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Nutritional significance
Fruits and vegetables provide an abundant and cheap source of vitamins, minerals, and
fibre. Their importance in the diet is largely determined by culture, for example, a religion
such as Hinduism demands that its followers are vegetarian and their diet therefore
contains a high proportion of fruit and vegetables. Other communities, however, only serve
vegetables as accompaniments to main meals, and fruits as appetizers and desserts.
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It is preferable to consume fruit and vegetables when fresh, as the nutritional content is
then usually at its highest. Some techniques, such as blanching, leach out many watersoluble vitamins into the surrounding liquid and if this liquid is not consumed, many
nutrients are lost. Other methods such as sterilization expose the food to high
temperatures which destroy some of the B vitamins. The table below illustrates the stability
of nutrients, when exposed to certain processing or storage conditions.
Stability of vitamins under different conditions
Nutrient
Vitamin A
40
Vitamin C
100
Biotin
60
Vitamin D
40
Vitamin K
40
75
55
Processing
Although there are many similarities between the processing of fruit and vegetables, it is
important to realize the following differences.
Fruits are nearly all acidic and are commonly called 'high acid' foods. This acidity naturally
controls the type of micro-organisms that are able to grow in fruit products. The spoilage
microorganisms that are likely to be found in such products are moulds and yeasts, which
if consumed, rarely cause illness. Processing may be achieved by using preservatives
such as sugar, salt and vinegar, and by drying, concentration or fermentation.
Vegetables are less acidic than fruits and for that reason are classified as 'low acid'
products. A wide range of micro-organisms are able to grow in moist low-acid products,
which may lead to spoilage and the possibility of food poisoning. To prevent this,
vegetables can be processed by heating to destroy bacteria, or by pickling, salting, or
drying to inhibit bacterial growth. Care is needed when processing low acid products, such
as vegetables, to minimize the risk of transmitting food poisoning bacteria to consumers.
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and the gelling compound 'pectin' (pectin is present naturally in plants, but may also be
added in a commercially-produced form), to achieve the desired gel structure. The
ingredients are then boiled together to evaporate water and achieve the correct sugar
content.
Jams
This is a solid gel made from fruit pulp or juice, sugar, and pectin. It can be made from a
single fruit or from a combination, but in either ease the fruit content should be at least 40
per cent. In mixed-fruit jams, the first-named fruit should be at least 50 per cent of the total
fruit added (based on European legislation). The total sugar content of jam should not be
less than 68 per cent to prevent mould growth after opening the jar.
Jellies
These are crystal-clear jams, produced using filtered juice instead of fruit pulp.
Marmalades
These are produced mainly from clear citrus juices and have fine shreds of peel
suspended in the gel. Commonly-used fruits include limes, grapefruits, lemons and
oranges. Ginger may be used alone or in combination with the citrus fruit. The fruit content
should not be less than 20 per cent citrus fruit, and the sugar content is similar to jam.
Fruit cheeses
These are highly boiled jam-like mixtures that have a final sugar level of 75-85 per cent and
thus set in a solid block. They can be cut into bars or cubes, or further processed as
ingredients in confectionery or baked goods.
The table below outlines the stages needed for the production of some fruit and vegetable
products:
Production stages for some preserves
Process/product
Prepare raw
material
Jam (whole-fruit) *
*
Add other
ingredients
Jam
Jelly
Marmalade
Fruit cheese
Equipment required
Processing stage
Prepare raw material
Equipment
Section reference
14.1
Peeling machinery
51.0
De-stoners
21.0
12.1
Fruit presses
53.1
Pulpers/juicers
55.0
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Sieve/strain
Juice centrifuges
07.3
Sieves
29.3
Strainers
29.4
52.0
56.0
Thermometer
63.0
Heat source
36.0
28.2
Sealing machine
47.1
Capping machine
47.2
Cutting pineapple
Preparation of the raw material
The process begins with washing the incoming raw materials, and it is vital that the water
used is potable. In some regions it may be difficult to obtain a supply of clean water and it
may be necessary to purify it. This can be carried out by boiling the water and allowing it to
settle, but this is a slow process and is costly in terms of fuelwood. It is possible to
purchase water-filters or make your own. In all cases it is advisable that local expert advice
is sought on the suitability of the water in any location before processing takes place.
