CBLM Food Processing

COMPETENCY BASED LEARNING MATERIAL
Sector Processed Foods and Beverages
Qualification Title FOOD PROCESSING NC II
Unit of Process Food by Salting, Curing and Smoking

competency
Module Title Processing Food by Salting, Curing and Smoking
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CBLM for Food Processing NCll
Prepared and Developed by: Ma. Carina Santiago-Villanueva
Processed Foods and Beverages Sector
HOW TO USE THIS COMPETENCY – BASED LEARNING MATERIAL
Welcome!
The units of competency, “Process Food by Salting, Curing and

Smoking”, Process Food by Fermentation and Pickling; Process Food by
Sugar Concentration; Process Food by Drying and Dehydration; Process
Food by Thermal Application are the competencies of FOOD PROCESSING
NCII. a course which comprises the knowledge, skills and attitudes required for
a TVET trainer to possess.
The module, Processing Food by Slating, Curing and Smoking,

Processing Food by Fermentation and Pickling; Processing Food by Sugar
Concentration; Processing Food by Drying and Dehydration; Processing
Food by Thermal Application contains training materials and activities
related to identifying learner’s requirements, preparing session plan, preparing
basic instructional materials and organizing learning and teaching activities for
you to complete.
In this module, you are required to go through a series of learning

activities in order to complete each learning outcome. In each learning outcome
are Information Sheets, Self-Check, Operation Sheets and Task/Job Sheets.
Follow and perform the activities on your own. If you have questions, do not
hesitate to ask for assistance from your facilitator.
Remember to:
 Work through all the information and complete activities in each section.
 Read information sheets and complete the self-check. Suggested
references are included to supplement the materials provided in this
module.
 Most probably, your trainer will also be your supervisor or manager. He
is there to support you and show you the correct way to do the things.
 You will be given plenty of opportunities to ask questions and practice on
the job. Make sure you practice your new skills during regular work
shifts. This way, you will improve your speed, memory and your
confidence.
 Use the Self-Checks, Operation Sheets or Task or Job Sheets at the end
of each section to test your own progress. Use the performance.
 When you feel confident that you have had sufficient practice, ask your
Trainer to evaluate you. The results of your assessment will be recorded
in you Progress Chart and Accomplishment Chart.
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You need to complete this module before you can perform the next
module, Test Systems Network.
UNIT OF COMPETENCY: Process Food by Salting, Curing and Smoking
UNIT DESCRIPTOR : This unit deals with the knowledge, skills and
attitudes required to process foods by salting, curing and smoking. Include
packaging using plastic bags only.
LEARNING OUTCOMES:
1. Prepare equipment tools, materials and utensils

2. Prepare the raw material
3. Cure raw materials
4. Process cured materials
5. Pack processed cured materials
6. Perform post production activities
LEARNING OUTCOME 1 Prepare equipment tools, materials and

utensils
Information Sheet # 1.1
Definition of Terms:
Food Processing- is a process of food preservation that improves the texture

and flavor of food products thus, lengthening their shelf life
Food Processing by Salting, Curing and Smoking
Salting: This is the most basic and most ancient form of preserving meat. This
process keeps the meat from going off by sucking it like a vacuum removing
most of the moisture where bacteria thrive and survive. By doing so, the meat
tends to be dry and tough but makes it a little salty.
Curing: This process is like salting where nitrates are simply added to the meat
which prevents the meat from spoiling. In this process, there is a little use of
salt but instead more on nitrates that makes the meat softer and less dry.
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Nitrates contribute to the yet delicious pink color and added flavor with the use
of herbs and spices.
Smoking: In this procedure, smoke is used to preserve the meat. Smoking is

done to maintain the pink color and instill the meat with a lot of flavorful
characteristics. But before smoking, meat is cured before the actual smoking.
Then after the meat has been smoked, it is slowly cooked at a very low
temperature in a lengthy amount of time so as the desired softness is achieved
and making it juice when served. Smoking is depended on the type of wood
used to achieve distinct flavors for different kinds of meat.
Common Equipment, Tools, Materials and Utensils and Their Uses
A. Equipment
1. Cooking range (Gas range or oven)- is the most

versatile equipment operating on either LPG or electricity. The
name implies, it can perform a range of functions such as cooking,
frying, boiling, grilling, and baking.
2. Refrigerator- a piece of equipment that uses

electricity to preserve food (vegetables, eggs and most leftovers) at
a cold temperature
3. Chiller- an equipment used to store semi-perishable

foods in a low temperature (examples: leftovers, eggs, vegetables)
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B. Tools
1. Weighing Scale- an instrument used to take the weight or mass of raw

ingredients and materials
2. Measuring Cups- a measuring tool used to measure dry ingredients of

large quantities
3. Salinometer-an instrument for measuring the amount of salt or brine

in a solution.
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4. Measuring spoons- these are used to measure small amounts of
ingredient either solid or liquid
5. Refractometer- an instrument used for reading the salinity or

measuring the sugar concentration of sap and syrup
6. Impulse Sealer- a device used in sealing purposes especially plastics
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7. Beaker and graduated cylinder- used in measuring liquid ingredients
C. Utensils
1. Grater and Shredder- for grating and shredding vegetables, lemon

rind and cheese
2. Wooden barrels- containers made of wood where salted fish are

placed or fermented.
3. Double Boiler- a cooking utensil used to simmer foods
4. Scissors and shears- used for cutting fins of fish
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5. Earthen Pots- are containers made of clay used for storing salted
products
6. Saucepan-a cooking utensil usually with handle used for heating

food
7. Strainer- a receptacle used for draining food items like fish,

vegetables and can either be stainless or plastic
8. Wooden Ladle- a stirring utensil made of wood in order to prevent

chemical reaction from the food product being stirred
9. Steamer-a cooking utensil used to steam food and other raw

materials and sterilizing bottles
10. Mortar and Pestle- made either of wood or marble used in

grinding food items in smaller pieces by pounding
11. Casserole Pot- A cooking utensil used for cooking, stewing food
and in cooking sugar concentrates
12. Saucepot- a cooking utensil usually a pot with cover and two
handles used to cook sugar concentrates.
13. Knives- used to cut ingredients

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14. Food tongs- used in lifting and picking hot objects
15. Cutting/Chopping Board- made either of plastic or wood used to

place a food material or item for cutting
16. Basin- a container used in preparing brine and other curing

mixture.
17. Smokehouse- a building, place or any construction used for

smoking fish or meat with the use of dense smoke
18. Soaking containers- used in preparing brine solution or for

soaking fish
D. Materials for Salting, Curing and Smoking
1. Smoking tray- a tray like container made of bamboo used to place the
fish
2. Fresh fish, meats, poultry and eggs (common raw materials)
3. Smoking materials like fuel, e chips, charcoal, hush
4. Flavoring and tendering ingredients like salt
E. Personal Protective Equipment (PPE)
PPE is specific safety gear, which workers may be advised or required to

wear, depending upon the nature of their work or workplace. In food
processing this is used to protect workers in the food preparation. PPE
shall include the following clothing:
1. Laboratory Gown- a clothing with sleeves worn as protection from

dirt while cooking or working; an apron can also be used
2. Face Mask- used as a mouth covering
3. Hand Gloves- used to protect workers hands in food handling
4. Splashers/working shoes- worn by workers to protect them from

slips or falls while working
5. Hair nets- worn on the head to protect from hair falling to food
preparation/processing
6. Hand Towels- at least 3 pieces used for personal use and for wiping
utensils
Self Check 1.1
1. Give examples of food items that are commonly processed and

preserved
2. What is the importance of using PPEs in food processing?
3. Identify what is being asked

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a. _____ worn on the head to protect from hair falling to food
preparation/processing
b. _____ a building, place or any construction used for smoking fish

or meat with the use of dense smoke
c. _____ made either of plastic or wood used to place a food material

or item for cutting
d. _____ A cooking utensil used for cooking, stewing food and in

cooking sugar concentrates
e. _____ a receptacle used for draining food items like fish, vegetables
and can either be stainless or plastic
f. _____ are containers made of clay used for storing salted products
g. _____ a device used in sealing purposes especially plastics
h. _____ an instrument for measuring the amount of salt or brine in a

solution.
i. _____ an equipment used to store semi-perishable foods in a low

temperature (examples: leftovers, eggs, vegetables
j. _____ a cooking utensil used to steam food and other raw materials
and sterilizing bottles
Answer Key 1.1.1
1. The food items that can be processed and preserved are : fish,
meats, eggs, vegetables
2. PPEs are important to be worn to protect the worker from dirt

and hazards in food preparation
3. A. hair net
B. smokehouse
C. chopping/cutting board
D. casserole pot
E. strainer
F. earthen pots
G. impulse sealer
H. salinometer
I. chiller
J. steamer
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Information Sheet 1.2
Sanitation in Food Processing
Product safety and quality are highly dependent on sanitation, as improper

sanitation will result in reduced shelf life and increased loss due to spoilage.
Sanitation is a prerequisite to HACCP and is intended to reduce the incidence
of microbiological, chemical and physical hazards in the food manufacturing
environment. The most effective sanitation program can be nullified if
employees do not follow Good Manufacturing Practices (GMPs), thus creating
contamination conditions. Conversely, strong sanitation programs,
incorporating multiple interventions and integrated with other critical food
safety systems, will enhance overall product safety. This article will introduce
the basic needs for effective sanitation and provide basic operational guidelines
pertaining to sanitation practices and sanitation employee expectations for
properly cleaning a food plant, its equipment, utensils and structure.*
Considerations for Effective Cleaning

When developing sanitation procedures, as when selecting cleaning
compounds, there are several factors that must be considered: first, the type of
soil to be cleaned; second, the function of various chemicals in the cleaning
process; and finally, the condition of the plant water.
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Soils. There are many types of soils that may be encountered in food plants,
depending on the types of product being made. Each different soil has a
different level of solubility. There is no general-purpose cleaner to address all
soils; no “one size fits all.” Cleaners or detergents are selected specific to the
needs. Table 1 illustrates the solubility of various soils typically found in food
processing plants.
Chemical Functions. Another important factor to consider when setting up

the sanitation program is the functionality of chemicals; that is, what they do
when used. The following are functions that cleaning chemicals perform when
used in a sanitation system:
• Emulsification: The breaking up of fats and oils to allow them to mix in water.
Once this is accomplished, they remain suspended in water until rinsed away.
• Saponification: The process of making fat soluble and easier to remove. Alkali
cleaners react with animal or plant fat, creating soap that is suspended for
rinsing.
• Sequestering/chelating: The process of removing mineral hardness from

water and making it softer for cleaning. Polyphosphates are examples of
sequestering/chelating agents.
• Wetting agents: Used to lower the surface tension of water, helping the water
to contact all surfaces of the soil and the equipment.
• Dissolving: This chemical reaction produces water-soluble product from

water-soluble soils. Some soils, such as alkali deposits, form strong bonds
with surfaces. Acid will solubilize these soils for removal.
• Dispersion: Also known as deflocculation, this is the breaking up of

aggregates into separate particles that are easily suspended and removed.
• Suspension: Once insoluble particles are in solution, suspension will allow

them to be flushed away, preventing them from settling and resulting in
deposits.
• Peptizing: Similar to dispersion but more applicable to protein soils. This is

the formation of solutions from soils that are only partially soluble.
• Rinsing: The condition of solution or suspension that will allow soils to be

flushed from a surface. This is done by reducing water surface tension
(wetting).
Water. Water used for sanitation must be potable whether it is from a private
well or a municipal source. Potable means that it is fit for human consumption
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without further treatment. In all situations, sufficient boiler capacity is need to
provide enough hot water for the entire cleaning process. Cold water will not
dissolve fats, so the plant must supply enough hot water to facilitate the entire
sanitation process.
Water hardness can have an impact on the effectiveness of cleaners and

sanitizers as well as on the performance of plant equipment. All water contains
some level of hardness because of minerals. Some of the problems with hard
water are reduction in effectiveness of cleaners and sanitizers, reduction in the
effectiveness of heating equipment (i.e., boilers or cookers) as scale forms on
transfer surfaces, and contributes to the formation of biofilm on equipment.
One means of softening the water is through the use of sequestering and
chelating agents in cleaning systems to reduce hardness. However, this can be
more expensive than softening the water in the plant system. This can be done
through the addition of chemicals (hydrated lime and soda ash) to precipitate
the hardness. This is especially effective for boilers. Another means to soften
plant water is through ion exchange in which sodium ions are exchanged for
calcium and magnesium, making the water more compatible with cleaning
solutions.
Cleaning Chemicals. When selecting cleaning chemicals and sanitizers, it is

also important to match the type of material used for the processing
equipment so that the equipment does not deteriorate. Soft metals such as
aluminum can pit from harsh chemicals such as acids or unbuffered alkali,
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and the pitting can become harborage for bacteria, supporting the formation of
biofilms. They must be safe for use and easily rinsed from equipment. Table 2
lists common cleaners or detergents.
The sanitation chemical supplier should be a source of technical assistance in

the use and application of cleaning chemicals, not just a chemical salesman.
The most effective supplier representatives will conduct a plant survey to
determine products, soils, equipment, facility flow, and personnel needs. They
will participate in setting up the cleaning procedures but will not set up the
procedures themselves. They will provide chemical safety training and training
on application and technique, and should have sufficient microbiological
knowledge to understand what organisms are of concern, given the products
made, and to assist with selection of sanitizers to control these organisms.
Cleaning Systems and Equipment

Central systems provide hot water and chemicals to stations placed around the
plant. They can be automatically set to deliver various combinations of water
pressure and volume for specific soils. The systems can be set to deliver
chemicals directly into the water or be equipped with a mixing valve to add
chemical from a central dispenser. The advantage to the mixing valve is that
the same hose can be used for prerinse and final rinse of equipment with the
valve off to prevent flow of chemical. If this type of system is used, it is
important to provide a sufficient number of hoses and hook-up stations for the
size of the plant and to have sufficient pump size to deliver the water or
chemical needed for the distance and number of units to be run at any time.
Spray guns for the cleaning system must be of sufficient size to deliver the
chemical to the areas being cleaned. If equipped with a nozzle with a 15°
spread, this should be sufficient for most applications. Nozzles are available to
alter the spray pattern for varying cleaning jobs.
An alternative to a central system is individual hose stations. These stations

have a supply of hot and cold water or steam injection for creation of hot
water. They require a gauge for direct reading of water temperature and will
also be provided with individual backflow prevention devices. As they operate
with city water pressure, the hoses will have adjustable nozzles for stream flow
or mist spray. Hoses must be made of material that is able to handle the
temperature and pressures for the system, and be lightweight, flexible, and
nonporous so that they can be cleaned.
Portable equipment can be used for wet cleaning of hard-to-reach areas. It may
require hot-water feed or have built-in heaters to create hot water. In addition,
it can incorporate detergent and create foam.
Wet/dry vacuums are valuable in any food plant environment on account of

their versatility. They can be used for small cleaning jobs and are highly
portable. Plants may also find value in purchasing floor scrubbers. Though
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they need space to operate, they are good for cleaning warehouse floors and
aisles.
The Cleaning Process

The frequency with which the plant is cleaned will depend greatly on the
operation and the types of soils involved. Dry-mix plants are often continuous,
with ongoing cleanup or a full cleanup at the end of a week. Slaughter and
further process plants now have flexibility from FSIS to determine what is
appropriate provided there is no insanitary condition or no production of
adulterated product. A rule of thumb is for plants to clean once within a 24-
hour period and after the following product changeovers: between allergenic
ingredients for food safety; between animal species (i.e., when changing from
chicken to beef to prevent economic adulteration); and between spices for
quality reasons (i.e., from more colorful or flavorful spice blends to less intense
blends).
Consult with the plant sanitarians and the QA department to determine

appropriate cleaning frequency. Decisions to clean equipment or rooms less
than every 24 hours must be supported by sufficient scientific documentation
to prove that this will not result in insanitary conditions and the production of
adulterated product. This may come in the form of microbiological testing,
scientific literature, or validation by a process authority. Environmental
cleaning of such areas such as walls, floors, ceilings, drains, etc., should be
conducted daily or as often as necessary (i.e., during midshift cleanup,
between shifts, etc.) to prevent product or contact-surface contamination.
Nonproduction areas should be cleaned as frequently as needed to prevent
transfer of insanitary conditions to production areas.
The following steps are basic procedures for effective cleaning and sanitizing.
Each step in the process depends on effective completion of the prior step.
The sanitation process starts with a dry pickup of scrap, paper, packaging,
and product or ingredient spills. This should be ongoing during the
manufacturing shift to prevent excess buildup and prevent insanitary
processing conditions.
1. Break down equipment into component parts or open equipment panels to

clean inside.
2. Cover electrical panels or motors with plastic and secure the plastic to
prevent forcing water into areas that may result in damage.
3. Lock out or tag out moving equipment, such as blenders, to prevent injury
(i.e., equipment someone may have to reach into). Do not place equipment
parts on the ground (floor) or on stairs or platforms where there is foot traffic,
as this may only create more bacterial niches and result in recontamination of
clean parts. Instead, have racks or clean-out-of-place (COP) tanks for these
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parts.
4. Follow dry cleaning with a hot-water rinse to break up fat, remove visible
soils, and combine with mechanical action to prepare surfaces for cleaning.
Water temperature for cleaning is very important, depending on the soils
present. Generally, the water temperature used is approximately 5°F above the
melt point temperature of fat. This means that the recommended temperature
will be between 130 to 160°F. As proteins denature and bind to surfaces,
making removal more difficult, do not let the water temperature reach 185°F or
higher.
5. Dry pickup and rinse are very important steps to remove as much soil as
possible as most chemical cleaners are not designed to remove excess soils or
gross contamination.
Wash all equipment and environmental surfaces with detergent and hot water.
Here again, the water temperature is most effective between 130°F and 160°F,
depending on the cleaning chemicals used. Cleaning may involve several steps
and cleaning compounds used may contain several ingredients, depending on
the soils to be removed, hardness of water, and prevention of scale formation.
The chemicals used will be selected to control soils identified in Table 1.
Chemical mixing, if not done by an automatic dispenser, is very important to
cleaning effectiveness and cost control. Train sanitors to properly mix
chemicals, and if verification of chemical strengths is required, use test strips,
titration chemicals, or pH/conductivity probes available with some ATP
devices. Ensure that they understand that excess chemical will not make
cleaning easier; in fact, it may make it more difficult by harming equipment,
leaving chemical film, and wasting money. Conversely, too little chemical does
not save money as it is not going to clean as effectively and will ultimately
result in failures such as reduced shelf life and quality, microbiological
problems, or regulatory noncompliance reports, or control action. A pumping
system with pressurized air is an effective means of applying cleaning
compounds with the creation of foam. Foaming cleaners are most effective
when large areas need to be cleaned, and they should be left on the equipment
long enough to break down soils but not long enough to dry, making removal
more difficult.
Once the chemical has been applied to the surface, it will require contact time
to penetrate and break up soil, but not so long that it begins to dry. Use
mechanical action as needed to remove soil and prevent buildup that can
contribute to biofilm formation. As a rule, scrub contact surfaces on a daily
basis and indirect surfaces such as frames at least once a week.
During the process of rinsing and applying cleaning compounds, run

