experimental report introduction to food technology bf2511e

TABLE OF CONTENT4 Double jacket tank5 Liquid piston filling machine6 Infrared roasting machine4 The purpose of mechanical and thermal process 5 Analysing factors effecting processing pro

HANOI UNIVERSITY OF SCIENCE ANDTECHNOLOGY SCHOOL OF BIOLOGY AND FOOD

Centre for Training and Food products Development

EXPERIMENTAL REPORTIntroduction to Food Technology – BF2511E

Lecturer: Ph.D Đỗ Thị Yến

MSc Bùi Uyển Diễm BSc Nguyễn Ngọc Viễn

Student name: Nguyễn Cao SơnStudent ID: 20211263

Class: BF2- E12 02Class ID: 725337Group: 2

Hanoi, 11/2022

First of all, the food industry, which provides the only source of energy andnutrition for humans obviously plays an important role in our life Thedevelopment of science and technology must be constantly growing to meet theenormous global demand for food As we can see when the pandemic breaksdown, the traffic is blockaded, food is the number one priority for all everyonewho must stay home.

Introduction to Food Technology provides some basic knowledge aboutfood industry and paints a simplified picture of the food industrial processing ina factory with giant scale Besides having acknowledged the generalunderstanding and summary of the food industry, I also had studied more aboutsome food machines and devices as well as food processes in the Center forTraining and Food products Development.

I had opportunities to experiment with the modern technique, to learnabout the theory and operating of some devices I also had manually participatedin the manufacturing of chili sauce and roasted sunflower seed in a pilot scale.Based on all the lessons, this experimental report will point out some basicsabout food machines and devices as well as manufacturing some products.

Finally, specially thanks to Mrs.Yến, Mrs.Diễm and Mr.Viễn who havealways accompanied and followed us closely in every lessons.

TABLE OF CONTENT

4 Double jacket tank

5 Liquid piston filling machine6 Infrared roasting machine

4 The purpose of mechanical and thermal process

5 Analysing factors effecting processing productivity and product quality

PRACTICE

100kg/h for wet products 10kh/h with dry products - Power supply: 380V three phases - Rotation speed: 1100- 2400 rpm

STRUCTURE:

- Rotation motor - Rotation screw - Crushing hammers - Safety lid

- Crushing process control system - Shell

- Step 2: Turn on the power of the device.

- Step 3: Press ‘Reset’ button If the light hasn’t active yet then check the tightness of the grinding cask and the emergency button.

- Step 4: Press ‘Start’(green) button to start and ‘Off’(red) button to shut down the motor.

- Step 5: Regulate the speed properly to match the required speed of the grinding materials.

- Do not forget to turn off the main switch everytime you have to test an electric component or disassemble a component of the generator.

- Do not put your hand through the gate of the grinding chamber.

- Ensure the grinding chamber is fully closed before and during operating for the safety of human, device and products.

- Announce the device manager if there is any problem.

MECHANICAL PROCESS:

- Cutting, crushing and grinding in order to reduce the size of material for the ease of others future processes (particularly in manufacturing chili sauce, it’s for the easeof heating evenly and rubbing process).

2 Screw-type continuous cooker

TECHNICAL DATA

- Seri: TA15D

- Steam Supply: 20kg/h at 1 bar - Water supply: from main - Power supply: 380V three phases - Rotating screw with various speed - Fast heating speed

- Motor system - Rotating screw.

- Steam control valves (manual and automatic) - Stagnant water discharging valves.

- Water supplying valve - Pressure stabilizer system - Steam temperature sensor - Output temperature sensor - Control system.

- Inner compartment contains materials - Outer compartment contains heating steam

- Step 4: Open the main steam supplying valve and other ways into the equipment then open the stagnant water discharging valve.

- Rotating shaft including 3 brushing blades.

- Scrub net has small holes with different sizes for desired smoothness - Steel support frame.

- 1 valve to supply water if needed.

- Lower hopper (on the side) for rubbed powder.

- Upper hopper (in the front) for shell, discharged particles - Control system.

- Sensor valve to open and close the door of the scrubber

OPERATION PRINCIPLE:

- Materials after grinding and heating are supplemented with water (to spreadthe rubbing solution to the scrubbing net and increase rubbing productivity) ispassed through the hopper into the scrub chamber.

