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. Some food processing methods play important roles in reducing food waste and
improving food preservation, thus reducing the total environmental impact of agriculture and
improving food security.

Industrial cheese production

Primary food processing is necessary to make most foods edible, and secondary food
processing turns the ingredients into familiar foods, such as bread. Tertiary food processing has
been criticized for promoting overnutrition and obesity, containing too much sugar and salt, too
little fiber, and otherwise being unhealthful in respect to dietary needs of humans and farm
animals.

Process

Primary food processing

These whole, dried bananas in Thailand are an example of primary food processing.

Primary food processing turns agricultural products, such as raw wheat kernels or livestock, into
something that can eventually be eaten. This category includes ingredients that are produced by
ancient processes such as drying, threshing, winnowing and milling grain, shelling nuts, and
butchering animals for meat.[1][2] It also includes deboning and cutting meat, freezing and
smoking fish and meat, extracting and filtering oils, canning food, preserving food through food
irradiation, and candling eggs, as well as homogenizing and pasteurizing milk.[2][3][4]

Contamination and spoilage problems in primary food processing can lead to significant public
health threats, as the resulting foods are used so widely.[2] However, many forms of processing
contribute to improved food safety and longer shelf life before the food spoils.[3] Commercial
food processing uses control systems such as hazard analysis and critical control points
(HACCP) and failure mode and effects analysis (FMEA) to reduce the risk of harm.[2]

Secondary food processing

Baking bread is an example of secondary food processing.

Secondary food processing is the everyday process of creating food from ingredients that are
ready to use. Baking bread, regardless of whether it is made at home, in a small bakery, or in a
large factory, is an example of secondary food processing.[2] Fermenting fish and making wine,
beer, and other alcoholic products are traditional forms of secondary food processing.[4]
Sausages are a common form of secondary processed meat, formed by comminution (grinding)
of meat that has already undergone primary processing.[5] Most of the secondary food
processing methods known to human kind are commonly described as cooking methods.

Tertiary food processing

Tertiary food processing is the commercial production of what is commonly called processed
food.[2] These are ready-to-eat or heat-and-serve foods, such as TV dinners and re-heated airline
meals.

History

Food processing dates back to the prehistoric ages when crude processing incorporated
fermenting, sun drying, preserving with salt, and various types of cooking (such as roasting,
smoking, steaming, and oven baking), Such basic food processing involved chemical enzymatic
changes to the basic structure of food in its natural form, as well served to build a barrier
against surface microbial activity that caused rapid decay. Salt-preservation was especially
common for foods that constituted warrior and sailors' diets until the introduction of canning
methods. Evidence for the existence of these methods can be found in the writings of the
ancient Greek, Chaldean, Egyptian and Roman civilizations as well as archaeological evidence
from Europe, North and South America and Asia. These tried and tested processing techniques
remained essentially the same until the advent of the industrial revolution. Examples of ready-
meals also date back to before the preindustrial revolution, and include dishes such as Cornish
pasty and Haggis. Both during ancient times and today in modern society these are considered
processed foods.

Michael Foods egg-processing plant in Wakefield, Nebraska

Modern food processing technology developed in the 19th and 20th centuries was developed in
a large part to serve military needs. In 1809, Nicolas Appert invented a hermetic bottling
technique that would preserve food for French troops which ultimately contributed to the
development of tinning, and subsequently canning by Peter Durand in 1810. Although initially
expensive and somewhat hazardous due to the lead used in cans, canned goods would later
become a staple around the world.[6] Pasteurization, discovered by Louis Pasteur in 1864,
improved the quality and safety of preserved foods and introduced the wine, beer, and milk
preservation.

A form of pre-made split-pea soup that has become traditional

In the 20th century, World War II, the space race and the rising consumer society in developed
countries contributed to the growth of food processing with such advances as spray drying,
evaporation, juice concentrates, freeze drying and the introduction of artificial sweeteners,
colouring agents, and such preservatives as sodium benzoate. In the late 20th century, products
such as dried instant soups, reconstituted fruits and juices, and self cooking meals such as MRE
food ration were developed. By the 20th century, automatic appliances like microwave oven,
blender, and rotimatic paved way for convenience cooking.