conveyors or other equipment at slow speeds to ensure that all surfaces are
contacted. The frequency of removal of belts for scrubbing and soaking must
be identified by the plant in the master sanitation schedule. Cleaning must
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include the undersides of the belts, and if the conveyor guides have removable
UHMW runners, identify the frequency with which they need to be removed for
cleaning and soaking. Do not allow employees to stand on top of conveyors or
product surfaces, as their boots may be a source of contamination that can be
ground into equipment. Provide them with the appropriate ladders or lifts to
reach high spots.
Once the cleaning process is completed, the rinsing process will remove soils
suspended in detergent. Rinse all surfaces with hot (130 to 160°F ) water to
remove all soap. Use care to avoid overspray or water spray into floors and
drains that might result in the creation of aerosols.
Sanitizing
Once cleaning is complete and prior to application of sanitizer, it is a good idea
to conduct basic monitoring, beginning with organoleptic inspection:
• Look in, around, and under equipment and structures for indications of soil
removal.
• Does the environment smell clean or are there sour or musty odors?
• Feel equipment surfaces for grease or grit from incomplete soil removal.
Provide the proper tools to monitor, including a flashlight; mirror (no glass) for
inspecting difficult-to-reach locations; test strips or kits to monitor cleaning
and sanitizing solutions; thermometer for checking water temperature; a
ladder or lift to inspect high equipment and overhead structures; and a
notepad and pen to record findings.
It is very important that sanitarians be trained to conduct inspection of their

work, and this inspection should also incorporate the use of ATP
bioluminescence technology to verify cleaning effectiveness. This technology
does not indicate the presence of microorganisms; rather, it measures the
presence of organic material, indicating an environment in which microbes can
live and grow. Thus, if used in conjunction with visual inspection, it provides
sanitarians with immediate feedback on the efficacy of their cleaning efforts.
The final step in the process is to apply sanitizer to all cleaned and rinsed
surfaces to destroy hidden microorganisms. Effective use of sanitizers is
integral to controlling microorganisms for the purpose of food safety and
product shelf stability. It must be understood that sanitizing does not replace
thorough handwashing or equipment and facility cleaning. Factors such as
organic materials, especially protein, decrease the effectiveness of sanitizers
against microorganisms. Therefore, plant employees must be trained to
properly wash hands and clean equipment/facilities, and to remove all
carbohydrate, fat, and protein soil and biofilms prior to sanitizing. The
sanitizing step will supplement effective cleaning through the reduction of
microorganisms to a level considered safe.
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The selection of sanitizers will be determined to a great extent by the
microorganisms to be controlled in the operation, as well as corrosiveness and
cost. Table 3 identifies many of the common sanitizers for food plant use. An
effective sanitizer will pass an efficacy test requiring that 99.999% of harmful
microorganisms be killed within 30 seconds. All sanitizers used in the plant
must be listed in the USDA Approved Chemical Compound book, and an
MSDS must be provided for each sanitizer and be available to employees.
Sanitation employees handling sanitizers must be trained to properly handle
and prepare them at the appropriate effectiveness level and be provided with
strips or chemical kits to test them. They must also be trained to clearly
identify any container bearing sanitizer with the type that it contains.
If the sanitation effort is effective, sanitizing will give an extra measure of

microbiological control. The environment to be cleaned and the organisms of
concern will again dictate selection of sanitizers. It is also recommended that
the maximum amount of sanitizer at a no-rinse level be applied to surfaces for
the maximum effect.
It is also recommended that plants alternate sanitizers during the week to

prevent bioresistance or proliferation of specific flora. As some sanitizers are
more effective against Gram-positive organisms, using them exclusively can
eliminate the Gram-positive organisms but will eliminate the competition for
the Gram-negative organisms, and they might flourish. So alternating
sanitizers will prevent the elimination of one organism only to allow the
proliferation of another. As an example, in a five-day production week, use
quat on four days and chlorine on one day. The progression of alternating
sanitizers would be quat on Monday and Tuesday, chlorine on Wednesday,
quat on Thursday and Friday and on the last day of the week if weekend work
is conducted. The use of chlorine one day per week will not affect equipment if
it is applied at appropriate levels. Alternating quat and chlorine to maximize
bacteria-killing effect is a good idea; however, for safety reasons never mix quat
and chlorine together, as they can produce a dangerous reaction and a toxic
gas.
Ozone is gaining wide acceptance in the food industry as a primary sanitizer or

as an alternative sanitizer where a “multiple hurdle” sanitizing approach is
used. We often associate ozone with the clean air smell after a thunderstorm,
when electrical charges pass through the air and create ozone gas. It can also
be created in food manufacturing plants by passing high-voltage electricity
through air, creating a tratomic form of oxygen. It has been used in Europe for
purifying drinking water and is also used in the U.S. to purify city water in
many areas.
Ozone is a disinfectant because it is an extremely strong oxidizer, which

accounts for its effectiveness. It works against a very wide range of organisms,
both Gram-positive and Gram-negative viruses and protozoa and because it
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works as an oxidizer of bacterial cells, they do not develop resistance as they
may with other sanitizers.
Operational Sanitation
Although this is a regulatory requirement, it should also be an objective of the
plant to ensure that product does not become contaminated from the effects of
operational processes:
GMPs: These are possibly the most important factor in the maintenance of
sanitary operating conditions. These include employee dress, hand washing
and maintenance of hand-wash facilities (providing hot water, soap and
towels), prevention of employee traffic from raw- to cooked-product areas, food
and tobacco control, and disease control. These controls must be enforced with
plant visitors as well.
Spill control: All areas within the building, storage and office areas, as well as
processing areas, must be kept clean, neat and free of soil or spills. Ingredient
spills in storage or manufacturing areas must be cleaned up immediately.
Excess accumulation of spilled product, ingredient or other material (i.e.,
grease) in or around the production area must be cleaned up for food safety
and employee safety.
Operational soil buildup: Remove buildup of food soils on equipment, especially

in product flow zones to prevent possible bacterial growth. Single-use,
disposable towels are preferred to multiple-use towels for wiping down
equipment surfaces. Towels used should be wetted with sanitizer before use to
provide an additional microbiological control benefit.
Trash/inedible bins control: The insides of trash or recycling bins will be kept
closed with lids secured or emptied frequently to prevent overflow. Inedible
carts will be emptied frequently and cleaned no less than daily. No trash or
solid waste will be stored within the plant except in covered containers. Waste
containers at packaging machines may be uncovered during the operation of
such equipment.
Idle equipment control: Idle equipment, not currently in use, will be covered to
prevent contamination from ongoing operations, maintenance, or sanitation
activities. If not covered, equipment will be washed on a daily basis and, in all
cases, washed and sanitized prior to use in production.
Floor mats or foamers: Foamers are the preferred means of delivering sanitizer
on the floors. They will be maintained to deliver quat at 800 to 1000 ppm and
set to create thick foam rather than a liquid pool. If floor mats or baths are
used, they must be maintained at optimum sanitizer strength. Use 800 to
1000 ppm quat for all floor mats.
Overhead control: Overhead structures (i.e., pipes, beams, lights, etc.) are to be
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clean, free of condensation as well as dust buildup, and rust and flaking
materials (paint, silicone, tape and plastic.) Place overheads on the master
sanitation schedule to prevent buildup of soils that can drop onto product
surfaces or product.
Packaging control: Direct product-contact packaging (i.e., film and bags) will be
covered while in storage areas to prevent accidental contamination. Packaging
materials returned to storage will be dry, clean and sealed.
Door control: Doors (including silos, compactor areas) should remain closed
during operations unless they have operating air curtains to prevent the entry
of pests and outdoor dust or soil.
Maintenance control: Food-contact equipment contaminated by maintenance
activity before or during operations should be properly cleaned and sanitized
before contact with food product or packaging.
Proper Handwashing Technique
It is very important that every worker practice proper handwashing

techniques during the preparation, handling and processing of foods. The
following are the steps in proper handwashing:
1. Wet your hands with running water — either warm or cold.
2. Apply liquid, bar or powder soap to a cupped hand.
3. Lather well.
4. Rub your hands, palm to palm, vigorously for at least 20 seconds. ...
5. Rinse well.
6. Dry your hands with a clean towel.
7. Use the towel to turn off the faucet
.
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Self Check 1.2
1. Write true if the statement given is correct. If the statement is false

encircle the word/words that made it incorrect
a. __________ It is very important that every worker practice

proper handwashing techniques during the preparation,
handling and processing of foods.
b. __________All areas within the building, storage and office

areas, as well as processing areas, must be kept clean, neat
and free of soil or spills. Ingredient spills in storage or
manufacturing areas must be cleaned up two days after use.
c. __________ The sanitation process starts with a dry pickup of

scrap, paper, packaging, and product or ingredient spills.
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d. __________ Decisions to clean equipment or rooms more than
every 24 hours must be supported by sufficient scientific
documentation to prove that this will not result in insanitary
conditions and the production of adulterated product.
e. __________ When selecting cleaning chemicals and sanitizers,

it is also important to match the type of material used for
the processing equipment so that the equipment does not
deteriorate
f. _________Potable means that it is fit for human consumption

without further treatment.
g. _________ The final step in the process is to apply sanitizer to

all cleaned and rinsed surfaces to initiate entry of
microorganisms.
h. _________ The final step in the process is to apply sanitizer to

all cleaned and rinsed surfaces to destroy hidden
microorganisms
i. _________ Product safety and quality are highly dependent

on sanitation, as improper sanitation will result in reduced
shelf life and increased loss due to spoilage.
j. _________ Dry pickup and rinse are not so important steps to

remove as much soil as possible as most chemical cleaners
are not designed to remove excess soils or gross
contamination.
Answer Key 1.2.1
a. True
b. Two days after use
c. True
d. More
e. True
f. True
g. Initiate entry of microorganisms
h. True
i. True
j. Not so
Task Sheet 1.2.2

Perform handwashing the proper technique.
22
Title : Perform the proper handwashing technique
Performance Objective: After completing this task, the trainees will be able
to demonstrate how to do the proper handwashing technique
1. Wet hands with water
2. Apply enough soap to cover all hand surfaces
3. Rub hands palm to palm
4. Right palm over left dorsum with interlaced fingers and vice versa
5. Palm to palm with fingers interlaced
6. Backs of fingers to opposing palms with fingers interlaced
7. Rotational rubbing of left thumb clasped in the right palm and

vice versa
8.Rotational rubbing backwards and forwards with clasped fingers

of right hand in left palm and vice versa
9.Rinse hand with water
10.Dry thoroughly with single use towel
11.Use towel to turn off faucet
PERFORMANCE CRITERIA CHECKLIST 1.2.3
CRITERIA YES NO
1. Wet hands with water
2. Apply enough soap to cover all hand surfaces
3. Rub hands palm to palm
4. Right palm over left dorsum with interlaced fingers and vice
versa
23
5. Palm to palm with fingers interlaced
6. Backs of fingers to opposing palms with fingers interlaced
7. Rotational rubbing of left thumb clasped in the right palm

and vice versa
8. Rotational rubbing backwards and forwards with clasped
fingers of right hand in left palm and vice versa
9. Rinse hand with water
10. Dry thoroughly with single use towel
11. Use towel to turn off faucet
** NOTE: IF STUDENT GOT 100% CORRECT ANSWER IN THIS TASK,

HE/SHE CAN NOW MOVE ON TO THE NEXT INFORMATION SHEET. IF
NOT, REVIEW THE INFORMATION SHEET AND GO OVER THE TASK
AGAIN
The Seven S of Good Housekeeping
The general concept of the 7S is that they are intended to eliminate

waste. Working in disorder is neither productive, nor safe. 7S is a simple
and practical method to build a quality culture at the work place. It is
relatively easy to undertake, and requires minimal additional resources.
The first and small investment made in time and effort pays off in a
much bigger manner when the results are realized and maintained. Only
implementation of the 7S or Workplace organization is not sufficient.
Continuous monitoring and controlling the all 7S activities is also
important and it can be monitored by conducting the questionnaire
survey at regular interval. If the responses by the respondents are poor
then it reflects the degradation of the workplace organization.
24
Benefits of implementing 7S are as follows-
• Workplace becomes cleaner, safer, well-organized and more pleasant;
• Floor space utilization is improved;
• Workflow becomes smoother and more systematic and non-value

added activities are reduced;
• Time for searching tools, materials and document is minimized;
• Machine breakdowns are reduced since clean and well-maintained

equipment breaks down less frequently and it also becomes easier to
diagnose and repair before breakdowns occur, therefore extending
equipment life;
• Errors are minimized leading to making defect-free products;
• Consumables and material wastage are minimized;
• Morale and satisfaction of employees improve;
• Productivity of the organization improves together with the quality of

products and services.
The description of each phase of 7S implementation is as follows-
25
Sort: This means distinguishing or sort out between wanted (Value
Added) and unwanted (Non Value Added) items at place of work and
removal of unwanted (NVA) items.
Action Steps:
• Identify a 5S-project area and take "before" pictures
• Review sorting criteria
• Create a local red tag area
• Tag, record, and move red tagged items
• Take "after" pictures
Resources required:
• Red Tags
• Red Tag Record Forms
• Camera for “before” and “after” pictures
Target Outcomes:
• Increase in floor space utilization.
• Searching time of tools, materials, and papers is reduced.
• Better flow of work.
• Inventory cost of unnecessary items is reduced.
26
Set in order: Arranging and labeling items in such a manner that they
are easy to find and use.
Action Steps:
• Take “before” pictures
• Implement workplace changes
• Mark locations by creating addresses and applying labeling, marking,

and color-coding
• Take “after” pictures Resources required
: • Existing plant standards for labeling, marking, and color-coding
• Labeling supplies
• Tape for creating borders on work surfaces and floors
• Paint and painting supplies
Target Outcomes:
• Take things out and keep things back easily.
• Make lesser mistakes.
• Reduce searching time.
• Work environment becomes safe
27
Shine: This means removing dirt, strain, filth, soot and dust from the
work area. This includes cleaning and care for equipment and facilities
and also inspecting them for abnormalities. In a way it also includes
primary maintenance of equipment.
Action Steps:
• Define "clean"
• Get cleaning supplies
• Take "before" pictures
• Clean the work area
• Identify contamination sources
• Fix small imperfections
• Take "after" pictures
Resources required:
• Cleaning supplies such as brooms, dust pans, rags, degreasers, and

floor cleaner
• Personal protective equipment such as gloves and eye protection.
Target Outcomes:
• Work place becomes free of dirt and stains which is the starting point
for quality.
• Equipment lifespan will be prolonged and breakdowns will be less.
• Creates a pleasant environment.
• Prevents accidents.
Standardize: This call for systematizing the above 4S practices. This

means ensuring that whatever cleanliness and orderliness is achieved
should be maintained. This should develop a work structure that will
support the new practices and turn them into habits. The purpose of
standardization is to make sure that everyone in the company follows the
same procedure, the same names of items, the same size of
signalization/floor marking, shapes, colours, etc. Standardize also helps
to do the right thing the right way every time.
Action Steps:
• Brainstorm ideas for making the 5S changes standard operating

procedure
• Update documentation to reflect changes
28
• Make sure all stakeholders are aware of the new standards - inform
and educate
Resources required:
• Support from those who can create documentation, job aids, and visual
aids
• Information and approval from those responsible for maintaining

company procedures
• Poster-making supplies for posting new standards in work areas
Target Outcomes:
• Activities will be simplified.
• Consistency in the work practices.
• Avoid mistakes.
• Better visual and transparency management work efficiency will

improve.
Sustain or Self Discipline: Sustain also means ‘Discipline’. It denotes

commitment to maintain orderliness and to practice first 3S as a way of
life.
Action Steps:
• Monitor processes established during S4 -Standardize
• Expand 5S efforts to other work areas
• Evaluate 5S effectiveness and continuously improve
• Recognize and reward strong efforts Resources required:
• Management audit forms
• Presentation tools for sharing best practices with other work areas
• Management commitment and focus on maintaining the new standards
Target Outcomes:
• Promotes habit for complying with workplace rules and procedures.
• Creates healthy atmosphere and a good work place.
• Helps you to develop team work.
• Provides you with data for improving 5S.
Safety: Safety is the condition of being protected against physical, social,

spiritual, financial, political, emotional, occupational, psychological,
educational, or other types or consequences of failure, damage, error,
accident, harm, or any other event that could be considered non-
desirable.
29
Action Steps:
• Error Proofing (Poka-yoke)
• Safety related instructions & symbols
• Alert, Warning, Hazard area identification and labeling with proper

symbols
• Safety trainings to employees
Resources required:
• Safety related instruction and Symbols
• Personal Protective Equipments (PPE)
• Safety Trainer or Expert Target Outcomes:
• Avoid errors or mistakes
• Reduces accidents
• Safer working environment
Spirit (Team Spirit): Team spirit is a willingness to cooperate as part of

a team.
Action Steps:
• Formation of 7S team with a team leader
• Regular meetings to set benchmark and strategies for achievement
• Motivational and co-operational speeches or trainings for each 7S team

on regular basis
Resources required:
brainstorming session or meetings
• Leader with knowledge, abilities, experience, good understanding and

cooperating skills
• Questionnaire survey at regular basis for measuring and analyzing the

team spirit
• 7S Audit form for checking overall performance
Target Outcomes:
• Better communication
• Higher confidence to do work
• Better Understanding & Analysis on problems
• Creates healthy working environment
• Reduces boredom approach toward the job
30
Self Check 1.3.1
1.Discuss the importance or benefits of the 7s implementation in a workplace
Answer Key 1.3.2
• Workplace becomes cleaner, safer, well-organized and more pleasant;
• Floor space utilization is improved;
• Workflow becomes smoother and more systematic and non-value

added activities are reduced;
• Time for searching tools, materials and document is minimized;
• Machine breakdowns are reduced since clean and well-maintained

