUSEKEEPING? Poor housekeeping can be a CAUSE OF

ACCIDENTS, such as:

1. TRIPPING OVER loose objects on floors, stairs and platforms

2. BEING HIT by falling objects

3. SLIPPING on greasy, wet or dirty surfaces

4. STRIKING AGAINST projecting, poorly stacked items or misplaced material

5. CUTTING, PUNCTURING, or TEARING the skin of hands or other parts of the body on projecting nails,
wire or steel strapping

a WORKPLACE must “MAINTAIN” ORDER throughout a workday.

7S: System of Good Housekeeping

Key Principles:

• Organization makes work and life easier.

• Organizing is a skill that can be learned.

• Becoming organized is a two-step process.

1. GETTING organized

2. STAYING ORGANIZED

What is HACCP?

HACCP, or the Hazard Analysis Critical Control Point system, is a process control system that identifies
where hazards might occur in the food production process and puts into place stringent actions to take
to prevent the hazards from occurring. By strictly monitoring and controlling each step of the process,
there is less chance for hazards to occur.

Why is HACCP Important?

HACCP is important because it prioritizes and controls potential hazards in food production. By
controlling major food risks, such as microbiological, chemical and physical contaminants, the industry
can better assure consumers that its products are as safe as good science and technology allows. By
reducing foodborne hazards, public health protection is strengthened.

How Does HACCP Work in Food Production?

There are seven principles, developed by the National Advisory Committee on Microbiological Criteria
for Foods, that serve as the foundation for a HACCP system. They are:
1. Conduct a hazard analysis to identify potential hazards that could occur in the food production
process.

2. Identify the critical control points (CCPs) -- those points in the process where the potential hazards
could occur and can be prevented and/or controlled.

3. Establish critical limits for preventive measures associated with each CCP. A critical limit is a criterion
that must be met for each CCP. Where appropriate, critical limits may reflect relevant FSIS regulations
and FDA tolerances.

4. Establish CCP monitoring requirements to ensure each CCP stays within its limit. Monitoring may
require materials or devices to measure or otherwise evaluate the process at CCPs.

5. Establish corrective actions if monitoring determines a CCP is not within the established limits. In case
a problem occurs, corrective actions must be in place to ensure no public health hazard occurs.

6. Establish effective recordkeeping procedures that document the HACCP system is working properly.
Records should document CCP monitoring, verification activities and deviation records.

7. Establish procedures for verifying that the HACCP system is working properly. Verification procedures
may include reviewing the HACCP plan, CCP records, critical limits as well as conducting microbial
sampling. Both plant personnel and FSIS inspectors will conduct verification activities.

What is OSHS?

11058 or the Occupational Safety and Health Standards (OSHS) law. The OSH Law aims to ensure a safe
and healthful workplace for workers by affording them full protection against all hazards at work.

what is OSHA in the Philippines? The Occupational Safety and Health Standards Act will protect the
health of workers in the Philippines. With this law, the Philippines comes closer to achieving the
Sustainable Development Goal 8.8 to protect the labour rights and promote safe and secure working
environments for all workers.

What is the purpose of the occupational health and safety?

The main purpose of the Act is to protect workers from health and safety hazards on the job. It sets out
duties for all workplace parties and rights for workers. It establishes procedures for dealing with
workplace hazards and provides for enforcement of the law where compliance has not been achieved
voluntarily.

What safety risk is present for each food

 Pathogenic microorganisms
• Bacteria, viruses
 Spoilage microorganisms
• Fungi, bacteria

Qualities to control

• Temperature

• 40 – 140°F = the temperature danger zone

– Rapid multiplication of microorganisms

• <40°F very slow growth

• <28°F – no growth – no death

• >140°F – death of microorganisms

• Moisture content & Protein content

• Bacteria need a high moisture content

• Fungi can grow in lower moisture

– Dry foods won’t make you sick

– Dry foods do spoil

• Bacteria need protein, fungi less so

– Candy & carbohydrates may spoil but don’t won’t make you sick

What are the OSHA standards?

OSHA standards are rules that describe the methods that employers must use to protect their
employees from hazards. There are OSHA standards for Construction work, Maritime operations, and
General Industry, which is the set that applies to most worksites.

What is PPE?

Personal protective equipment AKA PPE is a very important aspect in ensuring safety in food
manufacturing plant. As food handling safety tools, they provide a barrier between the contributing
factors and the workers. This is crucial in the food processing industry where most operations are done
by hand.

What is Halal?

Halal: Means permissible in the Arabic language

Why Halal Standards Needed?

As awareness amongst Muslim consumers around the World increases, demand grows for authentic
Halal foods. Besides meat, several other issues concerning food drew attention recently. Food
ingredients like flavors, oils, enzymes in cheese, and a variety of other derivatives plus new technologies
used in food processing have further complicated the picture.

Alcohol and pork derivatives could be embedded in all kinds of products that need to be identified and
avoided for food products to be considered Halal. Establishing and adopting Halal procedures in the
processing of consumable and non-consumable goods has become important for consumers and
producers alike.

The Halal Times attempts to standardize the Halal procedures to adopt and promote these Halal
Standards across industries around the globe.
Requirements Halal Foods and Ingredients/Derivatives

A. Plants and other Species

Generally, all plants and other species such as mushrooms, algae, bacteria, etc. are considered Halal
except those which are poisonous, intoxicating, or hazardous to human health.

B. Fruits, Juices and Vegetables

Fruits, vegetables, and natural juices are all considered Halal when they are pure. Processed fruits and
vegetables may not be accepted if they are processed in factories using non Halal oils, fats,
preservatives, flavoring, etc. The use of processing oils and other added ingredients must be evaluated
for Halal status.

C. Milk and Dairy Products

Milk: Milk derived from domesticated Halal species is acceptable.

Yogurt: Yoghurt and yogurt products should not contain gelatin. If gelatin is used, it must be derived
from the bones and hides of Halal slaughtered animals.

Cheese: Many kinds of cheese contain rennet and other enzymes, which are derived from animals. It is
essential to ensure that these enzymes are derived from Halal slaughtered animals or microbial or plant
sources.

D. Bread, Breading, Cakes, and Pastries

Bakery goods do pose Halal concern. Breading on products like fried chicken or cheese sticks or the use
of breading in the stuffing of fillers may contain questionable ingredients like cysteine, fats, oils, colors,
flavors, preservatives, and alcohol-based ingredients. It is important to make sure that no alcohol or un-
Halal animal-based ingredients are used in pieces of bread, breading, cakes, or pastries.

E. Fats and Oils

Fats must be derived from Halal slaughtered animals and oils from a plant source. Haram preservatives
or processing aids must not be used in vegetable-based oil.

F. Alcohol By-Products

Alcohol usually refers to ethyl alcohol. All products or ingredients containing alcohol are prohibited in
Islam, even for cooking purposes or in fillings such as candies. Artificial and natural flavors, colors, and
some type of meat or vegetable bases may contain alcohol products used to carry the flavor. The level of
alcohol in the final food product should be below 0.05% to be acceptable. This amount will vary by
country.

Vinegar, a by-product of alcohol, is permitted in Islam but it is advisable not to use the words “wine
vinegar” in order not to confuse consumers. Amyland Isomers of Amyl Alcohol is not acceptable.

G. Other Ingredients/ Derivatives

It is important to check all ingredients added to Halal Consumables and to Non-Consumables during
processing before use to make sure that such ingredients are Halal certified by a certifying organization.
The following is a list of some ingredients or derivatives. For more listing of ingredients check with the
manufacturer and with your Muslim scholars or advisors for opinions.

Anti-Caking: All anti-foaming agents are acceptable except for Edible Bone Phosphate, animal Stearic
Acid, and Animal Magnesium Stearate unless derived from Halal slaughtered animals. All vegetable oil or
silica-based preparations are Halal.

Antioxidants: All acceptable, except Tocopherols unless derived from vegetable oil.

Artificial Sweetening Agents: All Halal.

Clones and GMO’s: The acceptance of Clones of species and Genetically Modified Organisms for Muslim
consumption is still questionable. The final status of their approval or not is awaiting Muslim Jurists to
decide on. (see also Transgenic below).

Colors: All Halal, providing that animal emulsifier is not used as a carrier or ethanol used as a solvent.

Emulsifiers: Plant-derived emulsifiers and those derived from animals that are slaughtered Halal are
acceptable.

Enzymes: All plant and microbial enzymes are acceptable. Also enzymes from permissible animals that
are slaughtered Halal are acceptable.

Flavor Enhancers: Must not have animal enzymes used as catalysts.

Flour Treatment Agents: Sodium Stearoyl Lactylate, Calcium Stearoyl Lactylate, and L-Cysteine
Hydrochloride must be derived from a Halal source.

Food Acids: Lactic Acid must be derived from a Halal source.

Fusel Oil: This is a mixture of several alcohols, chiefly amyl alcohol, produced as a by-product of alcohol
fermentation. Fusel Oil is not acceptable for use as a flavoring for Halal goods.

Gelatin: Gelatin is a water-soluble protein prepared from collagen, which is obtained from the corium or
inner layer of beef hides from cattle slaughtered for human consumption. The extraction of gelatin from
collagen is a separation process not a change of state. Halal gelatin can only be obtained from collagen
obtained from the inner layer of beef hides of cattle that have been slaughtered Halal.

Islam allows the use of the skin or outer layer of the hide only after tanning for the production of
canteens or water carriers, garments, shoes, belts, etc. Muslims are forbidding from consuming the
hides unless under duress. All fish gelatin is considered Halal.

Glands from Cats or Beavers: Ingredients from these glands, which are used in some strawberry and
chocolate flavorings, cannot be used in Halal flavorings.

Glycerin /Glycerol: Must be derived from plant sources.

Humectants: Glycerin and Hydrogenated Glucose Syrups must be derived from a plant source.
Mineral Salts: All salts are Halal.

Non-Consumables: Non-food substances and materials such as cosmetics, clothing, shoes, etc. which are
applied to the human body and worn by Muslims should be checked to make sure that all the
ingredients used in their manufacturing are not derived from Haram sources. Also, Halal non-
consumables should not be toxic or hazardous to human health.

Preservatives: All preservatives are considered Halal except those which might be dangerous to human
health.

Propellants: All Halal.

Thickeners: Enzyme-treated starches must be Halal sourced.

Transgenic: Plants that have other plant genes transplanted into them are Halal. Plants with animals’
genes introduced to them may be acceptable only if the animal species are acceptable. The introduction
of genes from non-acceptable species to acceptable species is not permitted.

Vegetable Gums: All gums from plant sources are Halal.

Vinegar: Muslims are allowed to consume products that change from a Haram state to a Halal state. For
example, low fermented fruit juice with alcohol is Haram, however, vinegar resulting from it is
considered Halal.

Land Animals/Birds

Acceptable species among land animals include cattle, lambs, goats, buffalo, deer, and camels. Chicken,
turkeys, pigeons, ostriches, geese, swans, ducks, and alike are acceptable birds. The acceptable animals
and birds must also be alive and healthy at the time of slaughter.

