What is food processing?

Food processing is any method used to turn fresh foods into food products.1 This can involve
one or a combination of various processes including washing, chopping,
pasteurising, freezing, fermenting, packaging, cooking and many more.2 Food processing also
includes adding ingredients to food, for example to extend shelf life.3, 4

What are the methods of food processing?

Food processing includes traditional (heat treatment, fermentation, pickling,

smoking, drying, curing) and modern methods (pasteurisation, ultra-heat treatment, high
pressure processing, or modified atmosphere packaging). Some of the common methods are
described below:

Canning
The food is heated to a high temperature. This process is called pasteurisation. Then, the food
is packaged and stored in an air-tight can. Check our infographic showing the processing
steps for canned tomatoes.

Fermentation
The breakdown of sugars by bacteria, yeasts or other microorganisms
under anaerobic conditions. This means, no oxygen is needed for the process to take place
(apart from oxygen present in sugar). Fermentation is notably used in the production of
alcoholic beverages such as wine, beer, and cider, and in the preservation of foods such as
sauerkraut, dry sausages, and yoghurt, but also for raising dough in bread production.

Freezing
Food temperatures are reduced to below 0°C to decrease the activity of harmful bacteria. The
process can be used to preserve the majority of foods including fruits, vegetables, meat, fish,
and ready meals. Do you know the steps needed to produce frozen peas? Check them
out here!

Modified atmosphere packaging

Air inside a package is substituted by a protective gas mix, often including oxygen, carbon
dioxide and nitrogen – gases that are also present in the air we breathe. They help to extend
the shelf life of fresh food products - usually of fruits, vegetables, meat and meat products,
and seafood.

Pasteurisation
Food is heated and then quickly cooled down to kill microorganisms. For example, raw milk
may contain harmful bacteria that cause foodborne illnesses. Boiling it (at home) or
pasteurising (on a large scale) is crucial to ensure it is safe to consume. Apart from dairy
products, pasteurisation is widely used in preservation of canned foods, juices and alcoholic
beverages.
Smoking
A process of heat and chemical treatment of food to help preserve it by exposing it to smoke
from burning material such as wood. Smoked foods usually include types of meat, sausages,
fish or cheese.

Additives
Food additives play an important role in preserving the freshness, safety, taste, appearance
and texture of processed foods. Food additives are added for particular purposes, whether to
ensure food safety, or to maintain food quality during the shelf-life of a product. For example,
antioxidants prevent fats and oils from becoming rancid, while preservatives prevent or
reduce the growth of microbes (e.g. mould on bread). Emulsifiers are used for instance in
improving the texture of mayonnaise, or stopping salad dressings from separating into oil and
water.

What are the reasons and consequences of food processing?

Makes food edible

Grain crops, for example wheat and corn, are not edible in their natural state. Processing
techniques, such as milling and grinding, turn them into flour, after which they can be made
into breads, cereals, pasta and other edible grain-based products. There are 3 types of flours
depending on the processing level, choose wholegrain when possible. You can learn more
about the journey of grain to bread in our ‘Gain on grain’ infographic.

Safety, shelf life, and preservation

Processing improves or even ensures food safety by removing harmful microorganisms. The
main methods are pasteurisation, air-tight packaging, and the use of preservatives.

Nutritional quality
Food processing can affect the nutritional quality of foods in both ways: it can enhance it, for
instance by adding components that were not present, like vitamin D (through ‘fortification’),
or by lowering fat, salt or sugar. It can also cause some fibre and vitamins and minerals to be
lost, for example through excessive refining, heating or freezing.

Convenience
Processing and packaging technologies help to answer modern day time-constraints by
providing a range of convenient foods: ready meals, bagged salads, sliced and canned fruits
and vegetables that take little time to prepare and can be consumed “on the go”.

Price
Food processing can decrease the cost of foods. For example, frozen vegetables have a
similar nutritional value as fresh ones, but at a lower price, as they have already been
prepared, do not contain inedible parts, can be bought in bulk, and can last longer. This way,
processing increases the shelf life of food, and decreases the amount of waste, reducing
thereby the overall costs of food production.
Use Tools, Equipment, Instruments and Utensils by Following the
Standard Procedures TLE_AFFP (-12UT-0b-2)

Expectation: Specifically, this lesson will help you to: 1. interpret food processing procedure;
2. apply standard procedures in using tools, equipment, instruments, and utensils; 3. calibrate
tools, equipment, instruments, and utensils; 4. follow procedures in sanitizing tools,
equipment, instruments, and utensils; and 5. use tools, equipment, instruments, and utensils
according to job requirements and manufacturer’s specifications.