equipment breaks down less frequently and it also becomes easier to
diagnose and repair before breakdowns occur, therefore extending
equipment life;
• Errors are minimized leading to making defect-free products;
• Consumables and material wastage are minimized;
• Morale and satisfaction of employees improve;
• Productivity of the organization improves together with the quality of

products and services.
Learning Outcome 3 : Cut raw materials
Testing accuracy of Devices
1. Weighing Scale
The use of weighing scale is to get the exact weight of every

material and it varies to whatever specific weight is desired. Weighing
scales some in two types, the analog and the digital type.
Weighing scale calibration is to check that the device is in good
condition. Make sure that the pointer is at zero with an empty plate.
Weight is measured by grams or kilograms.
31
2. Refractometer-
Parts:
 eyepiece
 mirror tube
 adjustment screw
 cover plate
 prism
The device must be handled carefully to assure prolonged use and

reliable service. Manual instructions must be followed so as not to
damage the components of the device which are considered the most
delicate part of the refractometer. It should not be immersed in water
for it might cause the instrument to be foggy. Placing corrosive
chemicals on the prism may damage its coating.
Steps to calibrate the refractometer

a. Open the cover then place a drop of distilled water in the prism
or any solution wish to be tested of concentration
b. With closed cover, observe if the shadow or dark area visible
inside the eyepiece which shall indicate that the device is properly
calibrated. It should be calibrated to zero then get the reading
c. Clean the device cover or glass prism by opening the cover
using tissue or a piece of cotton cloth.
3. Salinometer-
The salinometer is allowed to float in a graduated cylinder with the

brine solution poured into it and the reading is taken at the surface of
the liquid. The reading when divided into 4 approximates the salt
concentration in percent.
32
Sorting of raw materials
1. Separate raw food from ready-to-eat food
Raw foods such as meat, fish and vegetables may contain harmful bacteria that
can spread very easily by touching:
 other foods
 worktops
 chopping boards
 knives
You should keep raw foods away from ready-to-eat food, such as salad, fruit
and bread. This is because these types of food won't be cooked before you eat
them, so any bacteria that get onto the food won't be killed.
To help stop bacteria from spreading:
 don't let raw food such as meat, fish or vegetables touch other food
 don't prepare ready-to-eat food using a chopping board or knife that you
have used to prepare raw food, unless they have been washed thoroughly
first
 wash your hands thoroughly after touching raw meat, fish or vegetables
and before you touch anything else
 cover raw meat or fish and store on the bottom shelf of the fridge where
they can't touch or drip onto other foods
 don’t wash raw meat before cooking
 wash, peel or cook vegetables unless these are described as 'ready-to-eat'
on the packaging
2. Check the label
It's important to read food labels to make sure everything you’re going to use
has been stored correctly (according to any storage instructions) and that none
of the food is past its ‘use by’ date.
Food that goes off quickly usually has storage instructions on the label that say
how long you can keep the food and whether it needs to go in the fridge.
This sort of food often has special packaging to help keep it fresh for longer.
But it will go off quickly once you’ve opened it. This is why the storage
instructions also tell you how long the food will keep once the packaging has
been opened. For example, you might see ‘eat within two days of opening’ on
the label.
3. Use by dates
You will also see ‘use by’ dates on food that goes off quickly. You shouldn’t use
any food after the ‘use by’ date even if the food looks and smells fine, because it
might contain harmful bacteria.
4. Best before dates
The 'best before' dates marked on most foods are more about quality than
safety. When this date runs out, it doesn't mean that the food will be harmful,
but its flavour, colour or texture might begin to deteriorate.
An exception to this is eggs, which have a best before date of no more than 28
days after they are laid. After this date the quality of the egg will deteriorate
33
and if any salmonella bacteria are present, they could multiply to high levels
and could make you ill.
If you plan to use an egg after its best before date, make sure that you only use
it in dishes where it will be fully cooked, so that both yolk and white are solid,
such as in a cake or as a hard-boiled egg.
The food industries, their raw materials and processes

Industry Materials Storage Processing Preserving Packaging of
processed requirements techniques techniques finished
products
Meat Beef, lamb, Cold stores Slaughtering, Salting, Loose or in
processing pork, cutting up, smoking, cans,
and poultry boning, refrigeration, cardboard
preserving comminuting, deep-
cooking freezing,
sterilization
Fish All types of Cold stores Heading, Deep- Loose in
processing fish or salted gutting, freezing, refrigerated
loose or in filleting, drying, containers or
barrels cooking smoking, in cans
sterilization
Fruit and Fresh fruit Processed Blanching or Sterilization, Bags, cans or
vegetable and immediately; cooking, pasteurizati glass or plastic
preserving vegetables fruits may be grinding, on, drying, bottles
stabilized vacuum- dehydration,
with sulphur concentration lyophilizatio
dioxide of juices n (freeze
drying)
Milling Grains Silos may be Grinding, Drying Silos (conveyed
fumigated in sifting, cooking or pneumatically),
storage milling, baking sacks or bags
rolling to other
processes, or
boxed for retail
trade
Baking Flour and Silos, super Kneading, Baking, Packaged for
other dry sacks and fermentation, cutting wholesale
goods, bags laminating surface trades,
water, oils surface treatments restaurants
treatments of and and retail
seasoning packaging markets
Biscuit Flour, Silos, super Mixing, Baking, Bags, boxes for
making cream, sacks and kneading, cutting institutional
butter, bags laminating surface and retail
sugar, fruit moulding treatments trades
and and
seasoning packaging
Pasta Flour, eggs Silos Kneading, Drying Bags, packets
manufacture grinding,
cutting,
extrusion or
moulding
Sugar Sugar beet, Silos Crushing, Vacuum Bags, packets
34
processing sugar cane maceration, cooking
and refining vacuum
concentration
, centrifuging,
drying
Chocolate Cocoa bean Silos, sacks, Roasting, - Packets
making and sugar, fats conditioned grinding,
confectionery chambers mixing,
conching,
moulding
Brewing Barley, hops Silos, tanks, Grain milling, Pasteurizati Bottles, cans,
conditioned malting, on barrels
cellars brewing, filter
pressing,
fermentation
Distilling Fruit, grain, Silos, tanks, Distillation, Pasteurizati Barrels,
and carbonated vats blending, on bottles, cans
manufacture water aeration
of other
beverages
Milk and Milk, sugar, Immediate Skimming, Pasteurizati Bottles, plastic
milk other processing; churning on, wrapping,
products constituents subsequently (butter), sterilization boxes (cheese)
processing in ripening coagulation or or unpacked
vats, (cheese), concentratio
conditioned ripening n,
vats, cold desiccation
store
Processing of Groundnuts, Silos, tanks, Milling, Pasteurizati Bottles,
oils and fats olives, dates, cold stores solvent or on where packets, cans
other fruit steam necessary
and grain, extraction,
animal or filter pressing
vegetable
fats
Types of Meat
1. Pork
Pork is one of the most popular forms of meat in the world. Despite
some confusion on the issue, pork is classed as red meat. This is because it
contains a large amount of myoglobin, a protein responsible for the red color
of meat. Bacon, Ham, Hot dogs, Jamon, Prosciutto, Salami, Sausages and
Spam are some meat products that uses pork.
35
Benefits
 Pork is a particularly significant source of thiamine (vitamin B1). The
content of this important vitamin is much higher than in other meat
and plays an essential role in glucose metabolism and protecting
cardiac health.
 Much cheaper than most other meat.
 Pork contains decent amounts of selenium and zinc, which are
responsible for boosting the immune system, defending against
stress, and optimal hormone production.
Concerns
 Compared to other meats, pork contains extremely high levels of omega-6

fatty acids. Despite being essential for health, an unbalanced ratio of
omega-6 to omega-3 can be pro-inflammatory in nature.
 Pork is more susceptible to bacterial contamination and food-borne
illness than other meat; ensuring pork is thoroughly cooked is essential.
2. Beef
When most people think of red meat, they probably imagine beef. There are
many different beef products and cuts of beef, ranging from hamburgers to rib
eye steaks. While mainstream health advice often dictates selecting the leanest
cuts of red meat, fatty cuts of beef are perfectly healthy.
Benefits
 Despite fearmongering over the fat content of beef, the main fatty acid in
beef is none other than oleic acid. If you haven’t heard of it before, then
it’s the main fat in olive oil (and known as “heart healthy”)
 Beef contains a wide variety of beneficial compounds that include
creatine, conjugated linoleic acid (CLA), and glutathione
Concerns
 Excessive beef consumption can increase circulating iron to unhealthy

levels in some individuals. These high levels can increase the risk of
various cancers and cardiovascular disease. This risk is especially the
case in those with a genetic mutation called hemochromatosis, which
causes over-absorption of heme iron.
 Overcooking beef (burning) can lead to the formation of polycyclic
aromatic hydrocarbons (PAHs) and heterocyclic amines (HCAs). Both of
these compounds are carcinogens, but we can minimize their risks by
sensibly
3. Lamb and Mutton
36
Both lamb and mutton are very similar types of meat, with one fundamental
difference;
 Lamb is from a sheep less than one-year-old

 Mutton is the meat of an adult sheep
Just like beef and pork, there are variety of popular lamb cuts- perhaps lamb
chops are the most popular.
Benefits
Generally speaking, both lamb and mutton is very healthy.
 Because sheep graze on pasture all day, the omega 6 to 3 ratio is very
low- and optimal—compared to other meats.
 Lamb contains a broad range of health- protective nutrients, especially
zinc, selenium and B vitamins.
Concerns
 Lamb is very expensive in comparison to different kinds of meat.
4. Chicken
Alongside beef and pork, chicken is one of the ‘big three’ popularity-wise.
However, chicken is a different classification of meat and comes under the
poultry category. People commonly refer to as “white meat” rather than red.
As one of the most popular foods in the world, there are all sorts of
chicken-based foods. These range from fried and roasted chicken to chicken
soup and even chicken popcorn.
Benefits
 Chicken is very cheap and easily affordable.

 For those who are trying to consume less
fat/calories, chicken offers a smaller amount than
other meats but with the same protein content.
 Chicken stock/broth offers a significant source of
gelatin. As chicken bones have a lower density than
other meats, the collagen and gelatin are far easier to
extract.
37
 Chicken provides a decent source of necessary
vitamins and minerals, particularly selenium,
potassium, phosphorus and B vitamins.
Concerns
 Due to commercial chicken feed – and similar to pork – chicken contains

an excessive amount of omega-6. Whether this is problematic or not
likely depends on the overall diet.
 Bacterial contamination with strains such as E. coli and salmonella is
too common in chicken. As a result, strict hygiene procedures are
necessary when handling the raw meat.
5. Turkey
Turkey is another type of white meat, probably best known for its
appearance at the Christmas table! It has both a deeper yet drier taste than
chicken and is a less prevalent form of poultry. As mentioned above, the most
popular kind is probably roast turkey, but you can find a variety of processed
and unprocessed turkey products.
Benefits
 Turkey is among the most protein-dense of all meats, offering 17.5 grams
of protein in only 149 calories.
 Similar to chicken, turkey also provides a significant amount of B
vitamins, potassium, selenium and phosphorus.
 Turkey provides an inexpensive source of high- quality protein.
Concerns
 Similar to other forms of poultry, turkey is more likely to harbour

foodborne bacteria than red meat
6. Venison
Venison refers to the flesh of a deer, and it is a traditionally rarer type of

meat. In recent years, sales of venison have been soaring as a result of its
healthy reputation among consumers.
Benefits
 As deer live and feed in the wild, venison is one of the healthiest and
most natural varieties of meat. The excellent omega 6 to 3 ratio (2:1)
shows the benefits of an animal living on a natural diet.
38
 Venison has more vitamins and minerals than beef despite having
significantly fewer calories. In short, venison is possibly the most
nutrient-dense meat out there.
Concerns
 While there are no major health concerns, one obstacle could be the
price; venison costs a lot. Expect to pay around $30 for one pound of
venison steak.
7. Duck
Duck is one of the less popular types of meat. However, it has immense
popularity in Chinese populations, where ‘ Peking duck’ is a showpiece dish.
Like chicken and turkey, we can consider duck as a kind of white meat.
Benefits
 Duck provides a significant amount of selenium, phosphorus, and B

vitamins. These vitamins are all important for optimal energy production
and a well-functioning immune system
Concerns
 Making duck at home- or having a roast duck- is perfectly healthy.

However, be aware that in Chinese cuisine, duck often comes in sauces
made from a variety of additives including sugars, oils, and monosodium
glutamate (MSG).
 Trichinellaspiralis, a parasite sometimes found in pigs, occasionally
contaminates wild boar meat. There have been several outbreaks of this
in recent years, but it is very rare.
Fish and other Marine Products
Fish as Food
Fish has been an important source of protein and other nutrients for
humans from time immemorial.
In culinary and fishery contexts, fish may include shellfish, such as

molluscs, crustaceans and echinoderms.
Species
39
Over 32,000 species of fish have been described, making them the most
diverse group of vertebrates. In addition, there are many species of shellfish.
However, only a small number of species are commonly eaten by humans.
Common species of fish and shellfish used for food

Mild flavour Moderate flavour Full flavour
Delicate Basa, flounder, hake, Anchovy ,herring, Atlantic mackerel
texture scup, rainbow trout, lingcod, moi, orange
hardshell clam, blue roughy, atlantic
crab, peekytoe crab, ocean perch, lake
cuttlefish, eastern victoria perch, yellow
oyster, pacific oyster perch, european
oyster. Sea urchin
Medium Black sea bass, Sable fish, atlantic Escolar , Chinook
texture European sea bass, salmon, coho salmon, salmon, chum
hybrid stripe bass, skate, Dungeness salmon, American
bream, cod, drum, crab, ki9ng crab, shad
haddock, hoki, allaska blue mussel,
Pollock, rockfish, pink greenshell mussel,
salmon, snapper, pink shrimp
tilapia, turbot, walleye,
lake whitefish, wolfish,
hardshell clam, surf
clam, cockle, jonah
crab, snow crab,
crayfish, bay scallop,
chinese white shrimp
Firm Arctic char, carp. Barramundi ,cusk, Barracuda ,
texture Catfish, dory, grouper, dogfish, kingklip, Chilean sea bass,
halibut, monkfish, mahimahi, opah, cobia, croaker,
pompano, dover sole, mako shark, eel, blue marlin,
sturgeon, tilefish, swordfish, albacore mullet, sockeye
wahoo, yellowtail, tuna, yellowfish tuna. salmon, blue fin
abalone, conch, stone Geoduck clam, squat tuna
crab, American lobster, lobster, sea scallop,
spiny lobster, octopus, rock shrimp
black tiger shrimp,
fresh water shrimp, gulf
shrimp. Pacific white
shrimp, squid
INFORMATION SHEET 1.2-2
Grading and Sorting of the Raw materials for salting, curing and smoking
Learning Objectives:
At the end of 3 hours, the students must be able to:
1. Identify the quality grade used in meat.
2. Identify the kinds of cut in poultry parts.

40
Grades of Meat
Quality Grades – Beef
Quality grades are reflective of the eating quality of beef. Beef carcasses
are cut between the 12th and 13th rib, making the ribeye easy to view. United
Sates Department of Agriculture (USDA) Graders evaluate the distribution on
marbling in the ribeye. The age or maturity of the animal is also factored into
the quality grade.
The ribeye on the left is the one most of you probably leaned towards. It
has a greater amount of marbling in the ribeye. Marbling is thw white pieces of
fat that are seen inside the lean. Additionally, it has a brighter, more cherry-
red coloredribeye. The ribeye on the right does have less fat along the ribeye.
However, it has less marbling than the other ribeye. In addition it has a duller
color to the meat.
The USDA grading system breaks down the quality grades of beef into
Prime, Choice, Select, Standard, Commercial, Utility, Cutter and Canner.
Prime is the highest quality of beef available. They have the most
marbling and are sure to provide a wonderfully juicy and extremely tasty eating
experience. The high level of marbling makes them great for grilling and other
dry cooking methods.
Choice is still high quality beef that has less marbling than Prime.
Consumers are going to receive a delicious and juicy eating experience. Tender
cuts are still great for grilling and other dry cooking methods, while less tender
cuts are more suitable for a liquid added type of cooking.
Select is a uniform, leaner quality of beef. It still is tender and can

provide pleasurable eating experiences, having less marbling Select beef is
going to tend to be less juicy and tender than Prime or Select. Most often select
cuts are either marinated or braised to achieve the most eating satisfaction.
Maturity or age is harder for the everyday consumer to see in the

supermarket. This is taken into consideration when the USDA graders are
grading the carcasses. Graders take the color of the ribeye in combination with
the skeletal maturity to come up with this component of the quality grade. Any
cattle that are graded Prime, Choice or Select are going to be young cattle
which have not reached full maturity.
Quality grading is a voluntary service that is provided by the USDA and

paid for by the processors and producers. The USDA has stamps that they use
to identify what quality grade the carcass is.
41
Pork Quality
The quality of pork depends on its color, texture, and marbling which
can be determined by visual evaluation or scientific tests such as ultimate pH.
Fresh pork is more tender and juicy when it is reddish-pink, firm and non-
exudative. The chart below helps to demonstrate the variations in pork quality.
The USDA does not grade pork in the same way it does in beef. Pork carcasses
are not ribbed, and grades of pork are determined by back fat thickness and
carcass muscling.
Lamb Grades
Lamb grades are based on age, conformation (carcass muscling), and

other lean quality factors such as color. There are five quality grades: Prime,
Choice, Good, Utility, and Cull. More than 90% of lamv in the US will grade
USDA Prime or Choice.
Poultry Grading
Quality refers to the inherent properties of a product that determine its