Pulping/juice extraction
Juice can be extracted in a number of ways:
by steaming the fruit
by reaming the fruit (for citrus fruit)
by pressing
by pulping, using purpose-made pulpers, blenders, or a pestle and mortar.
Straining
The starting material for the production of jellies is a clear juice. To achieve this, the
extracted juice must be strained using a muslin cloth bag. Additionally, sugar syrups should
be strained in order to remove any unwanted material.
Addition of ingredients and process control
As in all processing, it is necessary to ensure that the correct amounts of ingredients are
added, and that temperatures and other process conditions are standardized. This will
ensure that the product has constant quality time after time. To standardize recipes
successfully it is useful to have the following:
a pH meter or pH papers for checking the acidity level (the optimum range is
3.0-3.3)
a thermometer for temperature measurement
accurate scales for the measurement of small amounts of ingredients such
as preservatives
a refractometer for accurately assessing sugar content.
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(Note: the boiling temperature can also be used as a less accurate measure of sugar
content. The advantage is that a thermometer is cheaper than a refractometer.)
Boiling
Boiling can be carried out in a stainless steel or enamelled metal pot. If pans made from
other materials are used there is the possibility that the fruit acids will react with the pan
and cause 'off' flavours. For larger production it is best to use a steam jacketed pan.
There are two heating stages in the manufacture of jam. Initially, it is necessary to heat the
fruit slowly in order to soften the flesh and extract the pectin. Once this is completed, it is
vital to boil the mixture rapidly. This change in heat output is difficult to achieve without an
easily-controllable heat source and the choice of heat source should be an important
consideration before embarking on production.
Filtering sugar syrup
Filling jam into bottles
During boiling care must be taken to avoid localized overheating which is likely to lead to
burning and colour change. Boiling is carried out until the desired sugar content is reached.
There are various ways to test for this. It can be conveniently measured using a hand-held
refractometer, or a sugar thermometer. These may be out of financial reach for a small
producer, but if a product of consistent quality is to be produced, batch after batch, their
use is highly recommended. Alternative checks, including placing a drop of the product in
cold water to see if it sets, are less accurate, and require experience and skill to work
effectively.
Filling and packaging
A good product packed in a dirty container will soon deteriorate, therefore it is essential
that the containers used are thoroughly washed and sterilized. (For details refer to the
Packaging chapter.)
The preserve should be hot-filled into suitable containers which are then sealed with a lid.
The temperature of filling is important too hot, and the steam will condense on the inside of
the lid and drop down onto the surface of the preserve. This will dilute the sugar on the
surface and allow mould growth. If the temperature is too low, the preserve will thicken and
be difficult to pour and a partial vacuum will not form in the jar. Ideally the temperature
should be 82-85C.
Filling can be achieved using jugs and simple funnels. For higher production rates small
hand-operated or semiautomatic piston-fillers are available. In all cases, the jars should be
filled to the correct level, approximately 9/10ths full, to assist the formation of a vacuum as
the product cools.
Finally, the jars are held upright while the gel is formed during cooling. This can be done by
standing the jars on shelves, or, more quickly, using a low-cost water-cooler (see
Packaging chapter for more details). A partial vacuum should form between the surface of
the jam and the lid when the product cools. This can be seen by a slight depression in the
lid. If a vacuum does not form, it means that the jar is leaking or the filling temperature was
too low.