In western Europe and North America, the second half of the 20th century witnessed a rise in the
pursuit of convenience. Food processing companies marketed their products especially towards
middle-class working wives and mothers. Frozen foods (often credited to Clarence Birdseye)
found their success in sales of juice concentrates and "TV dinners".[7] Processors utilised the
perceived value of time to appeal to the postwar population, and this same appeal contributes to
the success of convenience foods today.

Benefits and drawbacks

Benefits

Processed seafood – fish, squid, prawn balls and simulated crab sticks (surimi)
Benefits of food processing include toxin removal, preservation, easing marketing and
distribution tasks, and increasing food consistency. In addition, it increases yearly availability of
many foods, enables transportation of delicate perishable foods across long distances and
makes many kinds of foods safe to eat by de-activating spoilage and pathogenic micro-
organisms. Modern supermarkets would not exist without modern food processing techniques,
and long voyages would not be possible.

Processed foods are usually less susceptible to early spoilage than fresh foods and are better
suited for long-distance transportation from the source to the consumer.[3] When they were first
introduced, some processed foods helped to alleviate food shortages and improved the overall
nutrition of populations as it made many new foods available to the masses.[8]

Processing can also reduce the incidence of food-borne disease. Fresh materials, such as fresh
produce and raw meats, are more likely to harbour pathogenic micro-organisms (e.g.
Salmonella) capable of causing serious illnesses.

The extremely varied modern diet is only truly possible on a wide scale because of food
processing. Transportation of more exotic foods, as well as the elimination of much hard labor
gives the modern eater easy access to a wide variety of food unimaginable to their ancestors.[9]

The act of processing can often improve the taste of food significantly.[10]

Mass production of food is much cheaper overall than individual production of meals from raw
ingredients. Therefore, a large profit potential exists for the manufacturers and suppliers of
processed food products. Individuals may see a benefit in convenience, but rarely see any direct
financial cost benefit in using processed food as compared to home preparation.

Processed food freed people from the large amount of time involved in preparing and cooking
"natural" unprocessed foods.[11] The increase in free time allows people much more choice in life
style than previously allowed. In many families the adults are working away from home and
therefore there is little time for the preparation of food based on fresh ingredients. The food
industry offers products that fulfill many different needs: e.g. fully prepared ready meals that can
be heated up in the microwave oven within a few minutes.

Modern food processing also improves the quality of life for people with allergies, diabetics, and
other people who cannot consume some common food elements. Food processing can also
add extra nutrients such as vitamins.
Drawbacks

Meat packages in a Roman supermarket

Processing of food can decrease its nutritional density. The amount of nutrients lost depends on
the food and processing method. For example, heat destroys vitamin C. Therefore, canned fruits
possess less vitamin C than their fresh alternatives. The USDA conducted a study of nutrient
retention in 2004, creating a table of foods, levels of preparation, and nutrition.[12]

New research highlighting the importance to human health of a rich microbial environment in the
intestine indicates that abundant food processing (not fermentation of foods) endangers that
environment.[13]

Using some food additives represents another safety concern. The health risks of any given
additive vary greatly from person to person; for example using sugar as an additive endangers
diabetics. In the European Union, only European Food Safety Authority (EFSA) approved food
additives (e.g., sweeteners, preservatives, stabilizers) are permitted at specified levels for use in
food products. Approved additives receive an E number (E for Europe), simplifying
communication about food additives included in the ingredients list for all the different
languages spoken in the EU. As the effects of chemical additives are learned, changes to laws
and regulatory practices are made to make such processed foods more safe.

Food processing is typically a mechanical process that utilizes extrusion, large mixing, grinding,
chopping and emulsifying equipment in the production process. These processes introduce a
number of contamination risks. Such contaminants are left over material from a previous
operation, animal or human bodily fluids, microorganisms, nonmetallic and metallic fragments.
Further processing of these contaminants will result in downstream equipment failure and the
risk of ingestion by the consumer. Example: A mixing bowl or grinder is used over time, metal
parts in contact with food will tend to fail and fracture. This type of failure will introduce into the
product stream small to large metal contaminants. Further processing of these metal fragments
will result in downstream equipment failure and the risk of ingestion by the consumer. Food
manufacturers utilize industrial metal detectors to detect and reject automatically any metal
fragment. Large food processors will utilize many metal detectors within the processing stream
to reduce both damage to processing machinery as well as risk to consumer health.