One of the vital activities to be done before starting any food processing activity is
inspecting and checking the tools, instruments, utensils, equipment, and machines to be used.
There should be one worker assigned to do the condition monitoring of tools, instruments,
utensils, equipment, and machines. Condition monitoring is the process of monitoring a
parameter of condition in machinery (vibration, temperature, etc.), in order to identify a
significant change that is indicative of a developing fault. It is a major component of
predictive maintenance. The use of condition monitoring allows maintenance to be scheduled,
or other actions to be taken, to prevent damages and avoid its consequences.

Condition monitoring has a unique benefit in that conditions that would shorten normal
lifespan can be addressed before they develop into a major failure. In order to avoid all those
worries, you should read and understand the lesson.

How do you apply standard procedures in using equipment, tools, instruments, and utensils?

It is important to review all procedures regarding the use of all standard measuring devices to
ensure that they will be properly used in accordance with the manufacturer’s specifications.
Being familiar with the procedure in using a standard measuring device like a “salinometer”,
thermometer, weighing scale or a measuring cup or spoon will enable you to use the
appropriate measuring device for a specific food processing activity. It is also important to
make work systematic and accurate.

Procedures in Using Standard Measuring Devices and Instruments

1. “Salinometer”  Prepare brine solution.  Pour brine solution in a cylinder.  Dip

“salinometer” in a brine solution.  Record the reading.  Clean instrument after each use

2. Thermometer  Dip thermometer in boiling liquid.  Record the reading by O°C or O°F 
Clean after each use.

3. Weighing scales  Put the food on the weighing scale.  Record the reading in grams or
kilograms
4. Glassware like graduated cylinder and beaker  Pour liquid ingredients into the cylinder,
beaker, or flask.  Bring the cylinder to the eye level.  Get the reading at the lower meniscus.
 Record the reading.  Clean after each use.

5. Measuring cups for dry ingredients  Gently spoon the ingredients into the cup, filling the
cup to overflowing.  Then level off with a metal spatula or straight-edged knife. Note: Do
not scoop the ingredient using the cup itself because this “packs” the cup too much and the
measurement won’t be precise. Tips: You have to measure dry ingredients over a plate or
bowl, so you can catch the excess and put it back in the container.

6. Measuring cups for liquid ingredients  Pour the liquid on a level surface of measuring
cups.  Have the measuring lines at eye level to be sure of the exact measurement. Note: You
have to measure liquids at eye level. Meaning, 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 of the cup How are equipment, tools, and utensils, calibrated?

Calibration is a process where measurements of a test instrument are compared against those
taken by a standard device with known accuracy. Calibration plays a critical role in quality
assurance and compliance for numerous industries, but it holds importance for process
industries, such as the food and beverage industry, where strict controls are required. These
controls have to be very precise and to achieve this; you need highly accurate measuring
tools.

Why do you need to calibrate equipment, tools, and utensils?

 Helps in saving energy  Optimizes quality  Provides traceable standards  Optimizes

performance  Reduces unexpected failures Here are some of the measuring tools that you
need to calibrate from time to time.

1. Weighing Scale Check the accuracy; see to it that the hand is pointed at zero in an
empty weighing scale
2. . 2. Thermometer Check the accuracy by dipping it in hot food to see if the mercury
rises to the desired temperature. Are you familiar with these measuring tools? Have
you tried using them? How are they calibrated? What are the procedures in sanitizing,
equipment, tools, utensils, and instruments?

In using the specifications below, make sure that you will measure the solution accurately. Be
careful in handling the solution, since it can be harmful and toxic. Wear personal protective
equipment when doing so.

1. Wash the equipment/instrument with soap.

2. Rinse with clean water.

3. Sanitize by dipping or soaking in sanitizing solution. Note: Since you are required to
sanitize equipment, tools, utensils, and instruments use the recommended amount of Chlorine
to be used.

4. Remove from the sanitizing solution.

5. Dry thoroughly (air dry).

6. Check the accuracy of each equipment and instrument. Maintaining a clean work
environment is critical in preventing foodborne illness.

Bacteria can grow on unsanitary surfaces and then contaminate food. Just because a work
surface looks clean does not mean that it is sanitary. Always ensure that you clean and
sanitize a work area before starting to prepare food. It is best to sanitize before the start of the
operation and after cleaning the equipment. You have to take note of that.