Aquatic Animals

Generally, all fish and seafood are considered Halal without having to be slaughtered. Excluded are
species that are poisonous, intoxicating, or hazardous to human health.

(Day 2)

WHAT IS THIS LESSON ABOUT?

This lesson deals on how to prepare equipment, tools, materials and utensils needed in salting, curing
and smoking. This includes lessons on Introduction to Food processing, methods of food processing,
principles of good quality kitchen, kitchen/laboratory rules and regulation and Lay out of Food
processing laboratory/kitchen.

Learning objectives:

At the end of the lesson, you should be able to:

1. Identify the methods of food processing.

2. Define food processing.

3. Evaluate kitchen lay out

Introduction

What is food processing?

Food processing is the transformation of agricultural products into food, or of one form of food into
other forms. Food processing includes many forms of processing foods, from grinding grain to make raw
flour to home cooking to complex industrial methods used to make convenience foods.

Why process foods?

• Extend edible time frame -Preservation

• Make better tasting foods

• Make more varieties of food

• Convenience

Methods of food processing

 Drying - Extraction of moisture by sun, air, heat or vacuum to inhibit the growth of molds,
bacteria and yeasts.
 Salting - The addition of salt or a brine solution to foods to decrease the activity of molds,
bacteria and yeasts.
 Curing - The addition of a chemical compound (sodium nitrate or sodium nitrite) to food to slow
the growth of bacteria.
 Fermentation - The use of special bacteria, molds or yeasts to prevent spoilage by converting
the elements of food that spoil easily to stable elements that act as preservatives.
 Freeze Drying - The freezing of food and the subsequent removal of water from the frozen food
through the use of heat and a vacuum.
 Smoking - The addition of smoke and heat to preserve food by the action of the chemicals from
the smoked wood and the partial drying of the food.
 Canning/Aseptic Packaging - The packing of food in a container, sealing the container and
heating it to sterilize the food.
 Pasteurization - The heating of milk and other liquids which reduces the number of diseases
producing bacteria.
 Refrigeration - The lowering of the temperature of food to inhibit the growth of bacteria, molds
and yeasts.
 Freezing - The lowering of the temperature of food to temperatures below 28 degrees F to stop
the growth of bacteria, yeasts and molds and to kill parasites.
 Food concentration - Heating food until it boils and removing the water or partially freezing food
and removing water in the form of ice crystals.
 Irradiation - Passing energy through food to destroy insects, fungi, or bacteria that cause human
disease or cause food to spoil.

Principles of a good quality kitchen

The layout- will help take much of the mystery out of the design process.

The work triangle is the line drawn from each of three primary workstation in the kitchen- the food
storage area, the cooking area, and the clean-up area.

System of Rotation for Food Supplies- It ensures that older supplies are used before newer ones.

Goals for Proper Storage- Safe storage of food Efficient use of storage space Effective use of simple
storage aids.

Principles for Efficient use of Storage Space- Items used most often should be easy to reach Heavy items
should be kept on low shelves. If counter space is limited, appliances that are used infrequently should
be stored in cabinets.

Storage Aids- Open shelving wall storage using gridded racks or board with hooks Cabinet aids Baskets.

Categories of Food processing Laboratory/kitchen

Can be divided into two types

A. On- Premises B. Off- Premises

Kitchen laboratory rules and regulation

[Link] permission to use the kitchen.

[Link] run, rush around or throw anything in the kitchen.

3. Work quietly; avoid unnecessary chat so that the instructions can be heard.

4 .All accidents and breakages must be reported at once.

5. A high level of personal hygiene is expected; wash hands before starting, always wear an apron, have
hair tied back and roll up

sleeves.

6. Do not move around the kitchen with hot objects e.g. frying pans, boiling water.

[Link] saucepan handles away from the edges of cookers and work

surfaces.

[Link] oven gloves to remove hot dishes from the oven.

[Link] sure all appliances are turned off after use.

10. Sharp knives are dangerous be careful using them.

11. Never touch plugs or electrical equipment with wet hands.

12. The kitchen is provided with fire blankets and fire extinguishers.

13. Keep units tidy at all times, all used cutlery should be placed on a plate and all waste put in the
correct bin

14. Handle food as little as possible.

15. Never dip fingers into food, never lick fingers during cooking. Use a clean spoon each time you taste.

16. Never sit in kitchen work surfaces.

17. Each unit must be left clean, cookers cleaned and sinks empty

and washed.

18. Wash and dry all dishes, cutlery, etc., after use and return them

to their correct unit.

19. All kitchen cloths must be hung on the clotheshorse after use.

20. Push chairs in under the table after cooking.

Lay out of Food processing laboratory/kitchen

The food processing industry is a subset of the manufacturing sector with unique challenges. Among
these, ensuring food hygiene and preventing contamination are two issues of prime importance. Hence,
designers have to overcome such challenges when designing facilities suitable for food processing. The
paper formulates a model that simplifies the layout planning process for the food processing facilities.
The model classifies the areas of FPF into five: primary, secondary, utilities, warehouse, and
administration based on the activities and the level of risk present in food processing.
(Day 3)

WHAT IS THIS LESSON ABOUT?

The lesson deals on the study of the uses of specifications for equipment, tools and utensils; the study of
the parts and functions of equipment, tools and utensils; the uses and specification of sanitizing agents
and the proper stowing of tools, equipment and instruments. It also covers inspecting and checking the
condition of equipment/ machines before operation and performing minor prevention maintenance.

Learning Objectives:
At the end of the lesson, you should be able to:
1. Prepare for use appropriate tools and equipment or utensils according to food
processing methods;
2. Inspect and check food processing tools and equipment or utensils according to
manufacturer’s specifications;
3. Set up, adjust and made ready food processing equipment according to job
requirements; and
4. Appreciate the importance of performing pre – operation activities.
Self – Check
Pre Test
Multiple Choice
Directions: Carefully read the questions and choose the best answer from the options given.
Write only the letter of your answer in your test booklet.

1. Which of the following tool/equipment specifications are used by manufacturers?

a. dimension as to size, height, capacity, etc.
b. handling and operating requirements
c. proper care and maintenance
d. all of these
2. Why are specifications for food processing tool, equipment and utensils necessary?
a. they provide information to the user on how to handle and operate the equipment
properly.
b. specifications give information concerning the proper use, care and maintenance of the
tools, equipment and utensils
c. it provides information about the tools, equipment and utensils
d. both a and b

3. If you are a food processor, why do you need to know the parts of the equipment, tool
and utensil and their functions?
a. to appreciate the usefulness of a particular device
b. to be able to correctly operate/manipulate a tool,
equipment or utensil
c. to be able to do some simple repairs on them
d. to easily determine if a part is missing

4. If you are going to pack processed foods in tin cans, why do you need to seal it with a
can sealer?
a. cans cannot be sealed manually
b. tin cans are difficult to seal
c. to properly seal them
d. a can sealer is the appropriate equipment for attaching the cover to the body of a tin
can with is first and second operation rolls

5. Which of the following will help you determine the kinds of tools, equipment and
utensil you will assemble, sanitize, inspect or check?
a. the kind of product to be produced
b. the method of food processing to be done
c. the raw materials to be processed
d. the availability of tools, equipment and utensils
6. You have already removed the dirt from the tools, equipment or utensils have used in
processing the food by washing them with soap and water. Why do you still need to sanitize or
disinfect them?
a. washing with soap and water only removes the adhering dirt
b. washing alone cannot remove the microorganisms and germs
c. to effectively kill or destroy all the germs and
microorganisms which remained after washing
d. all of these
7. Which of these is a sanitizing agent you can use for killing the germs and
microorganisms present in tools, equipment and utensils?
a. sodium chloride
b. sodium hypochloride
c. magnesium sulfate
d. calcium chloride

8. How will you properly store tools, equipment and utensils after using them?
a. wipe dry all tools, equipment and utensils which were washed with water before
keeping them
b. stow them in a clean dry place with a good ventilation
c. apply lubricant to parts of equipment that undergo friction to
prevent wear and tear
d. all of these

9. It is necessary to inspect and check the condition of equipment and machines before
operating them in order to .
a. to check if no parts are defective or missing
b. to check if electrical plugs are in good condition
c. to see if they are old or new ones
d. both and b
10. Which of this preventive machine maintenance will you check before using equipment
or a machine?
a. machine temperature and hydraulic fluid
b. wear and surface condition
c. crack and leak detection and electric insulation
d. all of these
Introduction
When processing food, there are several tools, equipment and utensils which need to be
properly inspected, checked, sanitized, assembled and operated based on specifications. The
appropriate tools, equipment and utensils are assembled according to the food processing
methods wherein they will be used. The food processing methods that will determine the kind
of tools, equipment and utensils to be assembled are:

1. Salting
2. Curing
3. Smoking
4. Fermentation
5. Pickling
6. Canning
7. Bottling
8. Processing using sugar concentration
9. Drying
10. Dehydration or artificial drying

When salting, the tools, equipment and utensils to be assembled, inspected, checked and
sanitized are those for salting purposes like salinometer, earthen pots, wooden salting vat, etc.
If the fish or meat is to be cured there is a need to prepare slicers, grinders, food processors,
wooden or stainless-steel basins, etc. In smoking fish, a smoke house, cooking vat, bakol, bistay,
bamboo tray, etc. are to be assembled. In the fermentation of food fermenting jars, bottles,
strainers, measuring spoons, measuring cups, etc. need to be prepared. In pickling,
preserving bottles and jars, aluminum utility trays, basins, etc must be assembled and prepared.
The can sealer, pressure cooker, thermometers, stove, etc must be prepared when canning. If
the food like fish and meat are to be dried, there is a need for dehydrators, drying trays, knives,
weighing scales, etc.
When processing food using different tools, equipment and utensils, it is also important to
inspect and check them based on manufacturer’s specifications which include:
1. Handling requirements
2. Operating requirements
3. Discharge label
4. Reporting
5. Testing
6. Positioning
7. Refilling

Equipment, Tools and Utensils: Uses and Specifications

Every equipment, tool and utensil that are purchased are accompanied with a manual
containing specifications as to how they are used, manipulated or operated, cared for and
stored to lengthen their service ability. Specifications usually include the following:

1. Important safeguards or basic safety precautions to follow when using the device like a
pressure cooker for instance.
2. Warning labels which serve as a reminder to the user to read and follow instructions on
the proper use and operation of a certain device equipment or tool.
3. Dimensions, weights and capacities as in the case of cookers, boilers and steamers.
4. Instructions on caring for the equipment, tool or utensil.
5. Instructions on the correct usage of the device.

When using any equipment, tool or device it is important to read and understand the
manufacturer’s specifications in order to properly or accurately use or manipulate them and
prevent any accident that may occur due to ignorance or lack of information pertaining to their
correct usage. Being familiar with all information pertaining to food processing equipment
results to systematic, orderly and accurate accomplishment of tasks.