relative degree of excellence or value. Experience and research have identified
certain properties in poultry that are desired by producers, processors, and
consumers. Some of these properties are a good proportion
of meat to bone, adequate skin covering, absence of feathers, and freedom from
discolorations.
Standards of quality enumerate the factors that affectthese properties
and apply to individual ready-to-cook poultry carcasses, parts, and products.
There are no grade standards for giblets, detached necks and tails, wing tips,
and skin.
For carcasses and parts, the factors include conformation,fleshing, fat
covering, defeathering, exposed flesh, discolorations, disjointed or broken
bones, missing parts from whole carcasses, and freezing defects, if applicable.
For poultry products, such as boneless-skinless breasts, factors include
presence of bones, tendons, cartilage, discolorations, and blood clots, as well as
other product-specific factors.
Grades apply to lots of poultry of the same kind and class,each of which
conforms to the requirements for the grade standard. The U.S. consumer
grades for poultry are U.S. Grades A, B, and C.
Grading involves evaluating poultry in terms of the standardsto
determine the grade. Figures 11-14 show an A quality young chicken, turkey,
duck, and goose. A given lot of poultry may contain a smallpercentage of a
42
quality lowerthan the grade specified because some defects are permitted.This
is an unavoidable necessity due to today’s production-
type processing methods.
Poultry grade standards have changed over the years toreflect
developments in poultry production, processing, and marketing. Standards for
ready-to-cook poultry were added to the regulations in 1950. Roasts were
added in 1965. Parts and boneless breasts and thighs were added in 1969.
All provisions for grading live and dressed poultry were eliminated in 1976.
Large poultry parts, skinless carcasses and parts, and tenderloins were added
in 1995. As the need arises and meaningful quality factors are established for
other products, additional grade standards will be developed.
Quality Factors for Carcasses and Parts of Poultry
The following factors must be considered when determining the quality of

an individual ready-to-cook carcass or part.
Conformation
The structure or shape of the bird may affect the distributionand amount
of meat, while certain defects detract from its appearance. Some of the defects
that should be noted are breasts that are dented, crooked, knobby, or V-
shaped; backs that are crooked or hunched; legs and wings that are deformed;
and bodies that are definitely wedge-shaped.
Fleshing
The drumsticks, thighs, and breast carry the bulk of themeat. There is,
however, a definite correlation between the covering of the flesh over the back
and the amount of flesh on the rest of the carcass. Females almost invariably
carry more flesh over the back and will generally have a more rounded
appearance to the breast, thighs, and legs. The common defects in fleshing are
breasts that are Vshapedor concave, rather than full and rounded; breasts that
43
are full near the wishbone, but taper sharply to the rear; legs and drumsticks
that are thin; and backs that have insufficient flesh to cover the vertebrae and
hip bones.
Fat Covering
Fat in poultry is judged entirely by accumulation under theskin. This is
true even for chicken parts. Accumulations occur first around the feather
follicles in the heavy feather tracts. Poorly fattened birds may have some
accumulation of fat in the skin along the heavy feather tracts on the breast.
Then, accumulations will be noted at the juncture of the wishbone and keel
and where the thigh skin joins the breast skin. At the same time,
accumulations will be noted around the feather follicles between the heavy
feather tracts and over the back and hips. Well-finished older birds will have
sufficient fat in these areas and over the drumsticks and thighs so that the
flesh is difficult to see. Fowl which have stopped laying have a tendency to take
on excessive fat in the abdominal area. Younger birds will generally have less
fat under the skin between the heavy feather tracts on the breast and over the
drumsticks and thighs than mature birds.
Feathers
Processors try to eliminate the problem of feathers by movingpoultry to
slaughter after feathering cycles are over. There is, for instance, a very short
period within which the slaughtering of ducklings must be done. With other
classes, the period is longer and attention is given primarily to noting if the
bulk of the pins have sufficient brush on them to facilitate picking.
Protruding feathers have broken through the skin and may or may not have
formed a brush. Nonprotruding feathers are evident but have not pushed
through the outer layer of skin. Before a quality designation can be assigned,
ready-tocookpoultry must be free of protruding feathers that are visible to a
grader during examination of the carcass at normal operating speeds. However,
a carcass may be considered as being free from protruding feathers if it has a
generally clean appearance (especially on the breast and legs)and if not more
than an occasional protruding feather is in evidence during a more careful
examination of the carcass. Hair on chickens, turkeys, guineas, and pigeons;
and down on ducks and geese must also be considered.
Exposed Flesh, Cuts, Tears, and Broken Bones

Exposed flesh can result from cuts, tears, missing skin, or broken or
disjointed bones. It detracts from the appearance of the carcasses and parts
and permits the flesh to dry out during cooking, thus lowering the eating
quality. The number and extent of such defects permitted depend on their
location—whether on the breast, legs, or elsewhere.
Cutting Poultry Parts
The USDA standards of quality apply to poultry parts cut in

the manner described below and illustrated in figures 15-29. While most
descriptions were developed when parts were cut from a carcass by hand, most
processors today disjoint whole carcasses by machine. Machine-cut parts may
be graded provided they are not misshapen and have nearly the same
44
appearance as they had prior to cutting from the carcass. Under certain
conditions, parts cut in other ways may also be officially identified when
properly labeled. Only skin or fat normally associated with a part may be
included unless stated on the label. The illustration of the skeleton of a chicken
(fig. 30) shows the points where the parts are cut and gives the names of the
skeletal parts.
Poultry halves (fig. 15) are prepared by making a full lengthback and breast
split of the carcass to produce approximately equal right and left sides.
Portions of the backbone must remain on both halves. The cut may be no more
than one-fourth inch from the outer edge of the sternum (breastbone).
Front poultry halves (fig. 16) include the full breast with corresponding back
portion, and may or may not include wings, wing meat, or portions of wing.
Rear poultry halves include both legs and adjoining portion of the back.
Quarters consist of the entire eviscerated poultry carcass which has been cut
into four equal parts, excluding the neck.
Breast quarters (fig. 17) consist of half a breast with the wing and a portion of
the back attached.
Breast quarters without wing consist of a breast quarterof a poultry carcass

from which the wing has been removed.
45
Leg quarters (fig. 18) consist of a thigh and drumstick, with a portion of the
back attached. It may also include attached abdominal fat and a maximum of
two ribs. A leg with a complete or entire rear back portion attached may also be
grade identified if certain criteria are met.
Breasts are separated from the back at the shoulder joint and by a cut running
backward and downward from that point along the junction of the vertebral
and sternal ribs. The ribs may be removed from the breasts, and the breasts
may be cut along the breastbone to make two approximately equal halves; or
the wishbone portion may be removed before cutting the remainder along the
breastbone to make three parts.
Breasts with ribs are separated from the back at the junction of the vertebral
ribs and back. Breasts with ribs maybe cut along the breastbone to make two
approximately equal halves; or the wishbone portion may be removed before
cutting the remainder along the breastbone to make three parts.
Split breasts with back portion or breast halves with back portion (fig. 19) are
prepared by making a full-lengthcut of front poultry halves without wings. If
labeled “splitbreast(s),” centering of the cut is not required to producetwo
approximately equal halves.
Legs (fig. 20) consist of the attached thigh and drumstick, whether jointed or
disjointed. Back skin is not included. The patella (kneebone) may be included
on either the drumstick or thigh.
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Thighs (fig. 21) are disjointed at the hip joint and may include the pelvic meat,
but not the pelvic bones. Back skin is not included. Thighs may also include
abdominal meat (flank meat), but not rib bones.
Thighs with back portion (fig. 22) consist of a poultry thigh with back portion
attached.
Drumsticks (fig. 23) are separated from the thigh and hock by cuts through
the knee joint (femorotibial and patellar joint) and the hock joint (tarsal joint),
respectively.
Wings (fig. 24) include the entire wing with all muscle and skin tissue intact,
except that the wing tip may be removed.
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Wing drummettes (fig. 25) consist of the humerus (first portion) of a wing with
adhering skin and meat attached.
Boneless-skinless poultry, except as noted, is free of tendons, cartilage, bone

pieces, blood clots, discolorations, and muscle mutilation.
Boneless-skinless breasts (fig. 26) or breasts with rib meat are prepared from
breasts cut as described for “breasts” and for “breasts with ribs.”
Tenders are any strip of breast meat.
Tenderloins (fig. 27) are the inner pectoral muscle which lies alongside the
sternum (breastbone). Tendons may be present.
Boneless-skinless thighs (fig. 28) are prepared from thighs cut as described for
“thighs.”
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Boneless-skinless drums (fig. 29) are prepared from drums cut as described for
“drumsticks.”
Information Sheet #1.3
How to Grade and Size Eggs
How can you tell the difference between a good egg and a bad egg? Eggs
are rated and graded into three classifications determined by the United States
Department of Agriculture (USDA). If you have chickens and plan on selling
eggs, grading and sizing is required. As a general rule, you should grade all
your eggs before you store, sell or consume them. At Southern States, we can
help you get the job done. Follow these steps to understand how to grade and
size eggs.
When grading eggs, both the interior and exterior quality is measured.
This process does not take into account weight or shell color. According to
USDA guidelines, eggs are graded and labelled as AA, A, and B U.S Grade AA
eggs are nearly perfect. The whites are thick and firm and the yolks are free
from any defects. The shells are clean and without cracks. U.S Grade A eggs
appear to be the same as Grade AA, but the difference is a slightly lower
interior quality. U.S Grade B eggs are noticeably different. They may have slight
stains and be irregular in shape and size. The quality of the interior is further
reduced. Grade B eggs are not sold in supermarkets, but are used
commercially in powdered egg products or liquids eggs.
Grading Eggs
Exterior Grading
Begin the egg grading process by checking the quality of the shell. The
ideal eggshell is clean, smooth and oval in shape with the one end slightly
bigger than other. Eggs with cracked or broken shells should be discarded. If
you are selling the eggs, remove any unusual shapes, textures or thin spots on
49
the shell. While they are edible, they break easily and will be unacceptable
because of their appearance.
Interior Grading
Grading the interior of the eggs is performed by a method called
candling. Using an egg candlerwill allow you to examine the air cell, the egg
white (called albumen) and the yolk. Candling also lets you check for spots and
cracks. Listed below are the different components to observe when candling an
egg:
Air Cell Depth - the air cell is the empty space between the shell and the white
usually found at the bigger end of the egg. As the egg ages, the air cell depth
grows and the quality of the egg diminishes.
White or Albumen – the white of the egg is called the albumen. The quality is
based on its clarity and thickness. Look for a clear color without discolorations
or floating foreign matter. Thick albumen allows limited movement of the yolk
and indicates a higher quality egg.
Yolk – the quality of the yolk is determined by the distinctness of its outline
and other features like size, shape and absence of any blemishes or blood
spots. It should be surrounded by a dense layer of albumen.
Spots – candling can help reveal foreign matter like blood spots or meat spots.
Eggs with interior spots should not be sold.
USDA Grade Standard Chart: This table is a quick reference for determining
the grade of an egg by candling. (From the article: Proper Handling of Eggs:
From hen to Consumption by the Virginia Cooperative Extension)
Quality AA Quality A Quality B Quality Inedible

Factor
Air Cell 1/8 inch or 3/16 inch or More than Doesn’t apply
less in depth less in depth 3/16inch
White Clear , Firm Clean , May Clean , May Doesn’t apply
be reasonably be weak and
firm watery
Yolk Outline Outline may Outline Doesn’t apply
slightly be fairly well clearly visible
defined – defined
Spots (blood None None Blood or Blood or
or meat) meat spots meat spots
aggregating aggregating
not more not more
than 1/8” in than 1/8” in
diameter diameter
Size Category Minimum Weight

Small 18 oz.
Medium 21 oz.
Large 24 oz.
X-Large 27 oz.
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Jumbo 30 oz.
Sizing Eggs
If you plan on selling your eggs, you need to sort and size them. Large
and extra-large eggs are the best sellers. You might be surprised to learn that
eggs are not sized individually, but rather sized by the combined weight of one
dozen eggs. A size breakdown by weight can be found in the chart on the right.
While there are a few things to learn about grading and sizing eggs, the
process is not difficult. You will be able to master the technique quickly with
just a little bit of practice.
Self Check 1.3.1
1. What are different poultry cuts?
Answer Key 1.3.2
1. Poultry halves
2. Front poultry halves
3. Rear poultry halves
4. Quarters
5. Breast quarters
6. Leg quarters
7. Split breast
8. Legs
9. Thighs
10. Drumsticks
11. Wings
12. Wing dummettes
13. Tenderloins
14. Wings
15. Neck
INFORMATION SHEET 1.3
Washing and Cleaning Guidelines of Raw materials for Salting, Curing and
Smoking
Learning Objectives:
At the end of 3 hours, the students MUST be able to:
1. Identify the steps in cleaning the raw materials for food processing.
2. Perform the steps in cleaning.
Washing Food: Does it Promote Food Safety?
51
Historically, we equate washing to cleanliness. We wash clothes, linens,
cars, dishes, and ourselves. So, it is logical that many people believe meat and
poultry can be made cleaner and safer by washing it. Is this true? Does
washing meat, poultry, eggs fruets, and vegetables make them safer to eat?
Washing Meat and Poultry
Washing raw poultry, beef, pork, lamb, or veal before cooking it is not
recommended. Bacteria in raw meat and poultry juices can be spread to other
foods, utensils, and surfaces. We call this cross-contamination.
Using a food thermometer is the only sure way of knowing if your food
has reached a high enough temperature to destroy foodborne bacteria. Cook all
raw beef and veal steaks, roasts, and chops to a minimum internal
temperature of 145 degree F as measured with a food thermometer before
removing meat from the heat source. For safety and quality, allow meat to rest
for at least three minutes before carving or consuming. For reasons of personal
preference, consumers may choose to cook meat to higher temperatures.
Soaking Meat and Poultry
Callers to the USDA Meat and Poultry Hotline sometimes ask about
soaking poultry in salt water. This is a personal preference and serves no
purpose for food safety. If you choose to do this, however, preventing cross-
contamination when soaking and removing the poultry from the water is
essential. Meat or poultry should be kept in the refrigerator while soaking.
Sometimes consumers wash or soak country ham, bacon, or salt pork

because they think it reduces the sodium or salt enough to allow these
products to be eaten on a sodium-restricted diet. However, very little salt is
removed by washing, rinsing, or soaking a meat product and is not
recommended.
Cross-Contamination
Hand washing after handling raw meat or poultry or its packaging is a

necessity because anything you touch afterwards could become contaminated.
In other words, you could become ill by picking up a piece of fruit and eating it
after handling raw meat or poultry.
Wash hands with warm water and soap for 20 seconds before and after
handling food, and after using the bathroom, changing diapers, tending to a
sick a person, blowing your nose, sneezing and coughing, and handling pets.
It is important to prevent cross-contamination from raw meat or poultry

juices by washing counter tops and sinks with hot, soapy water. For extra
protection, you may sanitize with a solution of 1 tablespoon of unscented,
liquid chlorine bleach per gallon of water.
Packaging materials from raw meat or poultry also can cause cross-
contamination. Never reuse them with other food items. These and other
52
disposable packaging materials, such as foam meat trays, egg cartons, or
plastic wraps, should be discarded.
Washing Eggs
Do not wash eggs before storing them. Washing is a routine part of

commercial egg processing and the eggs do not need to be washed again.
Federal regulations outline procedures and cleansers that may be used.
“Bloom,” the natural coating on just-laid eggs that helps prevent bacteria from
permeating the shell, is removed by the washing process and is replaced by a
light coating of edible mineral oil which restores protection. Extra handling of
the eggs, such as washing, could increase the risk of cross-contamination,
especially if the shell becomes cracked.
Washing Produce
Before eating or preparing fresh fruits and vegetables, wash the produce
under cold running water to remove any lingering dirt. This reduces bacteria
that maybe present. If there is a firm surface, such as on apples or potatoes,
the surface can be scrubbed with a brush. Consumers should not wash fruits
and vegetables with detergent or soap. These products are not approved or
labelled by the U.S. Food and Drug Administration (FDA) for use on foods. You
could ingest residues from soap or detergent absorbed on the produce.
When preparing fruits and vegetable , cut away any damaged or bruised
areas because bacteria that cause illness can thrive in those places.
Immediately refrigerate any fresh-cut items such as salad or fruit for best
quality and food safety.
How to clean a Fish
Use the Necessary Equipment
 Fillet Knife
 Scaling tool
 Bucket or other container for discarded parts
 Water source to keep the fish and work surface clean
 Zip top plastic bags store the fish if necessary
Scale the Fish
Always work with one fish at a time. Hold the head with one hand and,
using a scaling tool, dull knife or spoon, apply short, raking motions, moving
from the tail toward the head. Use caution around the sharp edges of the fins.
Repeat the action on both sides of the fish, around the fins and up to the gills.
Rinse the fish in water when you’ve finished.
Skin the Fish
53
Bullheads, catfish and other bottom-feeders lack scales, but are
protected by a thick skin, which most people prefer to remove before cooking.
First, cut the sharp spines off, which makes handling the fish easier.
Once you’ve removed the spine, make a cut behind the head and along
the pectoral or belly fins. Hold the fish by the head with one hand, grasp the
skin with the other, and pull toward the tail. Rinse the fish when it’s
completely skinned.
Cleaning and Gut Your Fish
On the belly of the fish, insert the knife into the anus, near the tail.
Slowly slide the knife toward the head of the fish and stop at the base of the
gills. Open the abdominal cavity, grab the entrails, pull, and remove. Some fish
have a kidney located by the spine, which you can remove with a spoon.
Always remove the darkened inner membrane (only some fish have this)
with a scraping motion- the membrane negatively affects the flavour. Remove
the head, if desired, by cutting behind the gills. Rinse the fish and the internal
cavity.
How to Prepare a Fish for Cooking
Fillet
Use the fillet method on large fish to negate the need for scaling or
skinning. Lay the fish on its side and hold the head. Insert the fillet knife
behind the pectoral fin and cut downward to, but not through, the backbone.
Turn the knife flat with the sharp edge pointed toward the tail and use a
sawing motion to slowly work down toward the tail; stay as close as possible to
the backbone. Once you’ve cut through to the tail, turn the scale side down on
the table. Insert the knife between the flesh and the skin and use the same
sawing motion to remove the meat. Repeat the process on the other side of the
fish and rinse in cold water when you’re finished.
Steaking
Use steaking as an alternative to filleting when you prepare salmon or

large fish. Cut perpendicular to the work surface, along the entire fish. These
cuts are traditionally 1/2- to 1-inch thick. Don’t forget to trim any excess fat or
bones without removing the backbone.
Learning Outcome 4 Process cured materials
How to cure meats

