WEBSCRIPT Food Processing NC II

MODULE 6 PROCESSING FOOD BY THERMAL APPLICATION

Description This module will cover the knowledge and skills required to process food by thermal
application.

You will learn how to prepare equipment and apparatus for thermal application.

You will also learn how to process food by pasteurization and pressurization.

Towards the end, you will learn how pasteurized and pressurized products should be
packaged and stored.
UNIT 1 PREPARING EQUIPMENT AND APPARATUS FOR THERMAL APPLICATION
Objectives At the end of this unit, you should be able to:

1. Identify equipment used in thermal application;

2. Use the following equipment in processing food by thermal application.

TOPIC 1 Boiler

Boiler is used to contain liquid for pasteurization.

A double boiler is a boiler with a detachable upper compartment heated by boiling

water in the lower compartment. It is placed over a stove to begin heating.

A modern version such as the steam jacketed kettle uses steam to heat liquid. It is
enclosed by a ‘jacket’ to ensure even heating and it has a spout for collecting volumes
of liquid. Some models can be titled for easier collection. The steam jacketed kettle is
operated by electricity.
TOPIC 2 Pressure Canner
Pressure Canner is a sealed pot that has a dial that indicates the pressure inside it
and a weighted gauge that allows steam to come in and out. It works by trapping
steam and building up pressure inside a pot.

Infographic on pressure canner – parts, labels

Dial

Weighted gauge

Steam vent

Rack

Pot

Lock

Steps in pressure canning:

Steam venting is done to allow air to escape and to reach pressure. To vent steam,
 fasten the lid on and leave the weighted gauge open. Turn the heat on and wait until
steam comes out of the vent. Let steam vent for 10 minutes before putting the weight
gauge on.

Adjusting pressure and temperature. Pressure is normally set to 10 pounds but this
can be changed based on the recipe. Temperature or heat is adjusted to maintain the
level of pressure for the entire processing time. If the pressure goes below the
specified amount, increase heat to bring the pressure back up and reset the
processing time.

Depressurizing. Contents tend to break apart as a result of rapid depressurization.

Once the processing time is over, turn the heat off and allow canner to cool down and
depressurize. Do not open the lid until the dial reads 0 pressure and there is no more
hissing sound from the weighted gauge.

TOPIC 3 Thermometer

Thermometer measures temperatures up to 200 C which makes them ideal for

measuring temperatures for pasteurization.

How to Calibrate a Thermometer

1. Insert thermometer into a pot of boiling water. Make sure it does not touch the
bottom of the pot. Leave it on for 10 minutes.
2. The thermometer should read 100 C or 212 F. If this is not the case, record the
difference.
3. If, for example, your thermometer reads boiling water at 90 C, then you should
remember that it reads temperatures 10 degrees lower than the actual
temperature. Or, you can simply replace your thermometer.

How to Use a Thermometer

1. Insert your thermometer into the pot while cooking. Make sure it does not touch
the bottom of the pot.
2. Continue to cook the mixture until it reaches the desired temperature.
UNIT 2 PROCESSING FOOD BY PASTEURIZATION
Pasteurization, also referred to as partial sterilization, entails heating food up to
100°C or less to destroy heat sensitive microorganisms. It is done to extend shelf-life
of milk and fruit juices but it can also be a step in the packaging process of fermented
foods.

Why Pasteurize?

 Pasteurization destroys yeasts, molds, gram-negative bacteria, and gram-

positive bacteria.
 Pasteurization destroys spoilage microorganisms without undesirably changing
the characteristics of food. When milk is exposed to higher temperatures for
longer periods of time, it changes in taste, color, chemical properties, and
microbiological stability.
 Pasteurization requires shorter time than other food processing methods.
 Pasteurization Temperatures

Temperature Time
63°C For 30 min (low
temperature long time
LTLT)
72°C For 15 sec (primary
high temperature short
time, HTST method)
89°C For 1.0 sec
90°C For 0.5 sec
94°C For 0.1 sec
100°C For 0.01 sec
LESSON 1 METHODS OF PASTEURIZATION

This lesson will focus on the two methods of pasteurization.

TOPIC 1 BATCH HOLDING METHOD

Batch (holding) Method

Batch method is the most commonly used method in households. It requires relatively
inexpensive tools such as the stove, pot/boiler, and thermometer.

In this method, the liquid is heated to at least 63 degrees Celsius and held for at least
30 minutes.

Products that are pasteurized by batch method include milk, juice, vinegar. Although,
these products can also be pasteurized by the High-Temperature-Short-Time
(HTST) method.