Parts and Functions of Equipment, Tools and Utensils

Knowing the parts and functions of equipment, tools and utensils used in processing food
ensures accurate or proper use, operation and care for them. It is very easy for a food
processor to manipulate a particular device if he knows all its parts and their respective
functions. Proper maintenance for the parts of any tool, equipment and utensil can also be
done if a processor is familiar with them.

The can sealer is equipment used to seal tin cans with its first and second operation rolls.

Some processed food products are usually packed in tin cans which are mechanically sealed
with a can sealer. Below are the functions of some parts of an automatic can sealer:

1. Clamp. This fastens the sealer on the table or arm chair and holds it tightly in place,
especially during operation.
2. Base plate or plunger plate. Its function is to hold the base of the can. It has grooves to
fit the can base wherein these grooves coincide the can size.
3. Can lifter handle. It is used to raise the base plate so that the can cover will reach up
to the chuck and lower the base plate so that the can cover will reach up to the chuck and
lower the base plate when sealing is through.
4. Crank. This part is turned during the sealing of can seams both first and second
operation rolls.
5. First seaming roll. It is used to clinch, partially or half – seal the seams of a can cover.
6. Second operation roll. It is used to complete – seal the seams of a can cover.
7. Seaming roller pin – first. It is placed on the hole of the first operation roll to fasten on
it.
8. Seaming roller pin – second. It is placed on the hole of the second
operation roll to fasten on it.
9. Rivet. This part is placed in the hole of the adjusting lever which coincides the can
cover size. If can cover size is No. 2, for instance, one – half pound tuna can rivet is placed in
No. 2 hole of the adjusting lever. Rivet is also called adjusting pin.
10. Chuck. It is used to hold the cover of the can while sealing is going on. Chuck has many
sizes, namely Number 1, 2, 2 ½, and 3, respectively. If No. 2 cover is used, hence, hence, chuck
No. 2 is used.
11. Height washers. These washers are placed in base plate shaft to match the height of
the can when lifted up to the chuck.
12. Adjusting levers. There are two adjusting levers, one for the first operation roll and the
other, second operation roll. There are numbered holes on these levers wherein rivets are
placed to coincide the can size.
13. Base compression spring. It acts as cushion while sealing is on the process.
14. Base plate shaft. This is the part where compression spring and height washers are
inserted.

The Pressure Cooker

A pressure cooker is important canning equipment used to process fish packed in a hermetically
sealed container at a high controlled temperature and pressure for a certain period of time.
Some of its parts and their functions are as follows:
1. Geared seam gauge or pressure gauge. It indicates the pressure and temperature
inside the cooker while processing.
2. Pressure regulator weight. It is used to close the vent pipe and regulate the
accumulated pressure inside the cooker while processing. It contains holes which correspond to
the desired pressure directly over the vent pipe. For instance, if the desired pressure is 10
pounds, the pressure regulator weight hole of 10 is inserted over the vent pipe.
3. Vent pipe for pressure regulator weight. It is where the pressure regulator weight is
placed. It releases steam when opened.
4. Bakelite wingnut or knob. It is used to securely fasten the cover of the cooker to its
body.
5. Arrowhead and arrow line. They indicate if the cover is properly seated on the body.
6. Automatic pressure control. It consists of the vent pipe and pressure regulator weight.
It automatically controls the pressure inside the cooker while processing.
7. Overpressure plug. It automatically vents or release steam if the vent pipe becomes
clogged.
8. Cover. Seals the body of the cooker during processing.
9. Body. It holds the water for processing and the metal rack where the canned products
are placed during processing.
10. Bakelite top handle. This is for holding the cover when lifting it away from the body or
seating it properly on the body.

11. Body or side handles. This is used for holding the body of the cooker when transferring it
from one place to another.

How to Use the Pressure Cooker

1. Place one – and – a – half (1/2) inch water in the cooker

2. Put rack with stand in the bottom of the cooker. A rack can be old bottles or milk cans
of the same height filled with water.
3. Place the packed glass jars on the rack in the cooker.
4. Put on the cover of the cooker. Be sure the cover arrow aligns with “line mark” on rim
of the body of the cooker.
5. Tighten two opposite bake lite wing nuts or knobs at the same time evenly. Never
tighten one wing nut or knobs at the same time evenly. Never tighten one wing nut or knob at
a time.
6. Turn on the stove. The water in the cooker begins to boil at 212 ∘F or 100 ∘C at sea level
forming steam. The steams dries out the air through the vent pipe and heat begins to penetrate
the glass jars.
7. Exhaust the air in the cooker for 8 to 10 minutes so that air cannot interfere with
the passage of heat.
8. Close the vent pipe by putting the pressure regulator weight. The hole of the pressure
regulator weight should correspond to the desired pressure directly over the vent pipe. For
instance, if the desired pressure is 10 pounds so the pressure regulator weight hole of 10 be
inserted over the vent pipe.
9. When vent pipe is closed, the steam can no longer escape so the pressure rises up to
the desired pressure. The pressure regulator weight jiggles or rocks when the pressure is
reached. This is called coming up time (CUT). Water under pressure boils at temperatures
above 212 ∘F. at 10 pounds pressure gauge pressure, water boils at 240 ∘F. Then regulate the
fire. If desired pressure is reached, start counting the processing time. If processing time is 90
minutes, so maintain the pressure and temperature for 90 minutes. At this stage, heat
penetrates the jar by conduction or heat passes from one vibrating molecule to another. It also
penetrates by convection in which heated fluids expand, rise, and are replaced by cooker fluids.
In other words, heat penetrates the jar by both conduction and convection. Likewise,
headspace of one half (1/2) inch of the jar acts as a cushion. In jars, the pressure usually gets so
great that most of the air is driven out under the cover. The pressure and temperature in the
jar is finally the same with the pressure cooker.
10. At the end of the processing time, turn off the stove. Temperature and pressure begin to fall
as the cooling off period starts. Wait until the gauge registers to zero (0) pressure and remove
the pressure regulator weight.
11. Loosen two opposite bake lite wing nuts or knobs at the same time. When all wing nuts
were loosened, open the cover of the cooker in slanting position away from the face.
12. Get immediately the glass jars one at a time from the cooker and close. Invert the glass jars
to determine if bubbles continuous to flow as sign of good sealing.
13. Cool the glass jars in room temperature as well as the cooker.

The Smokehouse

A smokehouse is a device used in treating the fish or meat with smoke. It can be a cold
smokehouse or a hot smokehouse. It is a hot smokehouse if the fish is in close proximity to the
source of smoke and a temperature of 66C to 88C is produced. If the source of smoke is 2
meters away from the fish and the temperature of smoke is 32C – 43C, then it is a cold
smokehouse. Some are simple like the barrel and drum types while others are mechanized and
controlled like the Torry smokehouse which can also be used as a drier

Parts of a Drier Smokehouse and their Functions

1. Removable slatted benches. They hold the fish to be smoked.
2. Removable hangers with hook. They are used for hanging fish to be dried or smoked.
3. Wooden hooks. They are nailed from the top of the drier smokehouse where fish are
also hanged when drying or smoking.
4. Vents. These are located below the roof at the front and back of the smokehouse to
provide the necessary air circulation.
5. Tunnel or pipe. Conveys the smoke from the concrete furnace into the smokehouse.
6. Concrete furnace. It is where the smoke – producing materials are placed and burned.
7. Tight sheathing rafters. Serve as the top cover or roofing of a smokehouse.
8. Meshed screen. Serve as a closure to openings like the vents to keep flies and insects
from entering the smokehouse.

Freezer and Refrigerator

The freezer and refrigerator are used in maintaining the freshness of raw materials and in
providing an ideal low or ambient temperature for storing processed foods.

Tools and Utensils Used in Food Processing and their Uses

1. Measuring Devices

a. Weighing scales

a. Measuring spoons
A measuring spoon is used to measure an amount of a substance, either liquid or dry, when
cooking. Measuring spoons may be made of plastic, metal, etc.

b. Measuring Cups

A measuring cup is a kitchen utensil used primarily to measure the volume of liquid or powder-
form cooking ingredients such as water, milk, juice, flour, etc. Measuring cups can be in plastic,
glass and stainless. From mini shot measure to measuring pitcher and batter bowl.

Measuring cups for measuring liquid ingredients like milk, vinegar, fish sauce, etc.

Measuring cups for solid ingredients like flour, salt, minced garlic, etc

c. Thermometers

Thermometers indicate the degree of hotness or coldness of a thing or body. It measures

how high or how low the temperature is.

Glass Tube Thermometers

d. Salinometer - an instrument used to measure brine strength.

e. Psychrometer

It is used to measure the relative humidity of the air when sun drying.

e. Anemometer

It is used to determine the velocity of the wind in sun drying.

2. Cutting Implements

a. Knives - For cutting or slicing fish or meat; for scaling fish

b. Filleting knives - For filleting fish

 c. Scissors - For trimming – off fins of fish

3. Descaler or scalers
They are used in removing the scales of a fish.

4. Salting Equipment

Oil drum – used as a container to keep during the process

Earthen pots are used in storing the salted products.

Wooden salting vat is a container used in the salting process.

Wooden shovel or spade is used for mixing or stirring the mixture of salt and small fish for
salting

5. Smoking Equipment

Baklad made of bamboo used in drying the fish prior to smoking

Bakol is a bamboo basket used to transport smoked fish

Bistay is a bamboo basket for collecting sun dried fish

Dinarayan is a smoking tray made of wood

Panakip is a bamboo cover used to keep fish submerged in the brine while boiling

Panandok is a big metal ladle to scoop up the cooked fish from the boiling brine

Bamboo poles used to hold the baklad with brine cooked fish while drying.
Pugon is a concrete heat source used when pre-cooking fish in a brine

6. Others

Basin – use in the preparation of brine or curing mixture.

Food tong - used to turn or lift food.

Cutting board - used to protect the table when slicing or cutting food.

Sanitizing kitchen tools and equipment

If you need to be thoroughly sanitizing kitchen tools and equipment to ensure there’s no
chance of any bacteria, follow these steps:
 Put your utensils in a large pan, covering them fully in water. Carefully bring the water
to the boil, putting a lid on the pan, for 5 minutes. Remove the lid and wait for the water to
stop boiling before removing the utensils with prongs.
 Another method for cleaning and sanitizing kitchen utensils is to combine a tablespoon
of bleach with a gallon of water, leaving your tools to soak before rinsing them thoroughly with
hot water.
What does ppm mean?
This is an abbreviation for "parts per million" and it also can be expressed as milligrams per liter
(mg/L). This measurement is the mass of a chemical or contaminate per unit volume of water.
Seeing ppm or mg/L on a lab report means the same thing.
One ppm is equivalent to the absolute fractional amount multiplied by one million. A better
way to think of ppm is to visualize putting four drops of ink in a 55-gallon barrel of water and
mixing it thoroughly. This procedure would produce an ink concentration of 1 ppm. Some other
analogies that may help you visualize the scale involved with ppm. One ppm is like:

Area to be sanitized with Volume of desired solution of sodium chloride

recommended chlorine
1000ml 1 gallon 5 gallons
concentration

Hand dip (30 ppm) 0.57 ml. 2.16 ml. 10.8 ml.