- When the motor works, the brushing blades rotates with the shaft , squeezesthe fluid into the net.

- The unneeded particles such as shells and seeds are retained and dischargedthrough the upper hopper.

- The rubbed powder get through holes in the net flows out through the sidehopper.

MANUAL OF EQUIPMENT:

- Step 1: Connect the power supply by turning the 3 phase electricity switch at 45°.

- Step 2: Turn on the power of equipment.

- Step 3: Use ‘Start’(green) button to turn on and ‘Off’(red) button to turn of the motor.

- Step 4: Regulating the scrubber motor speed by the turning switch

- Ensure the scrubbing chamber is closed entirely.

- Frequently check the amount of waste matter in the scrubbing chamber and remove if needed to avoid the motor being overloaded.

- Announce the device manager if there is any problem.

- Valves system for steaming air, stagnant water discharging and water supplying - Inner compartment containing materials.

- Outer compartment containing steaming air.

- Step 1: Check the power supply and turn on the mixing blades motor.

- Step 2: Open the steam supply valve, discharge the stagnant water and open the air discharging valve.

- Avoid touching the parts containing heating steam.

- When temperature reach the requirement, to avoid excess heat, the steam discharging valve must be closed a bit or fully.

- Absolutely never let the pressure excess 4 bar - Announce the device manager if there is any problem.

- Outer shell (steel insulation).

- 2 funnels to put materials into the device - Doors to put final products out - Vent.

- The heat generated by the infrared radiation heats and roasted the materials.

- The mixing blades rotating continuously ensure that the material is roasted evenly.

- Step 4: Set up the appropriate mode and temperature Turn on the mixing blades.

- Do not touch the heat- unproved part of the device.

- Wait for the temperature to reach desire before loading the materials in through the top funnel.

- Check the air discharging valves before starting - Loading the materials in slowly, not all at one - Remember to turn on the mixing blades to roast evenly - Announce the device manager if there is any problem.

THERMAL PROCESS:

- Heat, roast or dry materials especially for different types of seeds Particularlyin manufacturing of roasted sunflower seeds, this process does all the main jobssuch as dry, roast, mix to make sure the products accomplish the best quality:perfectly roasted, bright white seed, yellow shell and full of aroma.

2 Processing:

Step 1: Cleaning

+ Clean the infra-red rays toasting machine with air blower +Remove any excess material left in the machineStep 2: Producing roasted sunflower seeds

+ Select the same size and remove damaged seeds and then wash it several times.+Turn on the device and close all doors such as the steam outlet, product outlet, and sampling door to ensure rapid heat generation and a satisfactory temperature setting of 115°C.

+Pour the whole grain into the container without opening the stopper to prevent the product from falling inside until the required temperature is reached.

+ After about 10 - 15 minutes the temperature reaches the required level, open the steam outlet, turn on the mix mode and open the door to let the seeds fall into the machine and the temperature difference begins to take place on the meter (the lowest temperature is 91°C then starts to increase).

+ After about 20 minutes, take the first sample:

The seeds still have a slightly pungent, smell are still plastic+ Next 10 minutes continue to take the second sample

The seeds are still slightly moist, have lighter mass, the color is forming, and tastea little acrid.

+ Then take a sample every 5 minutes

+ Proceed to incubate for another 10 minutes to make the seeds more crispy before letting them cool.

Step 3: Packaging

+ Divide the product evenly into the bags for packing and sealing with a heat sealer.

3 The purpose of mechanical and thermal processes:

- Washing and cleaning – mechanical process: to remove the dirt and dust from the seeds, to eliminate rotten, molly, and damaged seeds.

- Roasting and incubating – thermal process: to heat the seeds until reaching perfect ripening, color, crunchiness, aroma, and taste.

- Air blowing – cooling process: to cool down the seeds for packaging.- Heat sealer and packaging- mechanical process: to prolong the longevity and strengthen the quality of products.

4.Analysing factors affecting processing productivity and product quality.

Initial material mass 5.0kgFinal products mass 4.3kgProductivity 86%

-The factors affecting productivity are mistakes in reading scale numbers, mistakeswith equipment, loss due to moisture, loss due to eliminated seeds, and loss due to sampling seeds.