TOPIC 2 HIGH TEMPERATURE SHORT TIME (HTST)

High-Temperature-Short-Time (HTST)

The high-temperature-short-time method is more commonly used in commercial

operations because it is more energy efficient than the batch method. It takes shorter
time and it can pasteurize large volumes of milk at once.

In High-Temperature-Short-Time (HTST), liquid is heated to at least 72 degrees

Celsius and held for at least 15 seconds. Ultra-High Temperature (UHT), which you
may see on the packaging of milk, entails higher temperatures and shorter times e.g.
135 degrees Celsius for 1 second.

Milk and juice are also processed by HTST.

LESSON 2 PRODUCTS

In this lesson, you will learn how products are pasteurized.

How to Pasteurize Milk (High Temperature Short Time)

You’ll need the following

  1L raw, fresh milk
 Water
 Double boiler
 Strainer
 Funnel
 Ice bath

Procedures:

1. Set up the double boiler by filling the lower boiler halfway with water. Place on
medium-high heat.
2. With the help of a strainer, pour raw, fresh milk into the upper boiler.
3. Place a clean thermometer in the upper boiler for monitoring.
4. Stir frequently.
5. Bring the temperature to 73 degrees Celsius and maintain for 15 seconds.
6. Carefully remove from the heat.
7. Cool in an ice bath immediately. Stir frequently and bring temperature down to
4.4 degrees Celsius.
8. Transfer into sterilized jars.
9. Store in a cool storage.

How to Pasteurize Fruit Juice (Batch Holding Method)

You’ll need the following:

 1L fresh orange juice

 Water
 Double boiler
 Funnel

Procedures:

1. Set up the double boiler by filling the lower boiler halfway with water. Place on
medium-high heat.
2. Pour fresh orange juice int the upper boiler.
3. Place a clean thermometer in the upper boiler for monitoring.
4. Stir frequently.
5. Bring the temperature to 63 degrees and maintain temperature for 30 minutes.
6. Carefully remove from the heat.
7. Transfer into sterilized jars. Seal.

UNIT 3 PROCESSING FOODS BY PRESSURIZATION

Objectives At the end of this unit, you should be able to:
1. Demonstrate the use of a can sealer;
2. Prepare pressure canner prior the canning process;
3. Process food by canning.
LESSON 1 PROCESSING FOOD BY PRESSURIZATION
Pressurization kills microorganisms by subjecting it to intense pressure and heat. In
this method, cans or glass jars filled with food are exposed to temperatures ranging
from 110 to 121 degrees Celsius.

Pressurization is also referred to as canning. It’s the only way to produce your canned
goods.

Pasteurization Pressurization
Purpose to kill bacteria found in dairy to preserve food in a can by
and fermented foods creating a vacuum where no
bacteria can survive
Method uses heat uses heat and pressure
Equipment boiler pressure canner
Impact does not necessarily change tends to affect taste, texture,
the taste, texture, and chemical and nutritional content
properties of food

Why Pressurize?

 Pressurization destroys yeasts, molds, gram-negative bacteria, and gram-

positive bacteria.
 Pressurization takes longer processing time but can extend shelf-life of food for
1 – 2 years.
 Pressurization can preserve just about any food – from vegetables to meat to
condiments.

The Canning Process

1. Pre-cooking. Fruits and vegetables are usually blanched while meat is either
stewed or braised. You can pre-cook food in any way you would like to. After pre-
cooking, the food is placed in a container or a can for exhausting.

2. Exhausting is a means of creating vacuum in the container by eliminating oxygen

which could potentially spoil the food inside. An unsealed container is placed in a pan
of water and heated up to 77° C. The air bubbles escape the container during the
heating. The contents will then contract during cooling and a vacuum is produced
inside.

This is only done to aluminum and steel cans. Once they have been sealed, the air
bubbles can no longer escape.

3. Sealing. For glass jars, the lid is manually attached to the container and is turned to
seal. For metal cans, the lid is attached to the body by a can sealer.

Headspace is the space between the lid and the surface of the food in canned
products. Knowing the recommended headspace for canned food prevents overfilling
and spilling. More importantly, it ensures a good vacuum seal.

During pressure canning, the air bubbles escape from the food. If there is not enough
headspace, the food will expand and boil out of the jar. If there is too much
headspace, the processing time will not be enough to drive out the air bubbles out of
the jar.
Recommended headspace:

 Jellies, jams, soft spreads, fruit juice: 1/4 inch (1/2 cm)
 Fruits, tomatoes, pickles, relishes, chutneys, condiments: 1/2 inch (1 cm)
 Low-acids: 1 to 1 1/4 inches (2 to 3 cm)

4. Pressurizing. The sealed cans are then arranged in a pressure canner and heated
to a certain temperature to reach a certain value of pressure. When pressure canning,
it is important to be precise with temperature, pressure, and time. If the recommended
value for each is not met, you will have to restart the process. Otherwise, it will yield an
unfinished product.