Food processing does have some benefits, such as making food last longer and making
products more convenient. However, heavily processed foods also have drawbacks. Whole
foods and those that are only minimally processed, like frozen vegetables without any sauce,
tend to be more healthy. An unhealthy diet high in fat, added sugar and salt, such as one
containing much highly processed food, can increase the risk for cancer, type 2 diabetes and
heart disease, according to the World Health Organization.

Added sodium

One of the main sources for sodium in the diet is processed foods. Sodium, mostly in the form
of sodium chloride, i.e. salt, is added to prevent spoilage, add flavor and enhance the texture of
these foods. Some processed food may contain over 2% salt.[14] Americans consume an
average of 3436 milligrams of sodium per day, which is higher than the recommended limit of
2300 milligrams per day for healthy people, and more than twice the limit of 1500 milligrams per
day for those at increased risk for heart disease.

Added sugars

While it is not necessary to limit the sugars found naturally in whole, unprocessed foods like
fresh fruit, eating too much added sugar found in many processed foods increases the risk of
heart disease, obesity, cavities and Type 2 diabetes. The American Heart Association
recommends women limit added sugars to no more than 420 kilojoules (100 kilocalories), or 25
grams, and men limit added sugars to no more than 650 kJ (155 kcal), or about 38.75 grams, per
day. Currently, Americans consume an average of 1,490 kJ (355 kcal) from added sugars each
day.

Nutrient losses
Processing foods often involves nutrient losses, which can make it harder to meet the body's
needs if these nutrients aren't added back through fortification or enrichment. For example,
using high heat during processing can cause vitamin C losses. Another example is refined
grains, which have less fiber, vitamins and minerals than whole grains. Eating refined grains,
such as those found in many processed foods, instead of whole grains may increase the risk for
high cholesterol, diabetes and obesity, according to a study published in "The American Journal
of Clinical Nutrition" in December 2007.

Trans fats

Foods that have undergone processing, including some commercial baked goods, desserts,
margarine, frozen pizza, microwave popcorn and coffee creamers, sometimes contain trans
fats. This is the most unhealthy type of fat, and may increase risk for high cholesterol, heart
disease and stroke. The 2010 Dietary Guidelines for Americans recommends keeping trans fat
intake as low as possible.

Other potential disadvantages

Processed foods may actually take less energy to digest than whole foods, according to a study
published in "Food & Nutrition Research" in 2010, meaning more of their food energy content is
retained within the body. Processed foods also tend to be more allergenic than whole foods,
according to a June 2004 "Current Opinion in Allergy and Clinical Immunology" article. Although
the preservatives and other food additives used in many processed foods are generally
recognized as safe, a few may cause problems for some individuals, including sulfites, artificial
sweeteners, artificial colors and flavors, sodium nitrate, BHA and BHT, olestra, caffeine and
monosodium glutamate — a flavor enhancer. [15]

Performance parameters for food processing

Factory automation - robotics palettizing bread

When designing processes for the food industry the following performance parameters may be
taken into account:

Hygiene, e.g. measured by number of micro-organisms per mL of finished product.

Energy efficiency measured e.g. by “ton of steam per ton of sugar produced”.

Minimization of waste, measured e.g. by “percentage of peeling loss during the peeling of
potatoes”.

Labour used, measured e.g. by “number of working hours per ton of finished product”.

Minimization of cleaning stops measured e.g. by “number of hours between cleaning stops”.

Women working in a cannery

Industries

Food processing industries and practices include the following:

 Cannery Meat packing plant

Fish processing Slaughterhouse

Food packaging plant Sugar industry

Industrial rendering

See also

Best before Food science

Brewery Food storage

Canning Genetically modified food

Clean-in-place Good manufacturing practice

Dietary supplement List of cooking techniques

Enzyme Material handling

Flavoring Nutraceutical

Food additive Pasteurization

Food and Bioprocess Technology Pink slime

Food coloring Shelf-life

Food extrusion Snap freezing

Food fortification Ultra-high temperature processing

Food quality Ultra-processed food

Food rheology Washdown

Food safety

Notes and references

1. Grumezescu, Alexandru Mihai; Holban, Alina Maria (2018-04-08). Food Processing for Increased Quality
and Consumption (https://books.google.com/books?id=6wIxDwAAQBAJ&pg=PA430) . Academic
Press. p. 430. ISBN 9780128114995.
 2. Hitzmann, Bernd (2017-08-11). Measurement, Modeling and Automation in Advanced Food Processing (h
ttps://books.google.com/books?id=c7swDwAAQBAJ&pg=PA30) . Springer. pp. 30–32.
ISBN 9783319601113.