Curing is an age-old process of preserving meat for later use. With just a few
ingredients — salt, nitrites, and time — the meat transforms: from water-
packed and pliable to dry and stiff. Over time, the flavor develops, too. Leeched
of excess water, dry-cured meat takes on an intense umami flavor that is equal
parts mouthwatering and soul-slaking. Learn how to dry- and wet-cure your
own meat for a fraction of the cost you'd ordinarily pay in a restaurant or fine
foods purveyor, paying attention to proper safety standards to avoid tainted
meat.
54
Methods:
A. Dry-Curing Method
1.)
Decide what kind of meat you'd like to use. Ham is a popular choice for curing,
but you can use anything from beef to venison and much more in between.
With a good piece of meat, you really can't go wrong, although the first-time
curers might want to go with a more forgiving piece of meat, like pork belly or
pork butt.
For the most part, use meats with whole muscle groups in their anatomical
connection. Pork loin and belly, beef hindquarter or brisket, mutton legs and
even duck breast are popular cuts for dry-curing.
2.)
If necessary, trim off any excess fat, tendons, or meat. Say you're trying to
make Capicola charcuterie. You might buy a boneless pork shoulder, and then
cut the picnic end of the pork shoulder from the pork butt, leaving you with
two distinct cuts of meat. You can then use the picnic end of the shoulder in a
sausage, for example, and the butt in your dry-cure charcuterie.
3.)
For larger cuts of meat, consider stabbing the meat with a prong for better salt
coverage. You don't have to stab the meat before applying the dry rub, but for
certain cuts of meat — larger cuts or cuts like pork belly, which are often
covered with a lining of fat — stabbing the meat allows the salt and nitrite mix
to penetrate deeper into the meat, improving the efficiency and effectiveness of
the cure.
55
4.)
Decide whether you want to cure with a pre-mixed curing salt or mix your
own.Dry-curing with salt will sap away the moisture from the meat and
intensify the flavor of the meat, but it still won't eliminate the possibility of
botulism spores germinating.[2] To combat botulism, sodium nitrite is often
used in combination with salt as "curing salts," "Instacure #1," and "pink
salts." Botulism is a dangerous illness characterized by paralysis and
respiratory problems caused by the bacteria Clostridium botulinum.[3]
 Consult manufacturer's instructions for how much curing salt to use alongside
regular salt. Usually, a 10:90 ratio of pink salt to regular salt is called for.
 If you are particular about exactly what goes into your cured meat, it might be
best to add the sodium nitrite on your own. (See next step.) Most casual curers,
however, will find it easiest to use pre-mixed curing salts, where they won't
have to fuss with the ratio of salt to sodium nitrite.
 Why are pink salts pink? Manufacturers of pink salt purposely dye the salt for
cooks so that they don't confuse curing salt with regular salt. That's because,
in large quantities, sodium nitrite is toxic.[4] Accidentally using pink salt
instead of regular salt in your chicken soup, for example, could be very
unfortunate. The pink dye itself does not influence the final color of the cured
meat; the sodium nitrite does.
5.)
Use a ratio of 2:1000 sodium nitrite and salt, if mixing your own curing salt. If
you want to make your own curing salts, be sure to nail the ratio of sodium
nitrite to salt. For every 2 grams (0.071 oz) of sodium nitrite, for example, use
1,000 grams (35.3 oz) of salt. Another way to do this is to take the total weight
of your salt, multiply it by .002, and use that much sodium nitrite in your mix.
56
6.)
Mix up your spices along with your curing salt. Spices add a rich dimension of
flavor to your cured meats. While it's important not to get too carried away and
spice the meat to oblivion, a good spice mix will intensify flavors and add
distinct profiles to your cures. In a small spice grinder, grind up your spices
and add them to the curing salt/salt mixture. Here are some suggestions for
spices to use:
 Peppercorns. Black, green, or white are essential in most spice mixes. There's a
reason they call peppercorns the "master spice."
 Sugar. A little Demerara sugar adds a touch of caramel sweetness to your cure.
 Coriander and mustard seed. Adds smokiness to the meat.
 Star anise. Silky and slightly sweet, a little bit goes a long way. Slightly nutty.
 Fennel seed. Adds a pleasantly green or grassy dimension to the cure.
 Citrus zest. Adds a light, pleasantly acidic element that cuts through fattier
pieces of meat.
7.)
With your hands, rub the curing salt and and spice mix over the entire cut of
meat. Cover a tray with parchment and line the bottom generously with your
curing salt and spice mix. Place your meat on the bed of curing salt (fat side
up, if appropriate) and cover the top of the meat with your remaining mix for
equal coverage. If desired, cover the top of the meat with another piece of
parchment, then another tray, and finally a pair of bricks or another heavy
object to weight the meat down.
 Do not use metal trays for this step without parchment. The metal reacts with
the salt and sodium nitrite. If using a metal tray for underlayment, always use
a piece of parchment between it and the salt mix.
 If you have a round piece of meat and want to keep it (more or less) round, you
don't have to weight it down. The salt will do its job naturally. Weighting down
is preferable for a pork belly, for example, that you later want to roll into shape.
57
8.)
Refrigerate the meat for 7 to 10 days. Allow for adequate airflow by leaving at
least a small portion of the meat uncovered. After 7 to 10 days, a lot of the
moisture should have been drawn out by the salt.
9.)
After 7 to 10 days, remove from the refrigerator and rinse off all the salt/spice
mix. Under cold water, remove as much of the salt/spice mix as possible and
allow to briefly air-dry over an elevated rack. Take a paper towel, as insurance,
and wipe away any excess moisture before proceeding to the next step.
10.)
Roll up the meat (optional). Most cured meats will not need to be rolled into
shape at this point, but some will. If you're taking pork belly, for example, and
trying to make pancetta, you want to start with a rectangular piece of pork
belly and roll up the longer end very tightly. The tighter the roll, the less space
there is for mold or other bacteria to inhabit.
58
If you are rolling the cured meat, it helps to start with an even square or,
usually, rectangle. Cut off pieces of meat on all four sides until you have a neat
rectangle. Save the scraps for soups or render off the fat separately.
11.)
 Wrap the meat in tightly cheesecloth. Tightly wrapping the meat in

cheesecloth will help wick away any moisture that forms on the
outside of the meat, keeping it dry while it ages. Fold the
cheesecloth over both sides of the meat, bunch the cheesecloth up
at both ends, and tie the ends into knots. If possible, create a
second knot at the top of the cheesecloth into which you can pry
your hanging hook.
12.)
Truss your meat to help it keep its shape while it ages (optional). Especially if
dealing with a rolled piece of meat, trussing will help the meat stay tightly
rolled and keep its shape. Use butcher's twine and simply tie off every inch
until the length of the meat is trussed. Remove any dangling pieces of twine
with shears.
13.)
Label the meat and hang in a cool, dark place for anywhere from two weeks to
two months. A walk-in refrigerator is ideal, being cool and dark, but anywhere
59
that doesn't get a lot of light and doesn't exceed 70 degrees Fahrenheit (21
degrees Celsius) will work.
B. Wet-Curing Meat
1.)
Choose your piece of meat. Wet-brining is great for ham or other smoking
recipes. Try wet-curing your Christmas ham, for example, and then finishing it
off in the smoker for a delicious recipe.
2.)
Mix up your brine cure. Making a simple brine, and then adding the nitrites in
the curing salt (which will cure the meat) is all it takes to wet-cure meat. Try
this basic brine recipe, or research brines with added nitrite for a different kind
of taste. In one gallon of water, bring the following ingredients to a boil and
then allow brine to cool completely:
 2 cups brown sugar
 1 and 1/2 cups kosher salt
 1/2 cup of pickling spice
 8 teaspoons of pink salt (not to be confused with sodium nitrite)
3.)
Place your meat in a brining bag. A brining bag is essential for larger cuts of
meat, like a Christmas ham. Smaller cuts of meat can simply go in resealable
60
freezer bags, but make sure that there's enough room for the meat and brine to
rest comfortably in. For larger cuts of meat, Place the brining bag in a larger
tub or container first, and then fill with brine. Add 1⁄2 gallon (1.9 L) to 1 gallon
(3.8 L) of ice water to the brine to dilute
the concentrated brine. Mix thoroughly before sealing.
4.)
In the refrigerator, brine your meat one day for every two pounds of
meat. If you have a five pound piece of meat, brine for approximately two and a
half days. Turn the meat every 24 hours if possible. The salt in the brine tends
to be thicker on the bottom half of the brine and turning the meat allows the
brine to work evenly.
Change the brine after 7 days during the curing process to help prevent
spoiling.
5.)
Rinse the cured meat thoroughly in fresh cold water to get rid of the
crystallized salt on the surface of the meat.
6.)
Set the meat on a wire mesh screen to drain for 24 hours in a well
ventilated area and store in the refrigerator for up to 30 days.
61
7.)
Smoke the meat. Wet-cured meat, such as ham, is great after smoking.
Smoke your wet-cured meat in a smoker and serve on a special occasion.
Learning Outcome 5 Pack processed and cured meats
Guide To Product Packaging For The Food Industry
Great packaging is a must for anyone producing physical goods. It tells

your customers about your company, your product, and what you stand for.
Not only do you have to get creative with your packaging, you need to attract
your customers and get them excited to buy. When it comes to packaging food,
however, there are even more things to consider.
You have to be attractive and attention grabbing to your customers, you have
to address every type of food separately; each having its own shelf life,
protection requirements, and regulations that need to be adhered to.
Taking all of that into account, and making your product look great? It’s a tall
order. With careful foresight, your packaging can protect and preserve your
food products, as well as help garner brand loyalty and ensure high sales.
Know Your Product
Obviously you know what you’re selling. But do you know enough? The more
intricate your knowledge is of your product the better, especially when you
attempt to package it. Ask yourself:
 Do you know all the ingredients of your food products?

 What kind of preservatives will you need to keep things fresh?
 Are there any allergens you need to warn people about?
Allergens are an important consideration, not just in the food products, but
elsewhere in your facility. Facilities that process nuts, dairy, or shellfish need
to have certain best practices set in place so that cross contamination is kept
to a minimum.
The Food Allergen Labeling Act requires you to be compliant, especially if you
process any of these 8 major allergen groups:
 Milk
 Eggs
 Fish (e.g., bass, flounder, cod)
 Crustacean shellfish (e.g., crab, lobster, shrimp)
 Tree nuts (e.g., almonds, walnuts, pecans)
 Peanuts
 Wheat
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 Soybeans
Be sure your facility is compliant with the Food and Drug Authority if you
process any of the major allergen groups. Any sort of mislabeling can be
disastrous to your brand!
It also wouldn’t hurt to properly vet any third party packagers you might deal
with for the same reasons. There is grunt work involved with this. Properly
cleaning and maintaining your machinery is just as important as packaging
your product safely.
There are rules and regulations laid out by both the FDA about this:
You should know what nutritional information, dates, and ingredients you
need listed on your package. The FDA recently began updating the nutrition
labeling guidelines for the first time in 20 years, so make sure you are clear on
what is required to be on your packaging and labeling before you go to market
with new foods. If you aren't confident in compliance, finding a food labeling
consultant is never a bad idea.
Protection
Product packaging in the food industry is unique because it must allow the
contents inside to stay fresh and safe for consumption, even after long hours of
shipment and distribution. Because of this, certain products will require
specific types of packaging materials that protect them against temperature,
manhandling, etc. Frozen food, dry grocery items, and perishables each need a
different type of packaging to maintain freshness. It is also important to choose
a packaging material that will withstand contamination.
Another important part protecting your product is making sure whoever is

involved in the packing knows the product as well as you do. Different food
items have different material requirements.
Different barrier materials can affect the overall look of your packaging, and
work better with certain films. Fresh foods like meats and produce will
need anti fog additives to maintain visibility and visual appeal.
Working with a packaging professional can help you choose the best materials
for your specific products. They will know which combinations work best, and
can help maintain your product's’ shelf life.
Budget
You can’t consider your packaging suppliers without first considering

budget. Packaging definitely doesn’t come cheap. In fact, packaging usually
costs about 10% of the overall cost of your product. When you add in
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production costs, shipping, and distribution, you might be stretched a little
thin when it comes to packaging your product.
Understand the costs of the total production FIRST, and then source your
materials and labor. If your business cannot afford its ideal packaging design,
don’t give up on it. Food packaging is constantly evolving and changing, so in a
year or two your design could very well be within reach.
Trends
On that note of an always-changing industry, packaging trends can play a big

role on your design. For example, eco-friendly packaging is taking off with great
popularity in multiple industries, including food and beverage.
Keep an eye on your competition, too. Don’t be the last one to jump on a
packaging trend! Staying on top of trends will provide insights as to what
elements of design are standard for certain products, and what can be
improved on. Be careful, however. While it is certainly important to be
innovative in your packaging design, deviating too much from widely-
recognized norms can actually confuse consumers and drive them away from
your product. Bottom-line: During your packaging design process, try your
best to strike a balance between being creative and being familiar.
Check out some excellent packaging in your industry to get inspired. Speak to
your target market in every step of your design, from the certifications you
choose to display, to the packaging material and its impact on the
environment.
Brand Personality
A product’s packaging design should reflect the brand image of the company
that manufactured it, and food product packaging is no exception. Make sure
that the packaging chosen for your business’s food product appeals to your
target audience.
As previously mentioned, your business’s packaging design shouldn’t deviate

too much from universally-recognized norms, yet it should help your brand
differentiate itself from others. The way a product is presented can be the
determining factor between your brand being purchased over another. The way
your packaging is designed can influence a consumer to purchase in many
ways. Packaging in the food industry has extremely specific considerations that
require forethought in order to prevent products from being tainted before
reaching your consumers. Keeping these factors in mind and being creative in
your design can draw in your target market and have a positive impact on your
bottom line.
Tiny things like the colors of certain elements of the packaging or whether or
not the package is resealable can make or break the purchase. The key is to do
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the proper research on your target markets and identify what your ideal
customers want or what they struggle with.
Types of Packaging
Food packaging is in immediate contact with food, or is used to contain it from

its production to final delivery to the customer. This packaging is used to
protect the food from external influences, alterations, contamination and
adulteration.
Its main purposes are protection, preservation and providing information such
as best-before date, manufacturing date, batch number and nutrition facts.
Health authorities typically describe the packaging as the container meant to
ensure the preservation, transportation and handling of food products.
The main types of food packaging are:

 glass containers
 vacuum packaging
 tetra pak containers,
 plastic packaging,
 tin packaging,
 cardboard packaging,
 wood packaging,
 long-life packaging,
 ice cream packaging,
 metal packaging,
 laminated packaging,
 juice packaging.
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66
Unit of Process Foods by Fermentation and Pickling

competency
Module Title Processing Foods by Fermentation and Pickling
Learning Outcome 1 : Prepare equipment, tools, materials and

utensils
Unit Descriptor This unit deals with the knowledge, skills and
attitudes required to process foods by fermentation and pickling
Tools Used in Fermentation
There are some other processing equipment, tools and utensils as

discussed in the previous topics, that will be used in pickling and
fermenting of fish, fruits and vegetables. Enumerated are still some of
the tools to be used:
1. Brix hydrometer- an optical instrument that measures the

concentration of sucrose or a sucrose and water solution
2. Dial thermometer- an instrument used to check the temperature

when pasteurizing vinegar
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A dial thermometer can be calibrated either by hot or cold method.
For hot method:
 Dip the dial thermometer in boiling water and turn the dial to read
100°C (212 °F)
For cold method:

 Dip the dial thermometer in a glass filled with crushed ice and
adjust the dial to 0°C (32°F). Make sure not to touch the bottom
part of the container or casserole as this would give different
temperature to the temperature. Dial thermometer can also be
used in measuring the temperature of the cold liquid.
3. Graduated Cylinder- a device with graduation designed to measure

the amount liquid ingredients like brine solution, water, and the like,
This is available in 100 ml, 250 ml, 500 ml and 1000 ml.
Graduated cylinder is used by pouring the liquid and bringing the

cylinder to eye level. The volume of the liquid material is taken by
reading the milliliters (ml). it is then recorded and cleaned after use.
After all tools are used and calibrated, proper cleaning and sanitizing are done.
Cleaning and sanitizing are important in combating the bacteria present prior
to food preparation. Wiping and removing dirt are done to remove dirt followed
by using detergents and soap plus chlorine to totally eradicate the bacteria
present.
Cleaning, sanitizing and disinfecting then reduces consumers’ rejection,

complaints, and even the possible return of products. Facilitating preventive
maintenance, continuous cleaning, and checking of equipment, tools, and
utensils before and after preparation of food can benefit the products,
consumers and the manufacturers.
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Sorting and Grading of Vegetables
Unlike fish and meats, vegetables and fruits have higher perishability
and greater variation. That is why it is important to know how to select the
good quality of fruits and vegetables. Sorting and grading of fruits and
vegetables are based on size and ripeness. It is important to be familiarized
with the characteristics. Fruits are of good taste when ripe. Fruits must be
preserved and vegetables must be cooked immediately to prevent any damage
in the vitamin content of some fruits like the ascorbic acid in bananas which is
greatly affected when overripe.
Fruits and vegetables are sorted by size, color and rind quality after they
are harvested. Vegetable quality depends on favorable conditions of their
growth, the season of their harvest, the variety of the fruits, degree of maturity
size and uniformity of shape and the presence of defects. Injured, bruised and
misshaped appearance of fruits and vegetables.
Common characteristics to choose when buying fruits:
 Should be fresh, particularly those harvested in the morning

 Have better quality especially those that are in season but should
be cheap
 Ripe, having firm and smooth texture; avoid buying overripe ones
 With attractive appearance
 With good color and aroma
 Cook immediately when overripe
Common characteristics to choose when buying vegetables:
 Should be cheap if in season and should be plenty

 Free from bruises or blemishes that may impair its appearance
when cooked
 Good quality vegetables that will best suit best suit the particular
purpose in cooking and possibly consider the cost
 Not wilted, choose leafy green vegetables that are
 Fresh and young or newly harvested
Fruit and Vegetable Preparation
Fruits and vegetables require different cutting techniques when prepared.