How are equipment, tools, instruments, and utensils according to job requirements and
manufacturer’s specification used? Manufacturing Specification means the commercial
specification for the manufacturing, quality control, packaging, labeling, shipping, delivery,
and storage of the product as set forth in a Drug Approval Application and/or in the
specification agreed upon in accordance with this Agreement or Ancillary Agreement

. How to use a blender:

1. Check and inspect the blender and outlets.

2. Insert the plug of the blender into the outlet.

3. Switch-on the blender.

4. Operate blender in accordance with the manufacturer’s specifications

6. Clean and sanitize in accordance with specifications.

Precautions:  Wear appropriate protective outfit when working.  Proper care in handling
the equipment.  Check accuracy of the equipment.
WORK IN A TEAM ENVIRONMENT
TEAMWORK

You are asked to work in teams often, so you are used to the idea.
However, it is worth taking a step back and thinking about how best to work
in a team.

To start, answer the following questions:

What is the best team you have been a part of and why?

 Was there a synergy?

 Comradery?
 A clear plan?
 Was everyone engaged?

Think about how you can be a good team member. This can be in general
and also based on your strengths. Communicating, active listening,
resolving conflict, setting and meeting expectations, motivating others,
staying organized and on task, and working with your team to reach a
consensus are all beneficial attributes to bring to a team. Discuss best
practices and expectations together as a team before you start your
project. Being a good team member is not just about your intentions; it is
also how you are perceived. Peer evaluations will be used to provide
feedback and improve teamwork.

Babe Ruth said it well, “The way a team plays as a whole determines its
success. You may have the greatest bunch of individual stars in the
world, but if they don’t play together, the club won’t be worth a dime.”

Building an Effective Team

Check out the team-building pyramid below adapted from Grow (2011)[1]. In
order to build an effective and strong team, it is important to start from the
bottom with vision, expectations, and then connectivity. Once a foundation
has been laid, trust can be built and problem-solving can start. Too often
teams start at the top. It is difficult to effectively communicate and make
decisions if team members are not on the same page in terms of vision and
expectations and have not built trust with each other.
 Team Building
Pyramid: It is important to start at the bottom and work upward. Image adapted from Grow,
2011.

Balancing the Team and Tasks

Forming and maintaining an effective and successful team takes work. One
of the challenges is how to allocate time and resources to balance getting
things done and keeping the team cohesive and working well together.
Below is an illustration of this challenge from Grow (2011) [2]. It is a good
idea to keep this balance in mind throughout the project. At times the scale
may tip one way or the other, but it is important to keep both the project
and team in mind as decisions are made.

Teamwork Balancing:
It can be difficult to complete tasks in a timely fashion and keep everyone in the team content
and on the same page. Image adapted from Grow, 2011.
What is the Occupational Safety and Health?

Occupational safety and health, also commonly referred to as occupational health

and safety, occupational health, or occupational safety, is a multidisciplinary field
concerned with the safety, health, and welfare of people at the occupation.

Occupational Work safety; is a series of measures to be taken to create a safe

working environment to prevent employees from accidents/incidents.

Occupational Health; keeps employees' health at the highest level socially,

psychologically, and physically, prevents the employees occupational diseases, and
works to make working conditions and means of production suitable for health. It
protects employees from all harmful effects of work environments. It is an integrated
science-based on engineering and medical disciplines.

Occupational Health and Safety in the Food Industry

When we think about OHS in general, especially Construction, Mining, and Metal
sectors are in the first place. However, considering the number of employees,
machinery, and equipment, the food industry is an important sector in terms of
occupational health and safety practices.

There are different risks and opportunities in terms of occupational safety in the food
industry. Starting from raw material production; there may be many occupational
health and safety risks such as electricity, production lines and machinery,
equipment used, chemicals used, temporary/seasonal workers circulation, seasonal
work, storage, and shipment ..etc. Food safety rules applied in the food industry also
support occupational health and safety rules; the best example of this is the Covid-
19 pandemic. Personal hygiene rules such as hand washing have already been
applied in the food industry for years, and the training and competence of employees
in this regard are at the top level.

Olam Progıda's OHS Approach

Olam is committed to providing a healthy and safe workplace for our employees,
contractors, and visitors. Our vision of embedding a ‘zero harm culture’ is delivered
through safety leadership and embodied in ‘Our Shared Values’.

For a sustainable occupational health and safety system, documents have been
prepared by Global EHS, and compliance with these rules is strictly followed in all
areas.

Olam has defined "6 IMPERATIVES" in OHS systems. Guidelines have been
created for each imperative and full compliance is expected in all areas.
‘6 IMPERATIVES’ include that;

1- Lockout Tagout

2- Permit to Work

3- Reporting, recording, and review

4- Systems Audit

5- Workplace Inspections and Risk Assessments

6- Driving Safety Rules