3. Ionescu, Gabriela (2016-05-25). Sustainable Food and Beverage Industries: Assessments and
Methodologies (https://books.google.com/books?id=nB9jDAAAQBAJ&pg=PA21) . CRC Press. p. 21.
ISBN 9781771884112.

4. US Congress, Office of Technology Assessment (June 1987). "Chapter 8, Technologies Supporting

Agricultural, Aquacultural, and Fisheries Development" (https://books.google.com/books?id=z7mxV6X9l
AYC&pg=PA278) . Integrated Renewable Resource Management for U.S. Insular Areas: Summary.
Washington, DC: US Government Printing Office. pp. 278–281. ISBN 9781428922792.

5. Hui, Y. H. (2012-01-11). Handbook of Meat and Meat Processing, Second Edition (https://books.google.c
om/books?id=1ZRCMRXbbwoC&pg=PA599) . CRC Press. p. 599. ISBN 9781439836835.

6. Martin Bruegel, "How the French Learned to Eat Canned Food," in W. Belasco, P. Scranton, ed., Food
Nations: Selling Taste in Consumer Societies (New York, Routledge, 2001)

7. Levenstein, H: "Paradox of Plenty", pages 106-107. University of California Press, 2003

8. Laudan, Rachel (September–October 2010). "In Praise of Fast Food" (http://www.utne.com/Environment/

Fast-Food-Culinary-Ethos.aspx?page=4) . UTNE Reader. Retrieved 2010-09-24. "Where modern food
became available, people grew taller and stronger and lived longer."

9. Laudan, Rachel (September–October 2010). "In Praise of Fast Food" (http://www.utne.com/Environment/

Fast-Food-Culinary-Ethos.aspx?page=4) . UTNE Reader. Retrieved 2010-09-24. "If we fail to understand
how scant and monotonous most traditional diets were, we can misunderstand the “ethnic foods” we
encounter in cookbooks, at restaurants, or on our travels."

10. Laudan, Rachel (September–October 2010). "In Praise of Fast Food" (http://www.utne.com/Environment/
Fast-Food-Culinary-Ethos.aspx?page=4) . UTNE Reader. Retrieved 2010-09-24. "For our ancestors,
natural was something quite nasty. Natural often tasted bad. Fresh meat was rank and tough, fresh fruits
inedibly sour, fresh vegetables bitter."

11. Laudan, Rachel (September–October 2010). "In Praise of Fast Food" (http://www.utne.com/Environment/
Fast-Food-Culinary-Ethos.aspx?page=4) . UTNE Reader. Retrieved 2010-09-24.

12. "USDA Table of Nutrient Retention Factors, Release 6" (http://www.ars.usda.gov/SP2UserFiles/Place/804

00525/Data/retn/retn06.pdf) (PDF). USDA. USDA. Dec 2007.

13. Michael Pollan (15 May 2013). "Some of my Best Friends are Germs" (https://www.nytimes.com/2013/0
5/19/magazine/say-hello-to-the-100-trillion-bacteria-that-make-up-your-microbiome.html?hp) . The New
York Times Magazine.

14. "30 Foods High in Sodium and What to Eat Instead" (https://www.healthline.com/nutrition/foods-high-in-s
odium) . 12 May 2020.
15. "Food Flavour Enhancer Market to Garner USD 15.2 Mn by 2032 at 6.8% CAGR, Says FMI | Scoop News"
(https://www.scoop.co.nz/stories/BU2204/S00425/food-flavour-enhancer-marketto-garner-usd-152-mn-b
y-2032-at-68-cagr-says-fmi.htm) .

Bibliography

Fábricas de alimentos, 9th edition (in Spanish).

Nutritional evaluation of food processing,

Food preservation 2nd edition, by Norman W. Desrosier.

External links

Media related to Manufacture of food at Wikimedia Commons

Frozen food trends (https://octofrost.com/news-room/frozen-foods-trends)

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