CANNED MUSHROOMS
White-button mushrooms are a common ingredient in soups and farinaceous dishes.
This type of edible mushroom is largely marketed as canned mushroom.

Ingredients:

 ½ kg white-button mushroom
 Water

Processing Pressure: 15psi

Pressurizing Time: 15 minutes

Procedures:

Pre-cooking

1. Trim off stem ends and discolored parts.

2. Soak in a bowl full of cold water for 10 minutes to loosen soil and dirt. Drain
afterwards.
3. Refill bowl with clean cold water and wash the mushrooms.
4. Cut into desired size and shape.
5. Transfer into a pot and bring to a boil. Boil for 5 minutes.
6. Transfer mushroom into a can, leave a quarter-inch of headspace.
7. Pour clean boiling water or the broth from the boiled mushroom into the can,
maintain headspace.
8. Stick a wooden chopstick or plastic spatula, poke the sides of the jar and press
contents towards the center. This will allow the air bubbles to escape.
Exhausting

1. Fill canner with water about half the height of the cans.
2. Place the open-filled cans in the pressure canner.
3. Gently boil mushrooms to a temperature of 77 degrees Celsius.
Sealing

1. Remove the cans from the heat using a jar lifter.

2. Wipe the rim with a paper towel.
3. Place can in the center of the platform.
 4. Put the lid on the top.
5. Secure the lid and the can by pulling the lever down.
6. Turn the sealing arm clockwise until you have completed one rotation. Turn the
sealing arm counterclockwise to finish sealing.
Pressure Canning

1. Place rack in canner and add about 3-inch depth of water.

2. Turn heat on to start heating water.
3. With a jar lifter, place sealed cans onto the racks. Leave space between the
cans.
4. Turn the heat on and wait until steam comes out of the vent. Let steam vent for
10 minutes before putting the weight gauge on.
5. Adjust pressure to 15 psi. Adjust the heat as necessary to maintain that level of
pressure for the entire processing time.
6. After 15 minutes, allow canner to depressurize.
7. Carefully open the lid of the pressure canner.
8. Take the cans out of the pressure canner using a jar lifter.
9. Allow the cans to cool down for 12 hours on a heat-resistant surface such as
folded towel, rack, or cutting board.
10. Examine lid for leakages, dents, and sharp edges.
SPANISH SARDINES

Spanish sardines can be eaten as is or as ingredient in pasta.

Ingredients:

 2kg fish (bangus/tunsoy/tapulok/tawilis)

 1L corn oil
 1L frying oil
 1/4kg refined salt
 1/4kg pickles, rondelle
 2pcs carrots, rondelle
 1pck whole pepper or pamintang buo
 1pck chili pepper or siling labuyo
 1pck bay leaf or dahoon ng laurel

Processing Pressure: 15 psi

Pressurizing Time: 15 minutes

Procedures:

Pre-cooking

1. Trim off the head and tail of the fish and remove the guts.
2. Soak in brine solution of 20% salt, 80% water for 30 minutes.
3. Half-cook by frying in cooking oil.
4. Fill the glass jars with fish. Garnish with carrots, pickles, bay leaves, and whole
black pepper.
 5. Add corn oil.
6. Seal tightly.

Pressure Canning

1. Place rack in canner and add about 3-inch depth of water.

2. Arrange the sealed jars into the racks. Leave space between the jars.
3. Lock the cover for safety.
4. Turn the heat on and wait for the steam to come out of the vent.
5. Let steam vent for 10 minutes before putting the weight gauge on.
6. Adjust pressure to 15 psi. Adjust the heat as necessary to maintain that level of
pressure for the entire processing time. If the pressure goes down, you will
have to restart your timer.
7. When the processing time has lapsed, allow canner to depressurize by letting it
stand for 10-15 minutes. Or until the pressure gauge reads 0 psi.
8. Carefully open the lid of the pressure canner.
9. Take the cans out of the pressure canner using a jar lifter.
10. Allow the cans to cool down for 12 hours on a heat-resistant surface such as a
folded towel, rack, or cutting board.
11. Examine lid for leakages, dents, and sharp edges. Store canned products in
room temperature.