The packaging is likely to be one of the main costs involved in production. Ideally, glass
jars should be used, with new metal lids. It is possible to use paper, polythene, or cloth tied
with an elastic band or cotton, to cover the jars. The appearance of the product is,
however, less professional, and there is a risk of contamination by insects. This is not
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Sweet pickle
fermented
Sour pickle
fermented
Unfermented
pickle
Sauce
* 5% brine + 1-2%
sugar; leave for 1-2
weeks
* 5% brine; leave
for 1-2 weeks
*
Add salt
Mix with vinegar
Boil
* 3% salt 5% vinegar
and sugar
* 3% salt + 5%
vinegar
* 3% + 6% vinegar
and sugar
Pasteurize
*
*
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Equipment required
Processing stage
Prepare raw material
Equipment
Section reference
14.1
Peeling machinery
51.0
De-stoners
21.0
12.1
Boil
Fill
Pack
Pasteurize
Steam blancher
01.0
or boiling pan
48.0
Heat source
36.0
Brine meter
64.6
Boiling pan
48.1
Heat source
36.0
Thermometer
63.0
28.1
28.2
Capping machine
47.2
Sealing machine
47.1
48.0
Pasteurizer
50.0
Peeling apples
Preparation of the materials
Equipment needed for de-stoning and cutting are as indicated in the section for jams.
Addition of ingredients
To ensure that the product has a long shelf-life, it is necessary to balance the sugar
concentration and acidity. To do this it is likely that the following pieces of equipment will
be necessary:
pH meter
Brine meter
Refractometer.
It is possible to calculate a value known as the 'preservation index'. This is used to assess
whether the product is safe from food spoilage and poisoning micro-organisms. The value
can be calculated as follows:
If you do not have access to basic laboratory equipment or are not sure how to carry out
the calculation, it is best to take the sample to a food-testing laboratory and they will be
able to tell you whether you need to adjust the recipe.
Pasteurization
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Air-dried fruit
*
Air-dried
vegetables
*
Fried/dried
product
*
Osmotically dried
fruits
*
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Blanch
Sulphuring/sulphiting *Some
*Some
Soak in syrup
Pulp
Strain/filter
Boil
Deep-fry
Pack
Equipment required
Processing stage
Equipment
Section reference
14.1
De-stoners
21.0
Peeling machinery
51.0
12.1
Soak in syrup
Pulp
Strain/filter
Dry
Deep-fry
Pack
48.0
Heat source
36.0
Boiling pan
48.0
03.1
Pulper/juicer
55.0
Muslin cloth
Stainless steel strainer/filter
29.0
Solar dryer
23.1
Fuel-fired dryer
23.2
Electric dryer
23.3
Fryers
33.0
Sealing machinery
47.1
Processing notes
During drying, many fruits and vegetables experience some changes in colour. These can
be lessened by carrying out some simple processing stages prior to drying (for example,
blanching, sulphuring, and sulphiting).
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response from rural producers. Most rural consumers are not willing to pay more for a
slightly improved product quality and the investment in a dryer may not prove to be
economically advantageous. In addition the relatively poor control over drying conditions
compared to that for fuel-fired or electric dryers, means that they are largely unsuitable for
high-value products such as spices, where an improvement in quality does generate higher
income.
There are also a large number of designs of fuel-fired dryers. These have better control
over drying conditions and therefore produce a higher quality product. They are able to
operate at all times of the day and year, and in most cases produce a higher rate of drying.
However, these benefits must be evaluated against higher capital and operating costs.
Sulphur cabinet
Packaging
Traditional packaging materials such as baskets, jute sacks, and wooden boxes have long
been established for packaging dried foods such as fish and vegetables. They are for
commodities which are transported in large quantities to a central marketing place and then
sold loose. These packages can be used several times and are usually cheap.
Traditional packaging is only suitable provided the climate does not cause an increase in
the moisture content of the food which will result in mould growth. If the climate is not
suitable, dried foods should not be transported in this way. Boxes are used to prevent
crushing of dried foods, and in humid climates, moisture-proof flexible films can be used
(see Packaging chapter).
Some semi-moist foods such as osmotically dried fruits have special needs to prevent the
reabsorption of water. Since dried fruit is a valuable product, it may be worth spending
more on the package, such as a moisture-proof sealed bag. A wide range of flexible
packaging materials is also available, but the use of many of these is limited due to high
costs. Low-density polyethylene is a moderately good moisture barrier and cheaper than
other films. It can be easily sealed using a powered bar-sealer.
Flexible materials may be used as the sole component of a package, but for most foods, a
sturdy outer container is also needed to prevent crushing or to exclude light.
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