Enumerated are the techniques used in cutting fruits and vegetables:
i. Chopping- slicing or cutting of vegetables in uneven, small,

irregular shaped pieces.
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ii. Mincing- Chopping/cutting fruits and vegetables into fine
cuts
iii. Slicing-Cutting fruits having uniform thin slices or cuts
iv. Peeling-Removing the cover of fruits and vegetables
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v. Dicing- Cutting vegetables or fruits into smaller pieces with
uniform cubes, approximately ¼ inch to ¾ inch cube
vi. Julienne strips- cutting vegetables or fruits into thin small

strips about ½ inch by 2 ½ inches long
vii. Diagonal slicing- Cutting fruits or vegetables diagonally
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Self Check 2.1
A. Write true if the statement is correct and if incorrect write the correct
word or words that will make the statement true.
1. _______ A dial thermometer can be calibrated either by hot or
cold method.
2. _______ Fruits and vegetables are sorted by size, color and
rind quality one month after they are harvested
3. _______Cutting fruits and vegetables into smaller pieces with
uniform cubes approximately ¼ inch by ¾ inch cube is
julienne strip cut
4. _______ Peeling is removing the cover of fruits and vegetables
5. _______ Diagonal slicing is cutting fruits and vegetables
diagonally
Answer Key 2.1.1
1. True
2. Right after
3. Dicing
4. True
5. True
Task Sheet 2.1.2
Perform Fruit and Vegetable Cutting Techniques
Title : Perform the different ways of cutting fruits and vegetables
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Instruction : By group of five members, assign to bring the different
vegetables for demonstration of cutting techniques and methods. Each
member shall take turn in performing the following techniques:
Materials :
 Carrots
 Cucumber
 Onions
 Knife
 Cutting/chopping board
Chopping
Mincing
Slicing
Peeling
Julienne Strip Cut
Diagonal Slicing
Dicing
CRITERIA YES NO
Did the candidate perform the following cutting techniques?
Chopping
Mincing
Slicing
Peeling
Diagonal Slicing
Dicing
** NOTE: IF STUDENT GOT 100% CORRECT ANSWER IN THIS TASK, HE/SHE
CAN NOW MOVE ON TO THE NEXT INFORMATION SHEET. IF NOT, REVIEW
THE INFORMATION SHEET AND GO OVER THE TASK AGAIN
Selecting and Preparing Fish and Other Marine Products for Fermentation and
Pickling
Sorting and Grading
After harvesting fish, it needs to be sorted and graded immediately to prevent

deterioration or changes in physical and chemical attributes due to its perishability.
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Maintaining the Freshness of Shellfish
1. Avoid the fish from struggling due to the onset of pre-rigor mortis
causing the fish flesh to stiffen at once.
2. Do not expose the fish to high temperature. Keep them in the shade
covered with wet burlaps or banana leaves
3. Eviscerate the fish when necessary to prevent autolytic changes because
its viscera or internal organs become the focal points for spoilage
4. Put ice while the fish is fresh to inhibit spoiling. Preserve them as quickly
as possible
5. Shellfish should be alive until it is cooked and processed. Crustaceans
like shrimps, crabs and mollusks should be handles properly and kept
alive until cooked. For shrimps, they could be preserved immediately
with ice to maintain its freshness.
6. Sort or classify the shell fish to prevent contamination leading to
spoilage.
Preparing Fermented or Pickled Fish and Shellfish
A. Preparing wet fish
Nowadays, because of the busy schedule, most consumers prefer buying

fish that are already cut according to their preferences.
Market forms or cuts to prepare fish for pre-treatment processes:
1. Live fish or whole round- transported and marketed alive. All parts
are intact and may be alive or dead.
2. Drawn Fish- fish has been eviscerated or gutted by making a slit on

the ventral side to remove the viscera or internal organs
3. Dressed Fish- the fish is drawn further to remove the gills, fins,
scales, head, and tail. This is already prepared for cooking or for
special preparation to improve the presentation
4. Steaks- this a cross section of a fish cut approximately at right angles

to the backbone or cut from dressed fish similar to chunks.
5. Fillets- Fleshy or meaty section of a fish removed from the backbone

and ribs of the fish. Fillet can be of different styles
a. Block Fillet/butterfly- the flesh from both sides of a

single fish usually joined along the back cut from
dressed fish. This is done by dressing the fish and
splitting after.
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b. Cross-cut fillet- a fillet from flat fish where the flesh
from each side is removed as a single piece
c. Quarter-cut fillet- a fillet from flat fish, the flesh from

each side is cut off in two pieces.
d. Single fillet- The flesh from one side of the fish
e. Sticks- are small elongated chunks of uniform size and

thickness cut from the fleshy portion of the fish.
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B. Cleaning and Eviscerating Fish
Cleaning and eviscerating are done by making a slit on the belly cavity of the
fish to remove the gills and fins. In some cases, scaling is done with the use of a knife
or scaler beginning from the tail toward the head. If head and tail are removed, cut off
gills with head followed by cutting the oval fin. For small fishes, cleaning is done by
removing the head and the gut in one stroke or using the index finger to nob.
C. Skinning Fish
Skinning fish involves the removal of the fish skin. This is done by
removing skin along backbone and cutting off a narrow strip of skin to
the entire length of the backbone. To do this, loosen the skin from top to
bottom then draw the skin off toward the tail. Make sure fish is fresh so
that skin can easily be drowned off.
D. Cutting Fish
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Most of the time, fishes are cut depending on the desired sizes and manner of
cooking or processing them. Consumer’s preference is always considered.
E. Dressing Fish
Usually, dressing of fish is done by removing the following:
 Fish head
 Tails
 Viscers or internal organs
 Scales
Steps in dressing fish:
1. Weigh the fish. Then wash it with clean water to remove the slime
2. Lay the fish flat on the cutting board. Holding the knife on the right
hand, and head of the fish with the left hand. Then scale the fish.
3. 3. Cut the tail and the head of the fish leaving only the trunk or body
of the fish.
4. Cut the dorsal and ventral fins using kitchen scissors.
5. Remove the internal organ and with the use of a sharp knife, scrape
the belly cavity, blood and false kidney.
6. Wash very well in clean water.
7. Weigh the dressed fish and determine the % left after dressing by
following the formula:
Net weight = weight of dressed fish x 100%

Weight of fish before cleaning
F. Splitting Fish
1. Weigh the fish (preferably milkfish)

2. Lay the fish on the cutting board with the head towards the worker
and the dorsal side along the edge of the table. Using a sharp knife,
cut on the nape through the head, keeping the knife hard against the
vertebral column.
3. Turn the knife facing the posterior end or tail portion and cut towards
the tail keeping close to the dorsal fin until it reaches the tail
4. Open out the fish like a butterfly with the use of knife but do not cut
through skin.
5. Remove the ineternal organs, gills, and black membrane (optional) or
peritoneal (black) lining.
6. Clean and split the fish.
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Self Check 1.3.1
1. Discuss the procedures in dressing fish
Answer Key 1.3.2
1. Weigh the fish. Then wash it with clean water to remove the slime
2. Lay the fish flat on the cutting board. Holding the knife on the right
hand, and head of the fish with the left hand. Then scale the fish.
3. 3. Cut the tail and the head of the fish leaving only the trunk or body
of the fish.
4. Cut the dorsal and ventral fins using kitchen scissors.
5. Remove the internal organ and with the use of a sharp knife, scrape
the belly cavity, blood and false kidney.
6. Wash very well in clean water.Weigh the dressed fish and determine
the % left after dressing
Fermentation of Fruits and Vegetables (Alcoholic)
Microorganisms may not always be harmful. Some are useful in

certain aspects like in the production of acid that is necessary to inhibit
the growth of microorganisms harmful you food.
Fermentation is the chemical conversion of carbohydrates like

sugar into alcohols or acids with the help of yeast under anaerobic
condition. A stuck fermentation occurs when fermentation stops prior to
complete conversion of sugar to alcohol. The action of microorganisms is
necessary to produce alcoholic beverages like wine, beer, and cider. It
produces lactic acid in sour food such as pickled cucumbers, yogurt, etc.
Three types of Fermentation:
o Alcoholic fermentation
o Acetic Acid Fermentation
o Lactic Acid Fermentation
b. Alcoholic Fermentation- the simple sugar in the food is

converted to ethyl alcohol by the action of enzymes and yeast
under suitable conditions of temperature. Fruit juices may
be fermented directly into wine by alcohol producing yeast.
Kasuy, pineapple, duhat, bignay and guava are examples of
fruits that can be made into wine.
Fermentation process of fruits and vegetables:
1. Selecting and preparing the fruits - Proper selection and

preparation of fruits mainly contribute to the success
of wine making. Fruits should be containing sufficient
sugar. The flavor of wine depends on the kind of fruit
that may be used. If fruits used are matured or ripe it
should be made sure that it has no blemishes that
may then affect the quality of the wine being produced.
2. Preparing and pasteurizing the juice- In order to extract

more juices from the fruits, it should be crushed or
mashed by using press or hand. Then with the use of
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cheesecloth, it is strained to get the juice. Dilute the
extracted juice adding 2 parts of water to increase the
quantity of fermented materials. Sugar may be added
depending on the desired sweetness of wine. Pasteirize
the sweetened juice. Allow the pasteurized mixture to
cool afterwards.
3. Fermenting the pasteurized juice- to hasten

fermentation process, add a small amount of baker’s
yeast or commercial yeast preparation to the mixture.
Pour the mixture in an open glass or enameled
container covered with a piece of cheesecloth of fine
mesh. Allow fermentation to take place within 48
hours after preparation. One way of knowing if
fermentation is successful is if froth or mass is
produced misture.
4. Sorting and Aging- When the fermentation is on

process, transfer the mixture to a suitable container,
preferably a wooden barrel or other similar container.
Cover the hole with cotton and keep the preparation
undisturbed. Store in a dark, quiet place for about 3
months or until no more gas evolves. This is an
indication that the mixture has aged completely and
proceed to the next step to clear the mixture or wine
produced.
5. Clearing of wine- to clear the wine, heat in a steam to a

temperature of 50°C to 60°C. Add well-beaten egg
whites (5%) to one liter of wine and stir the mixture
thoroughly. Maintain the temperature for 15 to 20
minutes and cool. Siphon and filter to remove
unnecessary residues.
6. Pasteurizing the filtered mixture. Pasteurize the filtered

mixture at 80°C for 20 minutes to kill microorganisms
that may cause spoilage.
7. Bottling- Pour the aged pasteurized wine in clear,

sterilized bottles and label if desired.
Wines Using Different Fruits
Pineapple Wine
Ingredients:
4 cups fresh pineapple juice

1 cup sugar
1 tablespoon dry yeast per 15-20 liters of juice
5% egg white by volume of wine
Procedure:
1. Extract the juice of ripe pineapples and measure
2. Add 1 cup of sugar per quart of extracted juice. Stir very well.
3. Heat to 60°C. Cool to lukewarm.
4. Add 1 tablespoon of active dry yeast per 15-20 liters to heated
juice placed in a clean, narrow necked flask. (1 ½ tsp. per quart
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juice)
5. Plug the mouth of flask loosely with sterile cotton for
fermentation.
6. At the desired end point of fermentation which is shorter for
sweet wines than for dry wines, heat wine to 50°C.
7. Decant clear and aged liquid in containers for at least a year.
8. After period of aging, clarify by heating wine in a steam bath to
60°C.
9. Add 5% beaten egg whites, based on volume of wine. Stir and
maintain temperature for 15 minutes. Cool and filter.
Guava Wine
Ingredients:
2 cups guava, ripe

1 1/3 cups sugar active dry yeast
4 cups water
Procedure:
1. Choose only ripe and sound fruits. Cut into squares and
measure
2. Boil water and fruit together until fruit is soft. Strain and
measure juice. Add the sugar to the juice.
3. Heat to 70°C and cool before adding yeast in the same
proportion as for pineapple wine up to clarification, if
desired
4. Heat to 70°C and cool before adding yeast in the same
proportion as for pineapple wine up to clarification, if
desired

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Acetic Acid/Lactic Acid Fermentation
Acetic acid is produced when various substances like starchy

solution, sugar solutions or alcoholic food like wine or cider are allowed
to ferment. Food is preserved by fermentation through metabolic
activities of selected groups of microorganisms where compounds such
as lactic acid, acetic acid, and alcohol are developed. It resulted to a
more or less stable form, hence it makes food more nutritious as a
dietary source of proteins, vitamins and minerals.
Weak fermented liquors like coco water with yeast become sour
due to the conversion of alcohol to acetic acid when exposed to the air.
Acetic acid is produced by fermenting various substrates such as starchy
solution, sugar solutions, or alcoholic food such as wine or cider with
acetobacter bacteria.
Vinegar is a product of acetic acid fermentation that undergoes two
phases which are: (1) alcoholic fermentation and (2) acetic acid
fermentation. In the first stage, raw materials containing sugar are
fermented to alcohol by the action of yeast which is normally observed
when coco water is used in making vinegar. After pasteurization and
when fermented for a week, the coco water with the addition of sugar and
yeast will undergo alcoholic fermentation. In the second stage, liquor is
converted to dilute acetic acid by acetic acid bacteria. This is the last
phase of fermentation in coco vinegar making, allowing the solution to
turn sour in taste. Vinegar or native vinegar has gone a long way from
being used at home to an export quality product. This is considered as a
by-product of fruit and wine processing. People who prefer the native
vinegar choose to consume sasa or sugar cane vinegar. The Acetobacter
aceti which is normally used to produce vinegar can make vinegar up to
14% acetic acid. When cider, wine, or malt are used as starting
materials, only about5% acetic acid are produced.
Raw materials used for vinegar making

 Peels from cores of fruits
 Sugar cane juice from sugar cane or tubo
 Potatoes/Sweet potatoes
 Pine apples, bananas, oranges
Procedure in making vinegar
1. Combine fruit peels and cores. Grind or crush them. Boil in water
until it reaches the desired softness. Then strain the juice through a
cheesecloth.
2. Add ¼ pound of sugar for every liter of juice extracted from fruit peels
and cores. Do not add sugar when using ripe fruit because ripe fruits
are sweeter.
3. Add ¼yeast for every liter of juice. Stir very well then place in glass
jars. Cover with a clean cheesecloth and let the mixture stand fopr
about two weeks to undergo alcoholic fermentation.
4. After two weeks, separate the clear liquid from the sediment. Prepare
fresh unpasteurized vinegar (mother vinegar) which is the white
gummy mass that usually forms in the vinegar. Add this to the liquid
and mix very well to undergo acetic acid fermentation. Cover and
allow to stand for weeks until a sour taste or strong aroma enough to
use is attained.
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5. Pasteurize to kill the bacteria. Filter the clear liquids, then pour in a
bottle and cover tightly ready for bottling.
Coconut Water Vinegar
Ingredients:
4 cups coconut water

¾ sugar
¼ tsp. yeast
1 cup vinegar starter
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Procedure:
1. 1. Using a cheesecloth or fine strainer, strain fresh coconut water to

2. remove the dirt or fine strain of coconut husk.
3.
4. 2. Measure the required coconut water and ingredients.
5.
6. 3. Dissolve ¾ cup d sugar in 4 cups coconut water and stir well ready for
pasteurization
7.
8. 4. Place in an enameled/stainless casserole and pasteurize by heating at 65°C
for 10-15 minutes. Use dial thermometer to check the temperature of
pasteurized solution.
9.
5.Transfer and pour sterilized glass jars, half filled. Cool and add ¼ tsp. dry yeast by
dissolving it in lukewarm coco water solution or separately in a cup.
6. 6. Cover the container with a clean cheesecloth or paper for sanitary purposes
and to hasten fermentation process. Allow the sugar solution to ferment for 4-7
days or until there are no more bubbles or carbon dioxide formed. This is
alcoholic fermentation, the first stage of fermentation.
7. Decant or filter the alcoholic solution to remove the yeast and other
solid materials. Pasteurize the alcoholic solution to 60-65°C (2nd time) using the
device to cool immediately
8. Add 1 cup vinegar starter to 4 cups alcoholic solution. Cover with

clean cheesecloth to allow the start of acetic acid fermentation, the 2nd and the
last stage of fermentation to occur to allow the presence of useful bacteria to
obtain sour taste. Let it stand for 1 month until the desired aroma and flavor
are attained. Allow the vinegar to age in glass or bottle container which is filled
to full capacity. Filter again.
9.Pasteurize again (3rd time) at 60°C to 65° to kill the microorganisms before
bottling the product. Filter until the vinegar becomes clear.
10. Bottle, label and store.
Self Check 1.5.1
Arrange the correct procedure in fermenting vinegar by writing the

correct number
___ Decant or filter the alcoholic solution to remove the yeast and other solid
materials. Pasteurize the alcoholic solution to 60-65°C (2nd time) using the
device to cool immediately
___ Transfer and pour sterilized glass jars, half filled. Cool and add ¼ tsp. dry
yeast by dissolving it in lukewarm coco water solution or separately in a cup.
___ Bottle, label and store.
___Cover the container with a clean cheesecloth or paper for sanitary purposes
and to hasten fermentation process. Allow the sugar solution to ferment for 4-7
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days or until there are no more bubbles or carbon dioxide formed. This is
alcoholic fermentation, the first stage of fermentation
____ Using a cheesecloth or fine strainer, strain fresh coconut water to
remove the dirt or fine strain of coconut husk.
____ Dissolve ¾ cup d sugar in 4 cups coconut water and stir well ready for
pasteurization
____ Add 1 cup vinegar starter to 4 cups alcoholic solution. Cover with clean
cheesecloth to allow the start of acetic acid fermentation, the 2nd and the last
stage of fermentation to occur to allow the presence of useful bacteria to obtain
sour taste. Let it stand for 1 month until the desired aroma and flavor are
attained. Allow the vinegar to age in glass or bottle container which is filled to
full capacity. Filter again.
____ Measure the required coconut water and ingredients.
____ Place in an enameled/stainless casserole and pasteurize by heating at

65°C for 10-15 minutes. Use dial thermometer to check the temperature of
pasteurized solution.
____ Pasteurize again (3rd time) at 60°C to 65° to kill the microorganisms before
bottling the product. Filter until the vinegar becomes clear.
Answer Key 1.5.2
1. 7
2. 5
3. 10
4. 6
5. 1
6. 3
7. 8
8. 2
9. 4
10. 9
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Task Sheet 2.1.3
Title : Perform the procedure in making vinegar from coco water
Instruction : By group of five members, assign to bring the different

materials in making vinegar with coco water.
Materials :
4 cups coco water

¾ cup sugar
Wide mouth plastic/glass container or jar
Cheese cloth
Kitchen tools
1 cup vinegar starter
¼ tsp. yeast
PPEs
Procedure:
1. Strain freshly collected coco water and measure
2. Add ¾ cup sugar to 4 cups coco water
3. Pasteurize for 10-15 minutes at 60-65°. Use dial thermometer to check

the temperature. Pour in the container.
4. Cool the solution and add yeast to allow the alcoholic fermentation to
set in for 7 days.
5. Filter to remove residues of yeast and pasteurize again
6. Transfer in another container and add 1 cup vinegar starter to 4 cups

alcoholic solution. Allow to stand for 1 month to undergo acetic acid
fermentation until the desired aroma is reached
7. Filter and pasteurize again to finally kill bacteria
8. Pour in the container or bottle.
9. Label the product
** Note: if student got 100% correct answer in this task, he/she can now move
on to the next information sheet. If not, review the information sheet and go
over the task again
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Performance Criteria
Criteria Yes No
Did the student...
1. Strain freshly collected coco water and
measure?
2. Add ¾ cup sugar to 4 cups coco water?
3. Pasteurize for 10-15 minutes at 60-65°.