UNIT 4 PACKAGING AND STORING PASTEURIZED AND PRESSURIZED PRODUCTS

Objectives At the end of this unit, you should be able to:

1. Identify packaging materials and equipment for pasteurized and pressurized

products.
2. Demonstrate the packaging process for pasteurized and pressurized products.
3. Determine type of storage to extend shelf-life of pasteurized and pressurized.
Introduction
LESSON 1 PACKAGING MATERIALS AND EQUIPMENT FOR PASTEURIZED AND
PRESSURIZED PRODUCTS

In this lesson, you will learn the proper packaging materials and equipment used for
pasteurized and pressurized products.
TOPIC 1 TYPES OF PACKAGING MATERIALS FOR PASTEURIZED AND PRESSURIZED
PRODUCTS

Glass container is ideal for packaging pasteurized products for a number of reasons:

 no chemical reactions between container and the contents;

 non-toxic;
 clear and transparent, growth of molds can be easily detected;
 reusable as long as it is washed and sterilized;
 high temperature resistance;
 impermeable, if properly sealed, gas and liquid cannot contaminate the
contents.

Types of Glass Containers

 Type Description
Jar Ideal for solid and semi-solid
products

Bottle Ideal for storing liquid products

Jug Large glass container, capacity

of at least half a gallon;
features a handle

Wide mouth bottle Bigger than a jar, ideal for

storing solid and semi-solid
products

Metal Container ideal for packaging canned products for a number of reasons:
 airtight packaging;
 easy to transport;
 does not oxidize if vacuum is properly formed;
 high temperature resistance;
 impermeable, if properly sealed, gas and liquid cannot contaminate the
contents.

Only metal containers from steel and aluminum substrates should be used for canning.

Types of Cans Based on Structure

Type Description
Two-piece Consists of a body with a
bottom lid and a top lid. Ideal
for canning because it
demands less labor.
 Three-piece Consists of a bottom lid,
cylindrical body, and a top lid
glued together by a process
called double seaming

Photo from: https://www.toyo-

seikan.co.jp/e/technique/can/kin
d/

Types of Cans Based on Material

Type Description
Aluminum More expensive, commonly
used for beverages

Steel Harder than aluminum

Less expensive, commonly

used for canned food

TOPIC 2 PACKAGING EQUIPMENT

Can Sealer is an equipment used to seal a lid to the can body.

How to use a can sealer

1. Place can on the center of the platform.

2. Put the lid on top of the can.
3. Secure the lid and the can by pulling the lever down.
4. Turn the sealing arm clockwise until you have completed one rotation. Turn the
sealing arm counterclockwise to finish sealing.

Bottle Capper uses pressure to seal bottles with a cap.

 How to use a manual bottle capper

1. Place the cap on top of the bottle.

2. Position bottle capper over the cap.
3. Align the crimper or the mouth with the cap.
4. Press down the levers until the cap is locked.
5. Carefully turn the bottle upside down to check if the cap is secured.

How to use an electric bottle capper

1. Attach the bottle capper onto the drill press.

2. Place the cap on top of the bottle.
3. Plug the drill press and position over the cap.
4. Press the switch until the cap is pushed down.
5. Carefully turn the bottle upside down to check if the cap is secured.
LESSON 2 LABELLING

Food labels communicate the ingredients and manufacture details of the product as
well as catch the attention of the consumer. Under the Philippine Consumer Act
(Republic Act No. 7394), labels must contain the following:

 Brand name;
 Product’s name;
 Manufacturer’s name;
 Place of production;
 Ingredients;
 Manufacturing and expiration dates;
 Net weight or gross weight
LESSON 3 STORAGE

Pasteurization kills 90-99% of microorganisms in food. To prevent these

microorganisms from growing in numbers, they must be properly stored. Meanwhile,
canned food has the longest shelf-life among the varieties of processed food and
would require a different type of storage.

TOPIC 1 TEMPERATURE REQUIREMENT

Pasteurized

Pasteurized milk should be stored at temperatures below 4 degrees Celsius.

UHT processed milk can be stored at ambient temperatures of 20 to 25 degrees

Celsius.

Refrigerate pasteurized fruit juice at 4.5 to 7.5 degrees Celsius.

Pressurized

Temperatures over 37 degrees Celsius can increase the rate of spoilage of canned
goods. Prolonged storage at temperatures over 24oC increase the rate of nutrient loss.
 To be sure, store canned goods in a cool, dry, and clean place at room temperature.

Do not freeze canned goods.

Protect canned goods from dents and deformities.

TOPIC 2 SHELF-LIFE

If properly stored, pasteurized and pressurized food have a shelf-life of 1 to 3 years.

Type Shelf-Life
Canned meats and seafood 1-2 years
Low-acid canned foods e.g. 1-2 years
vegetables and soup
High-acid canned foods e.g. fruit, 1-2 years
pickles, tomatoes
Canned fruit juice 1 year
Pasteurized fruit juice 2 to 3 months
UHT pasteurized milk 6 months
Pasteurized milk (batch method) 12 to 21 days