Floor (350 ppm) 6.67 ml. 25 ml. 125 ml.

Equipment (200 ppm) 3.81 ml. 14.4 ml. 72 ml.

Water for food processing

(75 ppm) for washing
1.43 ml. 5.40 ml. 27 ml.
vegetables, dressed
chicken etc.

How do you make a sanitizing solution?

To sanitize the equipment, prepare a solution as prescribed on the recommended dosage.
Wash the equipment with soap and water. Scrub or brush if necessary. Rinse with water then
sanitize and allow draining or rinsing with 5ppm chlorinated water.
Sanitizing and disinfecting the tools, equipment and utensils will destroy all germs and
microorganisms which were not removed after washing with soap and water. Proper cleaning
and disinfecting leads to:
1. minimizing product rejection, return and complaints due to defects resulting from the
use of defective or inappropriate tools, equipment and utensils;
2. lengthening product shelf life due to the reduction of contamination resulting from the
use of properly sanitized and disinfected tools, utensils and equipment;
3. reduction of the risk on food poisoning due to the use of unsanitized tools, equipment
and utensils; and
4. facilitating preventive maintenance which include checking the machine temperature,
hydraulic fluid, wear and surface condition, crack, leak detection, vibration, corrosion, and
electric insulation.

Proper Stowing of Tools, Equipment and Utensils

Tools, equipment and utensils must be properly stowed in order to protect them from rusting,
contamination, etc. and thus lengthen their serviceability. They must be kept in clean cabinets
which are well – ventilated and not subjected to drafts or rain.

Tools and utensils which were washed must be drained and wiped - dry before keeping them.
They should be kept in an orderly way in order to assemble them easily or
prepare them when needed. The cabinets or racks where they are kept must be properly
labeled for easier identification on the part of the user.

Inspecting and Checking Condition of Equipment and Machines

Before any equipment or machine is used, it must first be checked to make sure that it
functions well and in good condition. Checking and inspecting equipment and machines will
guarantee that all parts are intact and that no part is missing or defective. This will also assure
that electrical plugs and wirings are not defective and will not in any way cause problems on
short circuits, electrocution or any form of accident. Religiously checking and inspecting
equipment and machines will facilitate Preventive Maintenance which include checking the
following:

1. Machine temperature
2. Hydraulic fluid
3. Wear and surface condition
4. Crack
5. Leak detection
6. Vibration
7. Corrosion
8. Electric insulation
Reporting Breakdown of Equipment/Machine, Tools and Instruments

Report preparation is important when using food processing equipment.

The report will serve as a database for the company that serves as a ready
source of information as to the condition of equipment and tools. This will
help the company draft its contingency measures in relation with preventive
maintenance measures that will prevent or minimize the breakdown of
equipment or machines.

Reports on breakdown of machine parts will facilitate troubleshooting and

procurement of parts needed for repair or replacement of parts that
breakdown.

Below is a sample report on the breakdown of equipment/machine and

tools:

A Report on the Breakdown of Machine Parts

Equipment Type of TroubleshootiParts to be Remarks

Breakdo ng to be Replaced
wn Undertaken

Prepared by:

Post-Test
Multiple Choice
Directions: Carefully read the questions and choose the best answer from the options given.
Write only the letter of your answer in your test booklet.

1. Which of the following tool/equipment specifications are used by manufacturers?

a. dimension as to size, height, capacity, etc.
b. handling and operating requirements
c. proper care and maintenance
d. all of these
2. Why are specifications for food processing tool, equipment and utensils necessary?
a. they provide information to the user on how to handle and operate the equipment
properly.
b. specifications give information concerning the proper use, care and maintenance of the
tools, equipment and utensils
c. it provides information about the tools, equipment and utensils
d. both a and b

3. If you are a food processor, why do you need to know the parts of the equipment, tool
and utensil and their functions?
a. to appreciate the usefulness of a particular device
b. to be able to correctly operate/manipulate a tool,
equipment or utensil
c. to be able to do some simple repairs on them
d. to easily determine if a part is missing

4. If you are going to pack processed foods in tin cans, why do you need to seal it with a
can sealer?
a. cans cannot be sealed manually
b. tin cans are difficult to seal
c. to properly seal them
d. a can sealer is the appropriate equipment for attaching the cover to the body of a tin
can with is first and second operation rolls

5. Which of the following will help you determine the kinds of tools, equipment and
utensil you will assemble, sanitize, inspect or check?
a. the kind of product to be produced
b. the method of food processing to be done
c. the raw materials to be processed
d. the availability of tools, equipment and utensils

6. You have already removed the dirt from the tools, equipment or utensils you have used
in processing the food by washing them with soap and water. Why do you still need to sanitize
or disinfect them?
a. washing with soap and water only removes the adhering dirt
b. washing alone cannot remove the microorganisms and germs
c. to effectively kill or destroy all the germs and
microorganisms which remained after washing
d. all of these
7. Which of these is a sanitizing agent you can use for killing the germs and
microorganisms present in tools, equipment and utensils?
a. sodium chloride
b. sodium hypochloride
c. magnesium sulfate
d. calcium chloride

8. How will you properly store tools, equipment and utensils after using them?
a. wipe dry all tools, equipment and utensils which were washed with water before
keeping them
b. stow them in a clean dry place with a good ventilation
c. apply lubricant to parts of equipment that undergo
friction to prevent wear and tear
d. all of these

9. Why is it necessary to inspect and check the condition of equipment and machines
before operating them in order to
.
a. in order to check if no parts are defective or missing
b. in order to check if electrical plugs are in good condition
c. in order to see if they are old or new ones
d. both and b

10. Which of the following preventive machine maintenance will you check before using
equipment or a machine?
a. machine temperature and hydraulic fluid
b. wear and surface condition
c. crack and leak detection and electric insulation
d. all of these

LET US APPLY WHAT YOU HAVE LEARNED

Demonstration with Direct Observation:
Perform/Demonstrate the following pre – operation activities:

1. Checking and inspecting the parts of equipment like can sealer and pressure cooker.
2. Prepare a sanitizing solution and apply the steps in sanitizing equipment and utensils.
3. Sanitizing utensils for food processing.
Day 4

Prepare the raw materials

WHAT IS THIS LESSON ABOUT?

This lesson deals on how to prepare the raw materials needed in salting, curing and smoking.

Learning Objectives:

At the end of the lesson, you should be able to:

1. Records of weights and measurements of raw materials and ingredients are gathered and
summarized according to workplace standard operating procedure.

2. Records of weights and measurements of finished processed products are gathered and
summarized according to workplace standard operating procedures.

3. Summarized data are tabulated according to enterprise requirements.

Introduction:

Measurements and Conversions

It is important to weigh or measure all ingredients accurately, especially for beginners. There are cooks
and chefs who seem to be able to produce good results by guesswork and intuition because of their long
experience in cooking. However, that should not be the case. What generally matters is using precise
measurement.

When weighing things, it is essential to buy a good brand of weighing scale that would longer. A good
selection of measuring cups and spoons (as listed below) can be very handy.

a. Measuring Cups

 1 Cup (C)

 1/2 C

 1/3 C

 1/4 C

 1/8 C
 b. Measuring Spoons

 1 Tablespoon (tbsp or T)

 1 Teaspoon (tsp or t)

 1/2 tsp

 1/4 tsp

A clear glass measuring cup is necessary to get precise liquid measurements.

Dry Ingredients - The most important thing to know about measuring dry ingredients is that they should
be level with the top of your measuring cup. Dip your cup into the bin, fill to overflowing and level it off
by sweeping the edge of a knife across the top. Spoon flour and similar ingredients into measuring cups.
Do not scoop the ingredient using the cup itself because this “packs” the cup too much and the
measurement won’t be precise. Be careful if you are using a cup larger than what is needed (as in a 1
cup measure to get 1/2 C worth of ingredients). The same leveling technique should be used with
measuring spoons.

Tips : Measure dry ingredients over a plate or bowl so you can catch the excess and put it back in the
container.

Most ingredients don't need to be packed into the measuring cup. Granulated sugar does it for you.
Flour should actually be aerated or fluffed up before measuring. Brown sugar is one exception, if you
want to pack down while measuring in order to get the proper amount.

Measure liquids at eye level. In other words, place the cup on a flat surface and crouch down so your
eyes are at the same level as the cup in order to check the accuracy of the amount in the cup.

To measure solid fats (shortening, butter etc.) : Most butter has measurements listed on the wrapper, so
you can simply cut off the amount you need. If that information is not available, to measure fats
accurately, pack them down in the cup to get rid of air pockets. It’s easier to pack fats at room
temperature. Another method that works well for butter and Dry Ingredients - The most important thing
to know about measuring dry ingredients is that they should be level with the top of your measuring
cup. Dip your cup into the bin, fill to overflowing and level it off by sweeping the edge of a knife across
the top. Spoon flour and similar ingredients into measuring cups. Do not scoop the ingredient using the
cup itself because this “packs” the cup too much and the measurement won’t be precise. Be careful if
you are using a cup larger than what is needed (as in a 1 cup measure to get 1/2 C worth of ingredients).
The same leveling technique should be used with measuring spoons.

Tips : Measure dry ingredients over a plate or bowl so you can catch the excess and put it back in the
container.

Most ingredients don't need to be packed into the measuring cup. Granulated sugar does it for you.
Flour should actually be aerated or fluffed up before measuring. Brown sugar is one exception, if you
want to pack down while measuring in order to get the proper amount.
Measure liquids at eye level. In other words, place the cup on a flat surface and crouch down so your
eyes are at the same level as the cup in order to check the accuracy of the amount in the cup.

To measure solid fats (shortening, butter etc.) : Most butter has measurements listed on the wrapper, so
you can simply cut off the amount you need. If that information is not available, to measure fats
accurately, pack them down in the cup to get rid of air pockets. It’s easier to pack fats at room
temperature. Another method that works well for butter and

Abbreviation Long

c cup

gal gallon

gm gram

kg kilogram

lb pound

ml mililiter

oz ounce

pt pint

qt quart

tbsp tablespoon

tsp teaspoon

fl. oz. fluid ounce

Weight Measurements and Conversions

Weight Conversion Factors

Multiply By To Get

Grams (gm) 0.035 Ounces

Grams 0.0022 Pounds

Grams 0.001 Kilograms

Kilograms (kg) 2.21 Pounds

Kilograms 1000 Grams

Pounds (lb) 453.6 Grams

Pounds 0.4536 Kilograms

Pounds 16 Ounces

Ounces (oz) 0.0625 Pounds

Ounces 28.3 grams

Approximate Metric Equivalent by Weight (US-Metric)

U.S. Metric

¼ ounce (oz) 7 grams (g)

½ ounce 14 grams

1 ounce 28 grams

1 ¼ ounces 35 grams

1 ½ ounces 40 grams

2 ½ ounces 70 grams

4 ounces 112 grams

5 ounces 140 grams

8 ounces 228 grams

10 ounces 280 grams

15 ounces 425 grams

16 ounces (1 pound) 454 grams

Liquid Measurements and Conversions

 tsp. Tbsp. [Link] gill cup pint Quart gallon

1 teaspoon = 1 1/3 1/6 1/24

1 tablespoon = 3 1 1/2 1/8 1/16

1 fluid ounce = 6 2 1 1/4 1/8 1/16

1 gill = 24 8 4 1 1/2 1/4 1/8

1 cup = 48 16 8 2 1 1/2 1/4 1/16

1 pint = 96 32 16 4 2 1 1/2 1/8

1 quart = 192 64 32 8 4 2 1 1/4

1 gallon = 768 256 128 32 16 8 4 1

US Customary Spoons fluid oz. Approx.