Use dial thermometer to check the
temperature? Pour in the container?
4. Cool the solution and add yeast to allow

the alcoholic fermentation to set in for 7
days?
5. Filter to remove residues of yeast and

pasteurize again?
6. Transfer in another container and add 1

cup vinegar starter to 4 cups alcoholic
solution? Allow to stand for 1 month to
undergo acetic acid fermentation until
the desired aroma is reached?
7. Filter and pasteurize again to finally kill

bacteria?
8. Pour in the container or bottle.?

9. Label the product?
Performing Lactic Fermentation
Lactic Fermentation is due to the action of certain bacteria called lactic

acid allowing the sugar present in vegetables to ferment. Examples of
vegetables that have undergone lactic acid fermentation are burong mangga,
onions, cabbage and cucumber. The main objective of fermentation is to allow
the conversion of fermentable carbohydrates or sugars found in vegetables into
acid of 0.9% to 1.5% expressed as lactic acid. Salt medium is needed in order
for fermentation to occur.
Salt in Fermentation
1. Salt is essential in the fermentation process. A brine of about 5% to 10%

salt is sufficient for lactic acid bacteria to grow and to inhibit the growth
of other organisms and allow halophilic type to grow. Lower than 5% will
encourage the growth of proteolytic bacteria.
2. It allows the juices and other soluble substances to draw out in the
product through osmosis process. A concentration of 10% (40 degree
salometer) is best to maintain during fermentation period.
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Factors Affecting Lactic Acid Fermentation
1. Temperature of Fermentation.
The temperature should be favourable for the growth of lactic acid
and bacteria. A temperature of 30°C or 86°C allows organisms to grow.
Above and below those temperature will greatly affect the fermentation
process.
2. Rate of Fermentation.
The rate of fermentation process varies depending on the salt
concentration. Greater concentration of brine slows down fermentation,
the less the concentration, the faster the fermentation.
3. Kind of salt and water.

Pure coarse salt is better than fine salt. Too much chemicals in
salt hinders the pickling process making the pickled products soft due to
poor acid formation. Because of this, scum will appear on the surface
and if not removed will impair the appearance of the product. Besides,
the scum will serve as the medium where the organisms use the lactic
acid during fermentation allowing the growth of putrefactive organism
causing the softening and spoilage of pickles. One way of preventing the
formation of scum is by exposing the fermenting vegetables to sunlight.
Pouring a thin layer of neutral mineral oil on the brine surface will help
prevent this scum formation.
Characteristics of Quality Fermented Products
1. Brine becomes cloudy and milky white, an indication that the

fermentable carbohydrates have changed into acid.
2. In cucumber, the colour changes from bright green to olive or
yellowish green. The tissue becomes translucent compared to the
chalky white and opaque appearance of the fermented product. The
fermented cucumbers are known as “salt stock”. To remove salt from
the product, soak the cucumbers several times in warm water
maintained at 43°C to 57°C for 1 to 2 hours. To make the product
crisp and to intensify its color, alum and turmeric are often added in
the final water wash.
Preparation of Fermented Fruits and Vegetables
It has been studied that fermented fruits and vegetables are potential
sources of probiotics. In Asia, some common and popular fermented product is
the kimchi,( traditional Korean traditional fermented vegetable) sauerkraut or
sour cabbage ( Fermented vegetable from China).
Locally, the different vegetables are commonly fermented:
 Kamias
 Mustasa
 Cabbage
 Mangga
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Kimchi (prepared as a side dish) usually stored at low temperature to prevent
production of strong acid, over ripening, and extended period of optimum taste. It is
characterized by its sour, sweet taste differing from sauerkraut and pickles.
Ingredients:
 Cabbage or radish
 Green pepper
 Onion
 Ginger
 Salt
 spices
Procedure:
1. Prebrine the vegetables
2. Blend with various spices like red pepper, garlic, green onion, and ginger.
Add other seasonings and vegetables.
3. Ferment at low temperature (2°C-5°C). Fermentation usually last in one
week at 15°C, but took only 3 days if the fermentation temperature is at
25°C.
Burong Mangga- is the phrase that Filipinos use to refer to fermented green
mangoes in the Philippines. It’s simply a matter of pickling the fruit in salt.
Ingredients:
6 pieces of green mangoes (hilaw na mangga) with very firm flesh
half cup of white rock salt
2 cups of water
Procedure:
1. Wash the mangoes thoroughly in running tap water.
2. Peel and cut each mango into three flat pieces — the middle piece would be
the large, flat seed.
3. Shave the flesh off the side of the seed (if you do this skillfully, you’ll end up
with two long, fat slivers off each mango’s seed).
4. Slice up the remaining flesh into long, fat slivers.
5. Arrange the fat slivers upright in a large jar.
Meanwhile, prepare the brine solution by boiling the water and the salt for five
minutes. Let cool.
6. Pour the brine mixture into the jar.

7. Cover the jar loosely and let it ferment.
8. After three days, tighten the cap and place the jar in the refrigerator.
To get different flavors, experiment with the brine solution. Add sugar or, for
color, small chili peppers that Filipinos call sili.
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Self Check 1.6.1
Write T if the statement is correct and F if incorrect.

1. ____ Kimchi is a Korean side dish that always placed in high temperature
2. ____ It has been studied that fermented fruits and vegetables are
potential sources of probiotics
3. ____ Lactic Fermentation is due to the action of certain bacteria called
lactic acid allowing the sugar present in vegetables to evaporate.
4. ____ The main objective of fermentation is to allow the conversion of
fermentable carbohydrates or sugars found in vegetables into acid of
0.9% to 1.5% expressed as saturated sugars.
5. ____ To get different flavors, experiment with the brine solution
6. ____ in fermenting mangoes, Fermentation usually last in one week at
15°C, but took only 3 days if the fermentation temperature is at 25°C.
7. ____ Refined salt is better used in fermentation than pure coarse salt.
8. ____ Acetic acid is produced when various substances like starchy
solution, sugar solutions or alcoholic food like wine or cider are allowed
to ferment.
9. ____ When brine becomes cloudy and milky white, it is an indication that
the fermentable carbohydrates have changed into acid.
10.___ The rate of fermentation process varies depending on the salt
concentration
Answer Key 1.6.2

1. F
2. T
3. F
4. F
5. T
6. T
7. F
8. T
9. T
10.T
Pickling Fruits and Vegetables
As defined, pickling is a method of food preservation that uses vinegar

and other spices. Sugar can be added to prolong the shelf life of pickled
products like radish or papaya achara for more than a month if combined with
refrigeration method.
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Materials for Pickling and Pickling Solutions
The main ingredients in pickling solutions are vinegar, sugar, and other
spices. Pickling solution must be prepared with the right proportions to attain
a good pickled product desired. Vegetables should be firm, fresh, free from
blemishes, and well-washed.
Ingredients
1. Fruits and Vegetables
2. Vinegar- acts as preservative. Also gives flavor to pickles and makes the
product crisp. It should be clear, free from sediment, and should posess
4% to 5% acetic acid. Vinegar with low acid content causes the pickles to
become soft. Never use vinegar that has a darkening effect. Avoid
prolonged boiling for it depletes the acetic acid which is important in the
preservation of pickles.
3. Sugar- acts as preservative and increases the density of the pickling

solution. Also add sweetness to the pickles. Granulated white or light
brown sugar may be used. The amount of sugar depends on the kinds of
pickles to be made.
Kinds of pickles:
 Sour pickles- ½ cup sugar for every cup of vinegar
 Sweet and sour pickles- 1 cup sugar added to every cup of vinegar
 Sweet pickles- 1 ½ cup sugar for every cup of vinegar
4. Spices- Whole cloves, whole spices, celery seeds, mustard seeds,

cinnamon sticks, peppercorn, dill and garlic are some the common spices
added to pickled products. Spice gives flavor to the product. Fresh spices
should always be used for old spices may give undesirable flavor. Spices
should preferable not added directly to the pickling solution
Directions for use:
a. Tie the spices in a bag cheesecloth
b. Immerse this in warm pickling solution. Simmer.
c. Remove when the desired flavor is achieved.
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Spices should be used sparingly and it should not overwhelm the
flavor of the fruits or vegetables.
5. Other Preservatives- Alum (tawas) is added to improve the crispiness of

the pickles. Excessive use of alum is discouraged because it produces a
bitter after-taste which causes the softening of the pickles. Alum may be
added in the water used when washing salt from the fermented product
(2 tsps. Alum for every cups warm water) or it may be added to the
pickling solution (1 tsp. per pickling solution).Calcium chloride also
improves the crispiness of pickles. It can be added in the same way alum
is added (1/2 tsps. For every 4 cups of pickles). Pickles can be made
crispier through the use of a good vinegar (4%-5% acidity), water free
from mineral (soft water), and correct brewing procedure.
Preparation of Pickled Products
a. Preparing Pickles, Relishes and Chutneys
1. Prepare jars by sterilizing them for 10-15 minutes before use to kill
bacteria present.
2. Boil food in a large kettle or any casserole
3. Pack the product in glass jars allowing 3/16 of an inch for
headspace. Clean the rims of the jar by wiping with a clean damp
cloth.
4. Seal each jar tightly with its cover.
5. Place the sealed product in a kettle and simmer water for 15
minutes.
6. Allow the jars to cool and press the lid to check if seal is good. If
not, refrigerate or eat the contents immediately.
7. Store sealed jars in a cool dry place. Refrigerate after opening.
b. Homemade Papaya Achara
Ingredients:
4 cups green papaya
2 medium sized red/green bell pepper
1 large sized carrot
1 box raisin small
1 cup vinegar (4% acetic acid)
1 tsp. salt
1 cup white/washed sugar
2 medium sized onions
1 clove garlic
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Procedure:
1. Select good quality raw materials
2. Weigh, wash and peel, and grate vegetables according to desired
cut. Squeeze to remove juice extracted from papaya and drain.
3. Prepare sugar, salt and vinegar and mix thoroughly
4. Cook the solution until sugar dissolves
5. Pack the vegetables in sterilized bottle and pour solution while
hot. Observe proper headspace of 3/16 inch when filling into
jars. Remove bubbles.
6. Screw on caps and pasteurize for 5 minutes. Seal tightly
7. Cool and label. Refrigerate when opened.
**Proper measurement of the ingredients when cooking should
be observed, Hygiene and cleanliness should be obserbed.
c. Preparing Pickled mixed Vegetables
1. Select good quality of raw materials. Vegetables should be fresh,

free from any blemishes not and wilted
2. Weigh, wash, peel and cut vegetables according to standard
specifications.
3. Prepare pickling solution by heating vinegar until sugar dissolves.
4. Arrange the vegetables in the clean sterilized jar or bottles and
pour in the pickling solution. Remove air bubbles
5. Put on caps snugly and pasteurize in boiling water for 15 minutes.
Tighten caps by placing plastic seal using a blower or pouring
boiling water over caps with plastic seal attached.
6. Cool and label.
Fermentation of Fish and other Marine Products
Fermentation is defined as the process where fish is allowed to

decompose with the use of salt. When fish is decomposed, putrefaction occurs
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accompanied by a foul odor. But in this sense, decomposition of carbohydrates
takes place so no putrid or foul odor occurs due to the growth of useful
microorganisms that produce acids or alcohols that act as a food preservative.
It allows fermenting the fish until attaining a good quality fermented products.
Fermentation is one of the oldest methods of salting and at the same time the
oldest method of preparing fish. Fish paste or bagoong and fish sauce or patis
are produced using this method. Fish are died and salted and left to ferment so
the protein hydrolysis lakes place to produce paste and sauce. This involves
the use of salt. Some fish processors add papain or other enzymes to make the
fermentation period faster. In fermenting the fish the condition of the fish plays
an important role in producing good quality fermented products. Salt is an
important ingredient too.
Methods of Fermenting Fish and Other Fishery Products
1. Straining- separating the fish sauce from the fish paste

2. Filtering- pouring the sauce on a strainer or clean cloth to remove fish
paste from fish sauce or liquid
3. Cooking- heating the extracted sauce until done
4. Packing- pouring the patis in bottles
5. Cooling, labeling and storing- done by allowing the packed product to
cool at normal temperature before they are labeled and stored. The
product is then ready for consumption or marketing
Procedure in Fermenting Fish

1. Mix salt thoroughly with the fish ratio (halubaybay or anchovies are
preferred) of 1:4 (1 part salt to 4 parts fish) by weight or 20%. If 25% is
used, the ratio is 1:3 (1 part salt, 3 parts fish) by weight.
2. Add papain (enzyme from papaya) to shorten the fermentation process
(optional)
3. Pack the fish in plastic drum or glass container. Refrain from using
metallic container to prevent discoloration or chemical reaction to salt.
4. Store the fermented fish for a month to a year to develop the aroma
caused by the breakdown of proteins.
Sanitary Practices
1. Always wear PPEs for one’s safety and to assure clean, safe product
2. Wash and sanitize all utensils and equipment used to avoid any
contamination and for the consumers’ protection
3. Maintain cleanliness and orderliness during and after the process.
4. Sterilize the bottles.
Standards for fermented Fish and other Fishery products

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(As per BFAD Bureau of Food and Drugs)
1. Standard of Identity- patis should be a clear liquid sauce, straw yellow to

amber in color obtained from enzymatic fermentation of mixture of fish
and shrimps and salt. Having strong salty taste and fishy odor.
2. Standard of Quality- Patis should have the following composition:
A. Total solids- not less than 32%
B. Salt content-20-25%
C. Protein content varies with grade levels
(1.) For domestic trade
 Special- no less than 8%
 Regular-no less than 4.5%
(2.) For Export
 Special- no less than 8%
 Regular- no less than 6%
3. Level of Substandard Quality- fish of protein content not more than 4.5%
and no more less than 2.5%, shall be sold under the name patis flavor
4. Mandatory label of information
a. The label statement of class or type shall be in accordance with the
stated protein content
b. The name and address of manufacturer/producer should appear
c. Added preservative or coloring shall be limited to that approved as food
grade and should be indicated in the label.
d. Net content shall be no less than the amount stated in the label
Fermented Products
a. Patis
Procedure:
1. Select fresh fish. Wash with clean water
2. Mix fish with salt ( 1:3)
3. Pack tightly in jars and store for 6 months.
4. The liquid patis is extracted or drained producing first class patis.
They are then filtered and packed in bottles.
5. Second extraction (soli), saturated brine is added and aged for 2
weeks. Second class patis is produced and bottled.
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Flow Chart of Making Patis:
Securing Fresh Fish
Washing and draining
Mixing with salt (1:3)
Packing tightly in jars and storing for

6 months
Draining the liquid
Extracting Patis (FIRST CLASS) Solids residue
Filtering Ground and solid as Adding saturated brine

bagoong
Placing in bottles
Aging for 2 weeks
Second class Solid ground and sold as

bagoong
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Task Sheet 1.7
1. With the d]given ingredients, preapare bagoong either alamang or

anchovies (per group of 6 members)
Materials and Ingredients:
 1 kg. of anchovies (dilis)

 1 kg of alamang (small fish)
 Salt
 Glass jars/plastic containers
Procedure:
1. Wash the fish/alamang with clean water

2. For every 3 cups of fish/alamang, add 1 cup of salt and mix well.
3. Place the shrimp/fish and salt mixture in earthen ware pots
4. Avoid using metallic container to prevent any reaction of salt to the
container resulting to blackening of the product.
5. Cover the container tightly to keep away from flies and other insects that
might contaminate the food.
6. Let it stand for 2 weeks to 1 year to develop its characteristic aroma and
flavor.
Note: for fermented shrimps, 1 week will suffice to produce bagoong. For fish, let it
stand for months to 1 year as desired.
CRITERIA YES NO
Did the candidate perform the following procedures in making bagoong?