-The factors affecting product quality are the roasting model, roasting time and thepreciseness of equipment, preparation stage, packing stage

+ If there is a mistake in operating the Infra-Red Rays Toasting Machine, there could be a loss of productivity or various undesired states of products such asmoist, cooked unevenly, burned, no crunchiness, etc.

+ Carelessness in washing and cleaning could lead to remaining damaged seeds, dirty seeds, broken seeds, etc.

+ Not sealing the package fully could shorten the longevity of products.

PRACTICE 3

MANUFACTURING OF FRUIT AND VEGETABLE PRODUCT A PILOTSCALE

1 Materials and equipment1.1 Materials

- Tomato: 12kg and chili: 1.5kg

- Tomatoes and chilies are ripe, red color and not rotten.

- Ingredients: pepper, garlic, modified starch, monosodium glutamate (MSG), sugar, salt, acetic acid.

1.2 Equipment

Boiler Hammer Mill

Screw-type continous machineDouble jacket tank

Pulper

Liquid piston filling machine

Blender pH meterRefractometer

4-digital analytic balance1kg scale balance

Funnel500ml beaker Glass bottle and lid Inox pots

Inox knife Plastic bucketsPlastic basket Spoon and ladles

2 Chili sauce processing flowchart.

Step 1: Equipment cleaning

- Clean all the machines and equipment with supplied water - Run the machines with water as materials for better cleanStep 2: Manufacturing of chili sauce

- Select fresh tomatoes and chilies then wash them to reduce microbial load.- Cut tomatoes into halves or quarters Chilies were cut.

- Crush the tomatoes and chilies by the hammer milling machine Put half of the tomatoes into the milling machine Then put the other half with the chilies in later - Crush mixture is then heated immediately by a screw-type continuous cooker at 80°C for 5 seconds and then separate skin and seed by pulper.

- Sieved mass is weighed and poured into a double jacket tank before heating (slowsimmer under agitation) Determine the dry matter (Brix) using a refractometer andthen adjusted the solution until the dry matter reaches 4°B.

- Ingredients are weighed according to the formula:

msalt = 0.33 kg msugar = 1 kg mMSG = 0.01665 kgmmstarch = 0.5 kg mgarlic = 0.1665 kg mpepper = 0.01665 kg- Add sugar, salt and extracted solution to the mixture.

- Add gradually the modified starch that was mixed in a little amount of water The quantity of modified starch will vary according to the consistency of the tomato and chili mixture Ensure that the modified starch is fully dissolved in the mixture to avoid lump formation during heating/cooling/storage After heating, the obtainedsolution is named “pure”

= 1.5 ×

- Empty bottles and lids are cleaned and pasteurized in hot water of 100°C for 1- 2 min And then, fill hot pure into pasteurized glass bottles by hand, leave a headspace of 1cm and immediately close the bottles.

Step 3: Equipment and workshop cleaning

3 Purposes of mechanical and thermal processes.MECHANICAL PROCESS:

- Cleaning and washing of chili and tomato: to limit dirt, eliminate rotten ones and ensure quality of the product.

- Cutting: to reduce the size of materials for ease of next process – grinding.- Grinding (crushing): mix chilies with tomatoes and reduce materials size for ease of heating: reducing time and energy.

- Rubbing: to remove skin and seed out of the mixture for better taste and sensory of products.

- Bottles filling: final step before packaging.

4 Factor affects product quality.

- Choosing and cleaning the materials: the better quality of the materials means thebetter the quality of final products.

- The manufacturing environment: the surrounding environment must be clean and aseptic (if possible) to ensure food safety and food quality.

- Cleaning of equipment before manufacturing: the cleaner the equipment is also the better the quality of the product If there is dust or particles left in equipment, there is a high chance those particles also exist in the final product.

- Operating the equipment:

+ If there is a mistake inside the equipment or in the operating process, the product will be messed up and change some properties Also by false time control, the mixture could be undercooked or overcooked and even burned

+ Adding ingredients: mistakes in calculating, and measuring.

+ Bottles pasteurizing: ensure that the bottle is aseptic cause the microbial could shorten the longevity and lower product quality.

+ Bottles filling and packaging process: fill the bottles too much or too little, not fully close the lids.