System mililiters

1/16 cup (c) = 1 tablespoon (tbsp) = 3 teaspoons (tsp) 1/2 [Link] 15 ml

1/8 cup = 2 tablespoons 1 [Link]. 30 ml

1.3

1/6 cup = 2 tablespoons + 2 teaspoons [Link] 40 ml

1/4 cup = 4 tablespoons 2 [Link]. 60 ml

1/3 cup = 5 tablespoons + 1 teaspoon 2.7 80 ml

[Link]

3/8 cup = 6 tablespoons 3 [Link]. 90 ml

1/2 cup = 8 tablespoons 4 [Link]. 120 ml

2/3 cup = 10 tablespoons + 2 teaspoons 5.3 155 ml

[Link].

3/4 cup = 12 tablespoons 6 [Link]. 180 ml

1 cup = 16 Tablespoons 8 [Link]. 235 ml

14

1 3/4 cup = [Link]. 410 ml

16

2 cups = 1 pint = [Link]. 470 ml

3 cups = 24 700 ml

[Link].

4 cups = 1 quart = 32 940 ml

[Link].

MISCELLANEOUS EQUIVALENT

1 pinch 1/8 teaspoon or less

1 teaspoon 60 drops

1 dessertspoon (UK) 2 teaspoons

Approximate liquid measurement conversion factors

Multiply By To Get

Quarts (qt) 0.95 liters

Quarts 4 cups

Liters (l) 1.06 quarts

 Liters 1000 mililiters

Cups 235 mililiters

Cups 8 fluid ounce

Cups 0.25 quarts

Mililiters (ml) 0.0042 cups

Mililiters 0.067 tablespoons

Mililiters 0.034 fluid ounce

Fluid ounce (fl. oz) 29.6 mililiters

Fluid ounce 0.125 cups

Gallons (gal) 3.785 liters

Temperature Measurements and Conversions

To convert Degrees Celsius (Centigrade) °C to Degrees Fahrenheit (°F), multiply °C by

1.8 and add 32.

For example, to convert 100°C to °F,

100 x 1.8 + 32 = 212°F

To convert Degrees Fahrenheit (°F) to Degrees Celsius (°C), subtract 32 from °F first, then multiply by
0.56.

For example, to convert 200°F to °C,

(200 - 32) x 0.56 = 94°C

Freezing point for water = 0°C = 32°F

Boiling point for water = 100°C = 212°F

Temperature Conversion Table

Fahrenheit Celcius Celcius Fahrenheit

32 °F 0°C 0 °C 32 °F

40 °F 4.4 °C 10 °C 50 °F

50 °F 10 °C 20 °C 68 °F

60 °F 15.6 °C 30 °C 86 °F

70 °F 21.1 °C 40 °C 104 °F

80 °F 26.7 °C 50 °C 122 °F

90 °F 32.2 °C 60 °C 140 °F

100 °F 37.8 °C 70 °C 158 °F

110 °F 43.3 °C 80 °C 176 °F

120 °F 48.9 °C 90 °C 194 °F

130 °F 54.4 °C 100 °C 212 °F

140 °F 60 °C 110 °C 230 °F

150 °F 65.6 °C 120 °C 248 °F

160 °F 71.1 °C 130 °C 266 °F

170 °F 76.7 °C 140 °C 284 °F

180 °F 82.2 °C 150 °C 302 °F

190 °F 87.8 °C 160 °C 320 °F

 200 °F 93.3 °C 170 °C 338 °F

225 °F 110 °C 180 °C 356 °F

250 °F 120 °C 190 °C 374 °F

275 °F 135 °C 200 °C 392 °F

300 °F 150 °C 210 °C 410 °F

325 °F 165 °C 220 °C 428 °F

350 °F 175 °C 230 °C 446 °F

375 °F 190 °C 240 °C 464 °F

400 °F 205 °C 250 °C 482 °F

425 °F 220 °C 260 °C 500 °F

450 °F 230 °C 270 °C 518 °F

475 °F 245 °C 280 °C 536 °F

500 °F 260 °C 290 °C 554 °F

Day 5

At the end of the lesson you should be able to:

1. Show how to trim the fat off meat

2. Appreciate the importance of recording and documenting product input
Introduction

How to Trim the Fat Off Meat

1. Set the cut of meat on a cutting board. Cut or pinch off a small tag of the fat toward the top.

2. Still holding onto the tag of fat, set your knife in between this fat and the meat. Pull the tag of fat
away from the meat so that it is taut and begin cutting downward in a slicing motion. Tilt the knife
slightly toward the fat as you slice. If you cut straight downward, you’ll end up going into the meat.

3. As you trim the fat off, keep it taut and almost parallel to the cutting board. This will help pull it away
from the meat and make it easier for you to cut accurately.

4. Go slowly and work in clean, smooth strokes. Don’t try to remove all of the fat at once. Work in strips,
starting over at the top of the meat each time. 

Ingredients and Materials to be Checked According to Approved Specifications and Enterprise

Requirements

For curing fish/salting fish:

Ingredients:

Salt, water fish

For smoking:

Ingredients:

Salt, water

fish (bangus, galunggong, tilapia, and herring family

For sugar concentrates

Ingredients:

Sugar, calamansi or citric acid

fruit (mango, guava, pineapple)

For fermentation:

Ingredients:

Salt

dilis and alamang

Various Formulations and Concentrations of Solutions

 Salting/Curing:

The ratio of salt to fish depends on the method of salting to be applied to the fish. If kench salting is
used, the ratio is 1:7 by weight wherein one part of salt is added to seven (7) parts of fish. If brine salting
is used, the ratio is 1:4 by weight wherein one part of salt is added to four (4) parts of fish. In dry salting
to make brine, you use 1:3 by weight or you add one part of salt to three (3) parts of fish.

 Sugar concentrate:

The ratio of fruit juice or pulp to sugar depends on the degree of the pectin content of the fruit. If the
pectin is good, the ratio is 1:3/4 wherein one part of fruit juice or pulp is mixed to three fourths (¾) part
of sugar. If the pectin is not good, the ratio is 1:1 wherein one part fruit juice or pulp is mixed with one
part of sugar.

 Smoking:

The ratio of salt to water for brining and brine cooking is 250 grams of salt to 800ml

water.

Calculating Data on Raw Materials or Ingredients Consumption and Corresponding Percentage

Equivalent in Line with Enterprise Requirement
 Data gathering on raw materials and ingredients is necessary in order to compute and calculate
production input and output of the finished product. The following are examples of data that are
gathered based on the products to be done.

Smoked FishjSSmoked Fish

Data:
Item
Weight

Bangus 1 kg

Salt 250 g

Water 800 ml

Fermented fish

Data:

Item Weight

Fish or alamang 4 kilos

Salt 1 kilo

Pickled Fish

Data:

Item Weight

Fresh milkfish 1 kilogram

Vinegar 1 cup

Calamansi juice ½ cup

Soy sauce ½ cup

Salt 5 tbsp

Sugar 5 tbsp

Black pepper 1 tbsp

Garlic (minced) 1 tbsp

ACTUAL SPOILAGE/REJECTS

Actual spoilage rejects and their corresponding percentage depend on the product to be made.
For example, in mango jam, spoilage refers to the peel of mango and seeds. The products left during
packing are not classified as spoilage rejects. In pickled fish, the skin of the calamansi, garlic and the
intestinal organ of fish are included in the spoilage. In smoked fish, the intestinal organ is the reject.
Lastly, in fermented fish and other fishery product, small seashell, small stone and seaweeds are the
spoilage.

ACTUAL YIELD AND RECOVERIES

Yield refers to the number of finished products after computing for the production output and input.

Formula for getting the percentage yields

% Yield =production input x 100%

production output

Record’s Calculated Data

Report/records based on the data gathered and computed on production output, input, actual spoilage,
rejects, actual yields or recoveries are kept for documentation purposes. This will be the basis for
determining the progress of whatever products to be done on process.

IMPORTANCE OF RECORDING AND DOCUMENTING PRODUCTION INPUT

Steps in recording and documenting production input are as follows:

First, weigh all materials and ingredients needed.

Second, make a necessary listing in your notebook of all the materials and ingredients used. It is
important to note how much or how many. This is what we call recording or documentation.

Third, follow the correct format in documenting and recording.

Sample of Production Report

Product Name: Pickled / Marinated Milkfish

Production Date: February 26, 2012

Description of Materials:

Fresh Milkfish 1000 g

Other Ingredients:

Distilled vinegar 250 g

Calamansi juice 125 g

 Soy sauce 125 g

Salt 75 g

Sugar 75 g

Black pepper 15 g

Minced garlic 15 g

Input: 1680 g

Output: 1200 g
Marinated Fish

Wastage 480 g

Percentage Yield 71 %

Problem Encountered: NONE

Sample of Production Cost

Product: Pickled Mixed Vegetables

I – Raw Materials and Ingredients

Items Quantity wt/ml /gms Cost (P)

Chayote 3 kls. 3 000 gms. 60.00

Carrots 6 pcs. 550 gms. 30.00

red bell pepper 4 pcs. 80 gms. 5.00

Ginger 4 pcs. 270 gms. 10.00

Garlic 2 pcs. 100 gms 5.00

Onion 3 pcs. 165 gms 10.00

Sugar 1½ cups 275 gms 25.00

Vinegar 1½ cups 400 gms 10.00

Raisins 1 pack 100 gms 25.00

Salt 1 cup 150 gms 2.00

TOTAL 202.00

II. Packaging Materials

1. Preserving jars 8 pcs. x P 5. 00 = P 40. 00

2. Label 8 pcs. x P 1. 00 = P 8. 00

= P 48. 00

[Link] Expenditures

1. LPG / fuel for cooking P 2. 00

2. Tranportation P 7. 00

3. Water P 10. 00

= P 19. 00

Grand Total = P 269. 00

IV.

Number of finished products - 8 jars

V. Net Weight - 250 gms

VI.

Mark up price (20 % of Grand Total) - P 53. 80

VII.
 Selling Price - P 40.35

Day (6)

Implement food safety practices

At the end of the lesson you should be able to:

3. Implement sanitary practices in food safety in line with workplace safety regulations.
4. Observe cleanliness and sanitation.
5. Apply safety measures according to workplace rules and regulations.

Introduction

Sanitation in a processing plant is a primary concern of all food processing firms. It is necessary to
prevent or minimize hazards of product contamination and conditions aesthetically offensive to the
consumers, and to provide clean, healthful, and safe working conditions.

Sanitation standard operating procedures (SSOP) are components of Good Manufacturing Practices
(GMPs) emphasizing sanitation procedures on the topics to be discussed as follows:

Workplace Sanitation Regulation in Implementing Sanitary Food Handling Practices in the Following
Aspects;

In handling raw materials and supplies

 Check the source of supplies ( fish, salt, packaging materials)

 Check on the quality

- condition of fish( freshness and temperature

- presence of foreign materials

- color and purity of salt

- purity of other additives

In monitoring during production

 The preparation of fish must be monitored regularly to ensure complete removal of

entrails and gills for eviscerated fish and by thorough washing for whole fish.

 The correct brine concentration, amount of other ingredients and the time of soaking
must be strictly observed to ensure uniformity of every batch.
  The proper drying or cooking endpoint must be observed to ensure uniformity of
product quality.

 In packaging for retail packs, proper packing of products in polyethylene(PE) or

polypropylene(PP) bags must be checked.

For bulk packs, check if product is properly stacked in carton boxes or wooden (palochina) boxes that
are lined with high density polyethylene plastic film.

 In labeling, check if it carries appropriate labeling in accordance with the rules and
regulations on labeling of pre-packaged foods. The following information shall be
declared in every container whether in bulk or in retail package.

For locally produced products:

1. The name of the product and product identification (generic name), printed
in bold capital letters.

2. Name and address of the manufacturer

3. Net weight (in metric units)

4. Ingredients (itemized in decreasing order)

5. Chemical additives e.g. preservatives

6. Open date marking e.g. “Best before” or “Consume before Date”

7. Lot Identification Code (Repackers must use manufacturer’s lot I.D. code)
 8. Storage instruction: Store in a cool dry place.

For locally manufactured/repacked and imported/repacked products:

1. Same as in numbers 1, 3 to 8.

2. Name and address of manufacturer/repacker/importer

3. Country of origin

In Storing and Transporting

1. Check if properly identified and if new production batches are segregated from
previous batches

2. Check if during storage and transport, product is not exposed to any of the following

 direct sunlight or near source of strong sunlight

 high temperature and humidity

 contamination with moisture

 contamination with dust or filth from the environment

In Record keeping /Reporting

1. Check production record; daily control chart, weekly summaries of activities, and
corrective actions maintained for a period of at least 12 months from the date of
manufacture. Manufacturers shall provide traders with a Certificate of Quality of the
specified batch or lot sold to the re packers or traders.

2. Check quality control record.

3. Check marketing and distribution record.

Safety Measures to Be Observed in Implementing Sanitary Food Handling Practices

Good Manufacturing Practices (GMP) is a broad term and includes accepted standards in the safety and
maintenance of the following.

Production And Process Control Safety

1. All operations involving receiving, inspecting, preparing, processing, packaging

and storing of food must be conducted under such conditions that they do not
contribute contamination in the form of filth, harmful chemicals, undesirable
microorganisms or any other objectionable material to the finished product.

2. A strict quality control of raw materials should be enforced. Low grade raw
materials or those that fail to meet specifications should be rejected because this
would only result in an inferior finished product.

3. Containers and carrier of raw materials, packaging materials, storage and

transportation of finished products should be thoroughly inspected and
monitored.

Worker’s Hygiene and Safety

1. Good working conditions ensure not only the safety of workers but also safety of
food products that reach the consumers. Food processing plant personnel must
be adequately trained on the proper hygiene and accident prevention that must
be observed or practiced in the plant to assure continuous flow of work. These
minimize the chance of contamination and accidents that cause unwanted delays.

2. Workers infected with contagious diseases should not be allowed to work as they
can be sources of contamination. They should be quarantined until cured and
safe from spreading the disease. Food handlers with open and infected wounds
or sores in the hands or arms should not be allowed to handle food products
directly for they can contaminate the food they touch. They should always be
made aware of the dangers of haphazard or careless practices. Strict compliance
to sanitary measures should be observed.

Safety measures to be observed by food handlers:

 1. The hands should be washed thoroughly with soap and water. A disinfecting
solution of chlorinated water should be available for rinsing the hands before
handling food. Wearing rings, bracelets, and wrist watches during processing should
be avoided as these can be sources of contamination.

2. Smoking in the preparation, processing, and packing area should never be allowed.
Smoke can be absorbed in the food or the ashes and cigarette butts may get into the
food. Spitting and blowing of nose should never be done within the premises of the
plant. These unhealthy habits contribute to contamination and spread of diseases.

3. Food handlers should be properly dressed. The use of gowns, aprons, head caps or
hair nets, masks, rubber gloves and boots is ideal. This prevents contamination of
the food by foreign matters from the handler’s body like hair, dust, and germs
exhaled from the nose and mouth. However, for small scale industries, clean and
light colored shirts and caps or hairnets would be sufficient.

4. Whenever possible, food must not be handled by bare hands during preparation
and packing.

5. Packaging materials must never be handled directly particularly on the side that
shall be in direct contact with the food.

Equipment and Facilities Safety

1. Processing facilities should be well ventilated, adequately lighted and properly

maintained. Thorough washing and subsequent disinfecting of processing
equipment before and after use should be a standard operating procedure (SOP).

A good processing plant should have an effective pest control to keep it free from
rodents and insect pests. Cleanliness of processing equipment, utensils and
surroundings prevents both infestation and contamination.

2. Potable water supply should be available from adequate sources. Good drainage

and sewage disposal system should also be provided. These are essential for the
efficient maintenance of sanitation.

3. Waste disposal should be properly managed to prevent pollution of surroundings.

SELF - CHECK

Directions: Fill in each blank with a word or words to make the statement complete.

1. are components of GMP

emphasizing sanitation procedures designed for the promotion and maintenance of
health and cleanliness in a processing plant.

2. is the process of
putting/attaching labels on the immediate container.

3. is a primary concern of all

food processing firms to prevent or minimize hazards of product contamination and
conditions aesthetically offensive to the consumers.

4. refers to the practices and

procedures implemented in processing plants to ensure product safety, product quality
and prevention of economic fraud.

5. is any printed pictorial or

material attached to any container.

6. are situations that ensure

safety of workers as well as food products that reach the consumers.

7. is a disinfecting solution
available for rinsing hands before handling food.

8. are protective coverings

worn by food handlers to prevent contamination of the food from foreign materials.

9. refers to clean water that

is safe for drinking and cleaning.

10. is a mixture of salt and

water.
DAY (7)

Cure raw materials

At the end of the lesson you should be able to:

6. Appreciate the necessity of curing

7. Identify the ingredients of curing and its functions
8. Use and read the salinometer

Pre-Test

A. Multiple Choice

Directions: Read and analyze the questions below. Select the correct answer from the options given.
Write the letter of your choice on your answer sheet.

1. Which of the following mixtures would you use if you are instructed to prepare 10% brine solution.
How will you measure it?

a. 1 part salt, 8 parts water c. 1 part salt, 9 parts

water
 b. 1 part salt, 7 parts water d. 1 part salt, 5 parts
water

2. How many grams of salt is applied to 700 grams of fish in Kench salting using the ratio 1:7 by weight?
a. 100 grams of salt c. 200 grams of salt

b. 150 grams of salt d. 250 grams of salt

3. In preparing curing solution, the following are measured EXCEPT ONE

a. vinegar c. sugar

b. salt d. oil

4. How many cups of salt is added to 27 cups of fish for curing using 1:3 ratio?
a. 10 cups c. 8 cups

b. 9 cups d. 7 cups

5. If you are asked to prepare a brine with a concentration of 20%, what is its equivalent in terms of
ratio?

a. 1:4 c. 1:5

b. 1:7 d. 1:9

6. Which of the following consist the preparation of a 25% brine solution, with a 1:5 ratio meaning it
consists of:

a. 1 part salt, 5parts water c. 1 part water, 5 parts

fish

b. 1 part salt, 5 parts fish d. 1 part fish, 5 parts salt

7. How many volumes of water is added to salt to make a solution of 1:4 if the salt weighs 250
grams/cup?

a. 1,000 ml of water c. 500 ml of water

b. 800 ml of water d. 900 ml of water

8. Which among the concentration of salt given below is required to kill most species of unwanted
bacteria?

a. 10% c. 20%

b. 25% d. !5%

9. If the ratio of preparing brine is 1:9, what is the volume of water to dissolve 250 grams of salt?
 a. 2250 ml of water c. 1500 ml of water

b. 2500 ml of water d. 2000 ml of water

10. In using a salinometer to test for brine strength, at what

concentration is 20º S brine?

a. 250 grams of salt, 800 ml of water

b. 200 grams of salt, 800 ml of water
c. 250 grams of salt, 750 ml of water
d. 200 grams of salt, 750 ml of water

Test for Valuing

Explain briefly the importance of accurate weights and measurement of ingredients for salting and
curing solutions and mixtures.

Introduction:

Curing
Curing is a method of preserving food (usually meat or fish) to prevent spoilage. Food can be cured by
brining (soaking food in a saltwater solution), smoking, or salting (packing food in salt.

Necessity of curing

Untreated meat decomposes rapidly if it is not preserved, at a speed that depends on several factors,
including ambient humidity, temperature, and the presence of pathogens. Curing is able to significantly
extend the life of meat before it spoils, by making it inhospitable to the growth of spoilage microbes.

Curing ingredients and their functions:

1. Salt [NaCl]

Functions:
  for meat protein extraction

 contributes to a desirable flavor

 aids in water retention in processed meat

 controls bacterial growth

2. Sugar

Functions:

 counteracts astringent quality of salt

 enhances the flavor of the product

 aids in lowering the pH of the cure [cane sugar is more suitable]

3. Nitrates, nitrites, curing salt

Functions:

 for cured color development

 for cured flavor development

 inhibits the growth of clostridia

Recommended use level:

 ½ teaspoon/kilogram of meat

 0.2% or weight of meat

 200 ppm NaNa2 in finished products

4. Phosphates

Functions:

 improve water retention

 improve binding between meat chunks

 enhance emulsion stability

 help to suppress development of rancid flavors

 decrease emulsion viscosity

Recommended use level:

 1 teasepoon phosphate dissolved in ¼ cup water

 0.3% of weight of meat

5. Ascorbates, Erythorbates, Ascorbic Acid

Functions:

 hastens reduction of nitrate to nitric acid

 antioxidant

 improve color stability

 suppress nitrosamine formation

Recommended use level:

 ascorbic acid – 500mg/kg. of meat

 erythorbate – .05% of weight of meat

6. Binders, fillers, emulsifiers – usually added for economic reasons

6.1 Binders

 dissolve and bind meat particles together

 hold moisture during processing and/or subsequent heating

 produce better yields e.g. dried skim milk, cereal flour, starches, soy protein concentrate,
carrageenan

6.2 Fillers

 insoluble additive

 does not contain water soluble proteins

 serve only as added weight

 e.g. cereal grain products

6.3 Emulsifiers

 contain water soluble proteins in varying amounts

 aid in the emulsification of the ingredients in chopper e.g. dried whey, soy protein isolate, soy
protein concentrate

7. Extenders

Non-meat material added to meat in order to:

 increase the bulk, and

 modify the quality of a meat product

Examples:

 TVP [textured vegetable protein]

  ISP [isolated soy protein]

8. Flavoring agents – flavor improvement, bacterial inhibition, color improvement, antioxidant function.

 Spices

 pepper

 cloves

 mace

 cinnamon

 garlic

 onions

 nutmeg

 paprika

 Flavor modifiers

 MSG [monosodium glutamate]

 Hydrolyzed proteins

 Hydrolyzed vegetable protein

 Nucleotides

 Smoke flavor

 Starter cultures

9. Food color

 color improvement

10. Water

 universal solvent

Measuring/Weighing the Ingredients of the Curing Solution

To prepare a curing solution, the quantity depends on the type of cure, individual preferences and
processing requirements stated in the procedure. Measure the amount of ingredient using the required
measuring tools.
Measuring curing ingredient Preparing curing mixture

Preservation of Meat by Salting

 Salt-cured meat or salted meat is meat or fish preserved or cured with salt.

 Salting, either with dry salt or brine, was a common method of preserving meat until the middle
of the 20th century, becoming less popular after the advent of refrigeration. It was frequently
called “junk” or “salt horse”.

Religious Customs:

 Jewish and Muslim dietary laws require the removal of blood from freshly slaughtered meat.

 Salt and brine are used for the purpose in both traditions, but salting is more common
in Kosher Shechita (where it is all but required) than in Halal Dhabiha (as in most cases, draining
alone is sufficient).
Purpose of Salting:

 Salt inhibits the growth of microorganisms by drawing water out of microbial cells
through osmosis due to the high concentration of salt outside the cell. The cell loses water until
it reaches a state where it cannot grow and then cannot survive any longer, (hypertonic nature).
Concentrations of salt up to 20% are required to kill most species of unwanted bacteria.

 Smoking, often used in the process of curing meat, adds chemicals to the surface of meat that
reduce the concentration of salt required.

 It was discovered in the 19th century that salt mixed with nitrites (saltpeter) would color meats
red, rather than grey, and consumers at that time then strongly preferred the red-colored meat.
The food hence preserved stays healthy and fresh for days avoiding bacterial decomposition.

Methods Of Salting

Dry Salting:

 Dry salting, also called corning, is a process where meat is dry-cured with coarse ‘corns’ or
pellets of salt.

 Salted beef is sometimes known as corned beef. The use of the term ‘corned’ comes from the
fact that the Middle English word corn could refer to grains of salt as well as cereal grains.

 Salting meat can be accomplished by adding salt (dry), or in brine.

Dry Salting Procedure:

 The salt solution is prepared by adding the necessary amount of edible common salt to water
and dissolving it by intensive stirring.

 To obtain the recommended salt concentration of about 14 percent the amount of salt
necessary for different volumes of water (expressed in litres) is indicated below:

Water Salt

(litre) (g)

5 810
6 975

7 1 140

8 1 300

9 1 460

10 1 630

 As soon as the salt is dissolved in the water, the meat strips are dipped into the solution soaked
for about five minutes and then drained.

 Draining should be done by placing the strips into a plastic sieve in order to allow the brine to
drop off for collection and re-use

 After that drying (by uniform circulation of air) and then meat storage is done.

 Sugar may be added for taste and flavor enhancement, sugar is added to counterbalance all of
the salt.

 For example, half a pound of salt mixed with a quarter cup of sugar should be enough for ten to
twelve pounds of meat.

Draining

Draining facilitates removal of excess moisture from a fish

previously washed or soaked in a brine or curing solution.

Steps in Draining Raw materials

1. Arrange fish inside a colander or on bamboo trays.

2. Let the excess water drip-off from the fish. Draining takes 30 minutes to one (1) hour
depending upon the size of the fish.
 The colander is an important device in draining fish.

Brining:

There is also a method for wet curing, also known as brining. This technique involves you keeping the
meat submerged in a salty solution.

Brine is a common agent in food processing and cooking. Brining is used to preserve or season the food.
Brining can be applied to vegetables, cheeses and fruit in a process known as pickling. Meat and fish are
typically steeped in brine for shorter periods of time, as a form of marination, enhancing
its tenderness and flavor, or to enhance shelf period.

Brine Preparation

To prepare brine or salt solution, consider using the different concentrations:

 a. 10% (1:9 ratio)

 b. 20% (1:4 ratio)

 c. 25 % (1:3 ratio)

Examples:
1. 10% brine consists of 1 part salt and 9 parts water.
If 1 cup of salt is 250 grams, then for 9 cups of water is 2,250
grams or millimeters of water.
To weigh the solution dissolve 250 grams of salt in 2250 g/ml of
water, therefore the weight of solution is 2,500 ml.
2. To measure 20% (1:4 ratio) 1 part salt to 4 parts water.
If 1 cup of salt is 250 grams, then 4 cups of water is 1000 ml
3. To measure 25% ( 1 part salt to 3 parts water) 1 cup of salt=250
grams added to 750 ml of water would give 1000 ml solution.
4. To weigh the solution, dissolve 250 grams salt to 1000 ml of
water, therefore the weight of the solution is 1,250 ml.

Fig. Weighing the solution using A

weighing scale or simply a Beaker
 Note* A concentration of salt up to 20% is required to kill most of
unwanted bacteria.

Brining Procedure:

 Wash the meat and sterilize the jars or crocks then put the meat into jars after cutting

 Now add about a pound of salt and half a cup of sugar to three quarters of water, Add other
ingredients such as herbs and spices

 Repeat this process until you have enough water for all of the jars. Fill each one up.

 Unlike dry curing, the meat will need your attention on a weekly basis. Each week you will have
to take the meat out of the jars, stir the brine well and then place it back.

 After four weeks of repeating this process, your meat is ready. If you find the brine to be getting
too thick, you will need to replace it with a fresh batch.

Using Salinometer

Procedure:
1. Prepare brine solution.

2. Pour brine solution in a cylinder.

3. Dip salinometer in a brine solution.

4. Record the reading

5. Clean after using.

Part of a series on Water salinity

 Brine Solution Chart

Factors Affecting Salt Penetration

1. Types/kinds of salt

Table salt unrefined salt

 refined salt pepper corn

Sea salt sea salt

2. Brine temperature
The rate of salt penetration is affected by temperature. At 0 º C, salt penetration is
slower, but is faster at 15 º C and fastest at 30 º C at identical periods of observation.
3. Salt concentration
A difference in salt concentration between the fish and the brine results in gradual
diffusion of salt into the fish. The higher the salt concentration, the rapid the salt
penetration.
Salt concentration may be:

a. Saturated solution – there is an equal amount of salt dissolved in small amount

of water
b. Super saturated-great amount of salt dissolved in small amount of water
c. Unsaturated- - less amount of salt dissolved in more amount of water
4. Brine volume
A small volume of brine in proportion to the fish affects results in a small concentration
of salt.
5. Agitation of the brine
 If the brine is occasionally stirred while it surrounds the fish, salt diffusion into the fish is
hastened.

Day (8)
Process Cured Materials
At the end of the lesson, you should be able to:
1. Identify the different types of smokehouse
2. Describe the methods and techniques of post curing
Introduction
Post Curing Methods and Techniques
Smoking
Verify that smokehouses operate as intended (heat, airflow, moisture). Appropriate calibrated
thermometers should be used (for cooking temperature and meat internal temperature).
Procedures for delivering the appropriate thermal treatment of cooked meats in conformance
with the Food Code must be developed and used. Smoke itself, without proper cooking, is not
an effective food preservative (Hilderbrand 1999). Caution should be used when smoking meats
at temperatures in the danger zone 40-140°F for prolonged periods of time. In such a case meat
must have been salted or cured first.
Example of Curing and smoking

 Smoked Bacon/smoked pork

 Smoked Fish

 Smoke Cooking
Consumers should smoke cook foods to internal temperatures as listed by the USDA (USDA-FSIS
1999).

Table 6.1. Internal Temperatures for Smoke Cooking of Foods

(USDA-FSIS 1999).

Product °F

Ground Meat & Meat Mixtures

Table 6.1. Internal Temperatures for Smoke Cooking of Foods
(USDA-FSIS 1999).

Product °F

Turkey, chicken 165

Veal, beef, lamb, pork 160

Fresh Beef

Medium Rare 145

Medium 160

Well Done 170

Fresh Veal

Medium Rare 145

Medium 160

Well Done 170

Fresh Lamb

Medium Rare 145

Medium 160

Well Done 170

Fresh Pork

Medium 160

Well Done 170

Poultry

Chicken, whole 180

 Table 6.1. Internal Temperatures for Smoke Cooking of Foods
(USDA-FSIS 1999).

Product °F

Turkey, whole 180

Poultry breasts, roast 170

Poultry thighs, wings 180

Stuffing (cooked alone or in 165

bird)

Duck & Goose 180

Ham

Fresh (raw) 160

Pre-cooked (to reheat) 140

Seafood

Fin Fish Cook until opaque and flakes

easily with a fork.

Shrimp, lobster, crab Should turn red and flesh should

become pearly opaque.

Scallops Should turn milky white or

opaque and firm.

Clams, mussels, oysters Cook until shells open.

Cooling
Cool cooked products rapidly to below 40°F and keep refrigerated. Cooked fish products should
generally be cooled from to 70°F or below within 2 hours and to 40°F or below within another 4
hours (US FDA 1998). Minimize handling of cooked products. Dry (unfermented) products may
not be hot smoked until the curing and drying procedures are completed. Semi dry fermented
sausage must be heated after fermentation to a time/temperature sufficient to control growth
of pathogenic and spoilage organisms of concern.
Example of Curing followed by Cooling

 Ham/salted pork
 Bacon

Air Drying
Air drying can be done but it needs to be done on a hot, dry (low humidity), day. Or in a room
that is hot and dry with an air current. Room drying at room temperature works only if heat,
humidity, and air movement are adequate.
Example of Curing and air drying

 Biltong
 Dry herbs

Different types of Smoke house

A smokehouse is a simple version of a heat processing unit used by today's meat industry. The
size may be vastly different, but the principles are the same: it is an enclosed area where the
temperature and smoke level may be controlled with acceptable accuracy. 
The purpose of a smokehouse is to enclose heat and smoke, and reduce, but not entirely
eliminate, airflow. Depending on how much smoking you want to accomplish, you may
construct your own smokehouse or purchase a commercial unit.
Many types of smokehouses can be used successfully to smoke meats, fowl and fish.
Smokehouses can include simple equipment as a charcoal grill for very small amounts of meat,
metal barrels, water and electric smokers, and in more extensive units, those of frame or
concrete construction.
One of the least expensive methods to smoke small amounts of meats and sausages is on your
covered charcoal grill. This will require an oven thermometer to monitor the temperature. You
can fill the bottom of your grill with briquettes and burn them until gray ash appears.

Separate the coals onto two sides of the grill and place a pan of water between them. Place the
grate over the top and place your sausages above the water. As the sausages heat and cook,
the fat will drip into the heated water and create steam that will help destroy harmful bacteria.

Keep the vents open on the cover. For hot smoking, you will need to maintain an air
temperature between 225 to 300 degrees Fahrenheit throughout the process.
Vertical Water and Electrical Smokers:
A vertical water smoker is built with a bottom fire pan that holds charcoal briquettes and
generally has two cooking racks near the top.

The water pan positioned above the coals supplies moisture and helps regulate that internal
temperature. An electrical smoker is similarly constructed, except the smoke is controlled by
pre-moistened wood chips rather than charcoal. This will provide a more constant temperature
and may require less attention during smoking.

The sizes of electric smokers vary with some accommodating up to 40 pounds of sausages at
one time.

Barrel Smoker:
A clean, non-contaminated 50-gallon metal barrel, with both ends removed, can be used as a
smoker for small quantities of meat, fowl, and fish. Set the open-ended barrel on the upper end
of a shallow, sloping, covered trench or 10-to12-foot stovepipe.
Dig a pit at the lower end for the fire. Smoke rises naturally, so having the fire lower than the
barrel will aid its movement towards the meats. Mound the dirt around the edges of the barrel
and the fire pit to eliminate the leaks. You can control the heat by covering it with a piece of
sheetmetal.
Use metal or wood tubes as racks from which to suspend your sausages in the barrel. At the
beginning of the smoking, you want a rapid flow of air past the meat to drive off excessive
moisture.

Less rapid air movement near the end of the smoking period prevents excessive shrinkage of
meat. Use moist wood chips, sawdust, or charcoal for starting your fire.
You want a lot of smoke but very little flame. Once your fire is going, you can add green
sawdust or green hardwood to cool the fire and make more smoke. Never use gasoline or other
accelerants to start your fire. Besides their explosive potential, which can cause serious injury,
the fumes and residues will contaminate your sausage.
Metal strips can be attached to the cover, to help hold it in place, trapping the smoke near the
meat. You can monitor the inside temperature by suspending a thermometer from one of the
metal racks.
Frame or Concrete Smokehouse:
You can build a smokehouse out of wood or concrete blocks. While these are more elaborate
structures, they will accommodate larger quantities of meats at one time and will last for many
years.

They have the advantage of making temperature control easier and reducing fire hazards.

 Their tight construction and well-fitted ventilators can control air flow past the meat. A larger-
size building will provide space for several tiers of racks. This will let you adjust the hangers to
the size of the pieces of meat being smoked. Meats can be crowded into a smokehouse, but the
only rule is that no piece of meat be able to touch another or the wall.

Any building you construct should have four features: a source of smoke, a place to hold the
smoke, a method to hold the meat in the smoke, and a draft regulator near the top of bottom.

A smokehouse is a very slow oven in which the temperature does not exceed 200 degrees
Fahrenheit. Even though you will use and maintain low temperatures, build your smoke house
in a safe location from other buildings, particularly your home and away from all combustible
materials.

Let’s watch the video on How to process food by curing (food preservation).
[Link]

Day (9)
 Pack processed cured materials
At the end of the lesson you should be able to:
1. Differentiate the packaging materials
2. Identify the food labelling
Packaging Materials
Packaging is a container. It is a system or means of protecting goods for transport, distribution,
storage, retailing and end-use. It also serves as an important marketing tool for enhancing
product market appeal
Different packaging materials
 PRIMARY PACKAGING
Primary packaging is the packaging in direct contact with the product itself and is
sometimes referred to as a consumer unit. The main purpose of primary packaging is to
contain, protect and/or preserve the finished product, particularly against
contamination. This is the first layer containing the finished product, such as a plastic
pouch holding whole-grain cereal or the cardboard box containing the pouch of cereal.
This type of packaging is often intended for the end user or consumer.
 SECONDARY PACKAGING
This type of packaging is used outside of primary packaging to group a certain number
of products to create a stock-keeping unit, commonly referred to as a SKU. It facilitates
the handling of smaller products by collating them into a single pack. This type of
packaging also provides supplementary protection to help maintain the integrity of the
primary packaging. In addition, it can serve as a shipping container for small shipments,
making it highly useful in e-commerce. Secondary packaging is frequently made up of
multiple components (box, padding, separators, reinforcements, bags, paper, etc.). It
may also be customized to make a product easily identifiable in the warehouse setting.
In the case of cereal, for example, the secondary packaging would be the corrugated
cardboard box containing multiple individual boxes of cereal.
 TERTIARY PACKAGING
Often also referred to as bulk or transit packaging, this type of packaging is used to
group larger quantities of SKUs to transport them from point A to point B (e.g. from
production facility to point of sale). During this stage, products are handled as
distribution units. This type of packaging makes it easier to transport large and/or heavy
loads safely and securely. In addition to helping prevent damage, it consequently
facilitates the handling, storage and transport of goods. An example of tertiary
packaging is a stretch-wrapped pallet containing a quantity of cardboard boxes
(secondary packaging) to enable efficient product shipping.
Kinds of Packaging Materials for cured materials
1. Polyester – polyethylene (PET/PE) for local and foreign distribution of dried fish at ambient
and refrigerated conditions, and of smoked fish at refrigerated condition.
2. Polyethylene (0.002 inch thick) for local and foreign distribution at refrigerated conditions
3. Traditional packaging materials like wooden boxes, baskets, used cartons, jute sacks, etc.
These need to be improved to ensure product hygiene and safety.
Packaging of Smoked Fish

Smoked fish is packed either in bulk or in retail packaging materials.

Bulk packaging refers to those intended for wholesale or institutional distribution.

Retail packs contain the product until it reaches the ultimate end-user or consumer.
Procedure for Bulk Packaging
1. Sort cooled smoked fish according to size.
2. Pack or transfer smoked fish in bulk packaging materials by arranging the fish in a
manner that heads and tails are in uniform position.
3. When the packaging material is nearly full, weigh the whole pack (container and
smoked fish) to check product weight attained. Total weight minus weight of
container will give the weight of the smoked fish.
4. Close or seal the pack and store at refrigeration temperature (3OC to 5OC) or in a
cold storage.
Procedure for Retail Packaging
1. Sort smoked fish according to size.
 2. Pack smoked fish in plastic bags at retail weights of 250g., 500g, or 1,000g per
pack.
3. Seal the filled packs by using a portable or fast sealer.
4. Transfer the packed products in bulk packaging materials; seal and store
preferably at refrigeration temperature to maintain the quality of the smoked
fish.
Vacuum Packaging
Vacuum Packaging may be defined as taking off oxygen from the container during sealing in
order to preserve the products.
Packaging materials like polyamide/polythene laminates are suitable for vacuum packaging for
they are resistant to pinhole formation (Hermes, 1998).
The advantages of vacuum-packed products are as follows:
1. Vacuum-packed products have longer shelf-life than ordinary packed products due to non-
occurrence of oxidation.
2. They have better keeping quality especially on dried fish wherein no rancidity occurs.
3. They demand high price in the market.
The disadvantages of vacuum-packed products are the following:
1. Vacuum-packed products are not applicable to fish roe and mussel meat.
[Link] label of the vacuum-packed products are not readable due to deformity of the surface of
the pack.
[Link]-packed products should be refrigerated below 3°C or 37.4°F to prevent production of
toxin by clostridium botulinum.
Vacuum Skin Packaging.
Vacuum skin packaging is an extension vacuum packaging which can be applied to both film-to-
film and film-to-tray sealing (Hermes, 1998). The wrapper is heated and draped over the
product. hence, giving extra “skin”.
What is food labelling?
A food label, the information presented on food product, is one of the most important and
direct means of communicating information to the consumer. The internationally accepted
definition of a food label is any tag, brand, mark, pictorial or other descriptive matter, written,
printed, stencilled, marked, embossed or impressed on, or attached to, a container of food or
food product. This information, which includes items such as ingredients, quality and nutritional
value, can accompany the food or be displayed near the food to promote its sale.
Your food label should have the following information:
o Name of products
o Net weight
o Ingredients
o Production/expiry date
o Manufacturer’s address
o Allergen program

Perform post-production activities

At the end of the lesson, you should be able to:
1. note and document daily production input in accordance with basic accounting
procedures;
2. record and present all production data in accordance with basic accounting
procedures; and
3. practice accuracy in preparing production report.

Introduction
Format of a Production Report
Production Data Sheet
Product Name:
Product Date:
Description of Materials: __________________
Other Ingredients: _______________________
Weight of _____________________
Weight of _____________________
Weight of _____________________
Production Input _______________
Weight of Spoiled Materials _______
Production Output ______________
Percentage of Yield _______________
Number of Yield ________________
Problem Encountered ____________

Example of Production Report

Production Name : Smoked Fish Production

Date : May 31, 2007
Materials/ Ingredients:
Bangus = 220 grams
Salt = 500 grams
Production Input = 720 grams
Weight of Spoiled Materials =- 50 grams
Production Output = 670 grams
Percentage of yield = Production Output x 100%
Production Input
Percentage of yield =670 gramsx 100%
720 grams
Percentage of yield =.93 x 100%
Percentage of yield =93%
Number of yield = Production Output / Weight of the product
Number of yield = 4 pieces

Reporting the Breakdown of Equipment/Machine, Tools and Utensils

The person in charge of inspecting and checking equipment/machines used in processing foods
like fish, meat, fruits and vegetables must make the necessary report regarding the breakdown
of equipment/machine, tools and utensils and furnish the report to the person responsible in
scheduling the trouble shooting and repair of any equipment/machine, tools and utensils that
breakdown. In preparing such report, it is necessary to follow the prescribed format required by
the company or organization. This is done to rigidly monitor the condition of all
equipment/machines to ensure their serviceability in accordance with workplace rules and
regulations. Through the prepared reports, a conclusion as to the condition of
equipment/machines can be accurately made as to: a) serviceable, b) repairable and c)
defective. The compiled reports will provide a ready database as to the needs of the company
in terms of:
1. machine parts to be purchased
2. expenditures incurred for repair and purchase of machine parts
3. labor requirement for preventive maintenance and trouble shooting

A Sample Report on Equipment/Machine Breakdown

 Remarks and
Date:
Daily Inspection Report

Before During After Recommen

Condition Operation Operation Operation dations

Can Sealer

Pressure Cooker

Mechanical/Electric Smokehouse
Freezer

Refrigerator

Electric Scaler

Oven

GasRange

Gas Stove

Food Processor/Blender

Juice Extractor

Vacuum Packer

Electric Polysealer

Inspected by:
Reviewed by:

Procedure in Cleaning, Sanitizing, Calibrating and Stowing Equipments and Instruments

1. Wash the equipment or instrument with soap.

2. Rinse with clean water.
3. Sanitize by dipping or soaking in a sanitizing solution.
4. Remove from the sanitizing solution.
5. Rinse with clean water.
6. Dry thoroughly (air dry).
7. Check the accuracy of each equipment and instruments.
8. Pack and keep in a clean cabinet.
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Day (12)
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