Procedure:
1. Wash the fish/alamang with clean water
2. For every 3 cups of fish/alamang, add 1 cup of salt and
mix well.
3. Place the shrimp/fish and salt mixture in earthen ware
pots
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4. Avoid using metallic container to prevent any reaction of
salt to the container resulting to blackening of the product.
5. Cover the container tightly to keep away from flies and
other insects that might contaminate the food.
6. Let it stand for 2 weeks to 1 year to develop its

characteristic aroma and flavor.
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Unit of Process Foods by Sugar Concentration

competency
Module Title Processing Foods by Sugar Concentration
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UNIT OF COMPETENCY : Process food by sugar concentration
UNIT DESCRIPTOR : This unit deals with the knowledge, skills and attitudes
required to process foods by sugar concentration which include to prepare
equipment, tools, materials and utensils, prepare the raw materials, pack
sugar concentrated products and perform post- production activities.
Manufacturer’s Specification on the Use of Equipment and Tools

Food processing equipment is provided with the manufacturer’s manual
which serves as a guide to workers of the proper use of the said equipment.
This contains specifications on the uses and other pertinent information that a
user must know about the equipment or device. It also provides necessary
reminder in the form of a sticker or warning label that is attached to the
equipment. This indicates that the equipment, machine, or tool is in excellent
condition and has passed the quality control in its construction and
fabrication.
Specifications to consider on the use of equipment and tools:
1. Preheat cooking equipment according to the manufacturer’s
recommendations. Failure to follow instructions can increase energy
usage or sometimes may cause damage to the equipment.
2. Use cooking equipment to full capacity. Fully loaded equipment utilizes
energy more efficiently.
3. Turn off ovens during low production periods to save gas and electricity.
4. Use the recommended capacity of food to be cooked in certain equipment
according to manufacturer’s recommended capacity. Overloading can
increase cooking time and energy consumption.
5. Do not open the refrigerator too often or when not needed. Frequent
opening of doors whether oven or refrigerator increases electricity
consumption. Check for door seals or gaskets to ensure tight fit to avoid
leaks.
6. Clean equipment regularly as specified by the manufacturer to prolong
their usage and serviceability.
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Cleanliness should be observed during and after the preparation of tools,
equipment, and utensils. Handle the equipment properly by following the
recommended manufacturer’s specification provided.
Preparing Tools and Equipment for Sugar Concentrates
Same with the tools and equipment used in curing and fermentation,
preparation of sugar concentrates require different equipment and tools to be used.
Cleaning and sanitizing should be done after use to ensure prolonged serviceability.
1. Juice extractor. Used to extract juices of citrus fruits. It may be glass or

plastic, and may come in different sizes.
2. Slicer. Used to cut fruits and vegetables according to size. This may be
stainless, ordinary plated or plastic.
3. Osterizer or blender. Used to liquidize and blend foods particularly fruits
for sugar concentrates to improve the texture of mashed fruits.
4. Spatula. Used for leveling off dry ingredients like sugar, salt and flour.
5. Candy thermometer. Used to measure the setting state of jellies, jams,
and candies if the desired consistency of the product is attained.
6. Jelly Tester or thermometer. Used to test the sugar concentration in jams,
jellies or sugar concentrates.
Packaging Materials
Packaging materials for sugar concentrates can be the following:
 Thins cans
 Pouches
 Plastic jars
 Glass jars
Cleaning and Sanitizing of tools and equipment
Stove/Gas Range
1. Remove all burnt foods and dirt during cooking

2. Scrape grease from cracks, openings, and hinges and wash the plates
with soap and water.
3. Clean the top part of the stove when cooled.
4. Soak and scrub burners with a stiff brush to avoid clogging of holes that
may interrupt the flow of heat.
5. Wipe dry
6. Sanitize or disinfect
Refrigerator/freezer
1. Pack the food in separate container for easy cleaning
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2. Wipe up spilled food immediately to avoid stubborn spilled foods that
may impart odor to the equipment.
3. Keep trays and shelves clean by washing as often as possible. If
preferred, apply baking soda or charcoal to keep out bad odor. Rinse and
dry the shelves thoroughly.
4. Flush drains and defrost weekly if possible to maintain the cleanliness of
the equipment.
Cooking Utensils
1. Clean the utensils thoroughly by removing dirt that adheres and wash
with soap and detergents and rinse.
2. Immerse in sanitizing solution, then dry using cloth
3. Stow the utensils clean
Cutting Implements and other tools and equipment
1. Clean immediately after using. Remove all remaining food particles and
wash with water and detergent
2. Rinse and dip in sanitizing solution
3. Wipe with damp cloth and stow away properly
Selection and Preparation of raw Materials for Sugar Concentrates
Primarily, the right choices of raw materials contribute to the success of

any preserved sugar concentrates. Raw materials refer to fruits and vegetables
that have high pectin content in order to produce good jellies, jams and
marmalade. The variety of fruits, freshness, size and maturity of fruits should
always be considered.
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Guide to the selection of some common Philippine fruits
NAME Quality Undesirable

Characteristics characteristics
Shiny green, firm ripe Soft, decayed tip
Abokado (avocado)
Anonas (anonas) Not too soft, sweet Presence of insects, too
smelling, plump, whole soft, broken
Balimbing(carambola) Bright green,firm, crisp Shriveled, bruised, dull
green, decayed spots
Dalanghita (native Yellowish green rind, Decayed spots, dry rind
orange) plump juicy
Green rind Decayed spots, dry rind
Dayap (lime)
Yellowish green rind Decayed spots, dry rind
Durian (durian)
Guayabano (soursop) Whole, firm yet soft, Bruised, overripe, brown,
juicy decayed spots
Istoberi (strawberry) Firm, bright red Bruised, overripe,
decayed spots
Langka (jack fruit) Pulp-bright yellow, firm, Strong pungent odor,
sweet smelling, young overripe, fibrous
Bright red, juicy, plump Shriveled, dull, decayed
Makopa (curacao apple)
Mangga (Mango) Bright yellow, smooth Shriveled, overripe,
skin, plump, juicy decayed spots
Mangostan (mangosteen) Not too soft, sweet Shriveled, overripe,
smelling, plump, whole decayed spots
Milon (melon) Color characteristic of Broken, bruised,
variety, firm, juice, whole overripe, decayed spots
Pakwan (watermelon) hard green rind, pulp Broken, bruised, pulp
juice, firm limp
Pinya (pineapple) Whole, greenish, yellow Bruised, underripe,
rind, sweet smelling overripe, decayed spots
Rambutan (rambutan) Firm, bright red Bruised, overripe,
decayed spots
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Saging na saba Color characteristics of Broken, bruised,
variety, firm, juicy, whole underripe
whole broken
Sampalok (tamarind)
Santol (santol) Golden yellow, firm Shriveled, soft, decayed
spots
Siniguelas (Spanish Glossy green violet, firm, Bruised, underripe,
plim) plump, juicy overripe, decayed spots
Suha (pomelo) Light green, plump Shriveled, bruised,
underripe, overripe,
decayed spot
Guide to the selection of common Philippine vegetables
Name Good Quality Characteristics

Kalabasa (squash) skin, free from bruises, pulp-bright yellow, firm
Kamote (sweet potato) Free from ulalo
Karot (carrot) Crisp, good orange color, free form green tap
Gabi (taro) Free from decayed spots, firm
Luya (ginger) Firm, free from decayed spots
Mani (peanut) Firm, free from decayed spots
Niyog (coconut) Tender, young, juicy
Papaya (papaya) Color characteristics of variety, firm, juicy, whole
Steps in Making Jelly

1. Choose the ripe ones that are free from any blemishes. Slightly ripe fruits
can also be selected but not the overripe nor underripe ones
2. Two or more fruits of the same kind can be combined when boiling.
3. Wash the fruit thoroughly with water before crushing, grinding or
chopping it into pieces. Peels of the fruits contain a large amount of
pectin so these are not removed when crushing, grinding or chopping
4. Place the fruits in a large casserole or kettle. Add about ½ cup per one
kilogram of fruit. Crushed, mashed or chopped fruit should be immersed
in water.
5. If the fruit has low acid content, add calamansi to aid conversion of
protopectin to pectin. But if it has high acid content, add sugar to lower
down acidity.
6. Boil the mixture of mashed fruits and water on a low heat fire until the
flesh becomes soft. This is necessary to get the maximum extraction of
juice and pectin. If the fruit is soft, boiling it for three minutes is enough.
If firm, prolong the boiling time until it softens but do not overcook.
7. Cool the mixture and strain using a jelly bag or a clean piece of
cheesecloth. Twist and press the cheesecloth hard enough to squeeze out
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the juice. After the first extraction, return the pulp to the casserole or
kettle, add enough water and let it boil again.
8. Extract the mixture for the second time. Mix the first and second
strained juice.
Making Jam
Jam is a jelly-like product mad from fruit such as mangoes either crushed, cut,
or mashed cooked to moderate consistency. It contains not less than 45% of fruit by
weight and 55% of sugar.
Steps in making Jam
1. Select fresh, mature and well-ripened fruits.

2. Clean the fruits to remove adhering dirt, pesticide, etc. Wash thoroughly
to remove the chemicals present due to pesticide used or sprayed
3. Peel the fruits, soften or mashed. Fruits with seed may be left whole or
seeded. In some cases, fruits may simply be cut in smaller pieces.
4. Test the pectin and acid content of the fruit
5. Measure the amount of flesh produced when the sugar is added.
6. Add ¾ cup sugar for a cup of pulp. The amount of sugar varies
depending on the pectin content as tested.
Making Marmalade
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Marmalades differ slightly from jams for it contains pieces preferable thin slices
of fruit suspended in a clear sparkling jelly. Unlike jams, they are cut in small
pieces or mashed. The best known marmalades contain citrus fruits such as
calamansi, oranges, lemons, limes and grape fruits. These have uneven texture and
slightly has acidic taste.
Preparing the Fruits
Two ways of preparing marmalade:
a. Juice and peel prepared separately or combined

b. Whole fruit together with the peel chopped finely
Procedure:
1. Wash the fruits well in detergent water (1/2 tsp. detergent in 4 cups
water)
2. Scrub with a soft clean brush if the skins are all dirty
3. To peel fruit more easily, blanch them in boiling water for 1 to 2 minutes
especially if the fruits have tough skin or peel.
4. Cut the fruit. If citrus is used, slice the peel finely so that the pectin can
easily be dissolved. If marmalades with little pith are desired, cut the peel
finely but do not discard the pith. Instead, cut it up roughly, tie it loosely
in a pieces of muslin cloth and cook with the peel until just before the
sugar is added.
5. Squeeze the bag and remove it. Add calamansi juice or citric or tartaric
acid
6. Test for pectin. Apply the test for pectin when peels are soft. Use the
same test as in jellies.
Making Fruit Preserve
105
Fruit preserves are products made from small or large pieces of fruits cooked in
heavy thick syrup until crisp texture is attained. Fruits to be preserved should be
of high quality, free from blemishes, and possess uniform color.
1. Cut the fruits into halves and remove the seeds when necessary.
2. Prepare syrup using 1 cup sugar per cup of water and immerse the
fruits.
3. Boil the syrup, add the fruits.
4. Let the fruits soak in the syrup overnight making sure all is covered with
syrup.
5. The next day, remove the fruit from the syrup and drain. Repeat the
process depending on the fruits used.
The amount of sugar to add depends upon the texture and acidity of the
fruit, though ¾ part sugar per part of fruit by weight is generally accepted. If
fruits are soft and sour, more sugar is needed. If the fruit is sweet or hard, less
sugar is required.
6. Cook the fruit over a slow fire and stir making sure that cooking is done
shortly for successive days in syrup to ensure plumpness and better
flavor. A 40% sugar may be used as initial sugar concentration allowing
the fruit to cook for few minutes to make it tender and to allow the syrup
to penetrate into the fruit. Let the fruit stand in that syrup overnight. 7.
7. The following day, drain the syrup and increase the sugar concentration
by 10%.
8. Boil the syrup.
9. Add the fruit and allow the mixture to simmer for 3 to 4 minutes again
and set aside overnight.
10. Repeat the process until a syrup of desired consistency is attained.
Make sure that the fruit is clear, plump, and thoroughly impregnated
with the syrup. Prevent the fruit from shriveling by cooking hard fruits
106
like kundol or papaya in water until tender before adding the sugar.
Fruits that are soft may be cooked in heavy syrup right away.
Task Sheet 3.1.1

Making Fruit Preserves
Be able to prepared kundol preserve given the following materials and ingredients:
Materials:
 Mature kundol
 Lime solution (apog)
 Suagr
 Water
 Glass jars
 PPEs
Procedure
1. Cut and peel the fruit according to desired size
2. Soak overnight in lime solution 1T in 4 qt. water
3. Blanch the fruit and drain
4. Simmer ion water for 15 to minutes until pieces become translucent
5. Prepare syrup using 1 cup sugar per cup water. Bring to a boil and add
the fruit. Simmer for 5 minutes.
6. Soak fruit in syrup overnight. Drain and add ½ amount of sugar
previously used and add ½ tsp. kalamansi juice per cup of syrup
7. Bring syrup to a boil. Add fruit and simmer again for 3 to 5 minutes and
soak overnight
8. On the third day, add sugar and acid again. Repeat step 7
Criteria Yes No
Did the candidate…
1. Cut and peel the fruit according to desired size

2. Soak overnight in lime solution 1T in 4 qt. water
3. Blanch the fruit and drain
4. Simmer ion water for 15 to minutes until pieces become
translucent
5. Prepare syrup using 1 cup sugar per cup water. Bring to a
boil and add the fruit. Simmer for 5 minutes.
107
6. Soak fruit in syrup overnight. Drain and add ½ amount of
sugar previously used and add ½ tsp. kalamansi juice per
cup of syrup
7. Bring syrup to a boil. Add fruit and simmer again for 3 to 5
minutes and soak overnight
8. On the third day, add sugar and acid again. Repeat step 7
Preparing Production Report
Sugar concentrates should have a format on the preparation,

computation, recording and documentation.
Actual spoilage or rejects depends on the product to be made. For
example, in mango jam, excess refers to the peel and seeds of mango and
spoilage pertains to those flesh or mixture of mangoes in excess or that are not
included or left during packing.
Product Name : MANGO JAM

Production Date : May 2016
Description of Materials:
Ripe Mango 1000g
Refined Sugar 500 g
Other Ingredients:
Weight of Calamansi 10g
Total Weight of materials (input) 1560g
Output
Total Weight of leftover material 30g
Spoiled/reject 1530g
Percentage Yield = 1530 x 100%
1560
Approximate number of finished products= 2 bottles at 190 grams/bottle
Computing for the Percentage Yield
Yield refers to the number of finished product produced after computing the
production input and output.
Formula in getting the percentage yield:
% Yield= Production input x 100%

Production Output x 100%
108
Recording Calculated Data
All records and reports made from the gathered and computed
production input, output, rejects, spoiled, weight of peel, actual yields, or
recoveries are kept and recorded for documentation purposes. This will serve
as reference for future use and will determine the progress of succeeding
products to be made.
Self Check 4.1.1
Make your own production Report based on the following data provided.
Compute the input, output, and percentage yield.
1000g. ripe guava Manufacturing date: May 20,2012

500g sugar
10 ml. calamansi juice
Weight of excess material—50 grams
Answer Key 4.1.2
Product Name : GUAVA JAM

Production Date : May 2012
Description of Materials:
Ripe Guava 1000g
Refined Sugar 500 g
Other Ingredients:
Weight of Calamansi 10g
Total Weight of materials (input) 1510g
Output
Total Weight of leftover material 50g
Spoiled/reject 1550g
Percentage Yield = 1530 x 100%
1510
Approximate number of finished products= 2 bottles at 190 grams/bottle
109
110
Unit of Process food by drying and dehydration

competency
Module Title Processing food by drying and dehydration
UNIT OF COMPETENCY : Process food by drying and dehydration
Unit descriptor : This unit deals with the knowledge, skills and
attitudes required to process foods by sun drying, dehydrator, and solar drying.
It includes drying and dehydration of fruits, vegetables, herbs and spices, root
crops, fish and meat.
Dehydration, in food processing, means by which many types of food can

be preserved for indefinite periods by extracting the moisture,
thereby inhibiting the growth of microorganisms. Dehydration is one of the
oldest methods of food preservation and was used by prehistoric peoples in
sun-drying seeds. The North American Indians preserved meat by sun-drying
slices, the Chinese dried eggs, and the Japanese dried fish and rice.
Dehydration equipment varies in form with different food products and

includes tunnel driers, kiln driers, cabinet driers, vacuum driers, and other
forms. Compact equipment suitable for home use is also available. A basic aim
of design is to shorten the drying time, which helps retain the basic character
of the food product. Drying under vacuum is especially beneficial to fruits and
vegetables. Freeze-drying benefits heat-sensitive products by dehydrating in
the frozen state without intermediate thaw. Freeze-drying of meat yields a
product of excellent stability, which on rehydration closely resembles fresh
meat.
The dairy industry is one of the largest processors of dehydrated food,

producing quantities of whole milk, skim milk, buttermilk, and eggs. Many
dairy products are spray dried—that is, atomized into a fine mist that is
111
brought into contact with hot air, causing an almost instant removal of
moisture content.
Benefits
Molds, yeast and bacteria need water to grow. When foods are sufficiently
dehydrated, microorganisms cannot grow and foods will not spoil. Dried fruits
and fruit leathers may be used as snack foods; dried vegetables may be added
to soups, stews or casseroles. Campers and hikers value dried foods for their
light weight, keeping qualities and ease of preparation.
Nutritional value
The nutritive value of food is affected by the dehydration process. Vitamins A

and C are destroyed by heat and air. Using a sulfite treatment prevents the loss
of some vitamins but causes the destruction of thiamin. Blanching vegetables
before drying (to destroy enzymes) results in some loss of vitamin C and B-
complex vitamins as well as the loss of some minerals, because these are all
water soluble. Yet blanching reduces the loss of thiamin and vitamins A and
C during dehydration and storage.
Drying methods
Foods can be dehydrated by various means: the sun, a conventional

oven, an electric dehydrator or, for herbs only, a microwave oven. Dehydration,
like other preservation methods, requires energy. Unless sun drying is possible,
the energy cost of dehydrating foods at home is higher than for canning and, in
some cases, more expensive than freezing.
1. Solar drying is a modification of sun drying in which the sun's rays are
collected inside a specially designed unit with adequate ventilation for
removal of moist air. The temperature in the unit is usually 20 to 30
degrees F higher than in open sunlight, which results in a shorter drying
time. While solar drying has many advantages over sun drying, lack of
control over the weather is the main problem with both methods.
2. Oven drying is the most practical way to experiment with dehydration. It
requires little initial investment, protects foods from insects and dust
and does not depend on the weather. Continual use of an oven for drying
is not recommended because ovens are less energy-efficient than
dehydrators, and energy costs tend to be high. It is difficult to maintain a
low drying temperature in an oven, and foods are more susceptible to
scorching at the end of the drying period. Oven-dried foods are usually
darker, more brittle and less flavorful than foods dried by a dehydrator.
3. Electric deyhdrator produces a better-quality dried product than any
other method of drying. Electric dehydrators are self-contained units
with a heat source, a ventilation system, and trays to place the food on.
They are used to dry foods indoors. Therefore, as with oven drying, they
don't depend on the weather. Such dryers can be purchased or made at
112
home and vary in sophistication and efficiency. Although an electric
dehydrator requires a fairly high initial investment, it maintains low
temperatures and uses less energy than an oven.
Caution
It is not recommended that microwave ovens be used for drying foods, because
the food will partially cook before it dries, imparting an overcooked flavor.
Microwave ovens can be used to dry some herbs quickly—but watch them
carefully to prevent them from catching on fire. Check the owner's manual for
drying recommendations.
Drying times in conventional ovens or dehydrators vary considerably

depending on the amount of food dried, its moisture content and room
temperature and humidity—and in the case of oven drying, the use of fans.
Some foods require several hours, and others may take more than a day.
Interrupting drying time, or prolonging it by using lower temperatures, may
result in spoilage.
Air temperature and circulation must be controlled during the drying

process. If the temperature is too low or the humidity too high (resulting in
poor circulation of moist air), the food will dry more slowly than it should and
microbial growth can occur. Watch temperatures closely at the beginning and
end of the drying period. If the temperature is too high at first, a hard shell
may develop on the outside, trapping moisture on the inside. This condition is
known as case hardening.
Temperatures that are too high at the end of the drying period may cause food
to scorch. Temperatures between 120 and 140 degrees F are recommended for
drying fruits and vegetables. Temperatures up to 150 degrees F may be used at
the beginning, but should be lowered as food begins to dry. For at least the last
hour of the drying period, the temperature should not exceed 130 degrees F.
Selecting a dehydrator
Try drying several foods in your oven before buying a dehydrator. You will
become familiar with the process and pinpoint features to look for in the
appliance. Also, experiment with a variety of commercial dehydrated foods to
test your family's acceptance of dried foods. Remember, the equipment
available for commercial drying will probably produce a product superior to
that you can achieve at home.
Space requirements
Dehydrators vary in size and can be round, square or rectangular. You will
need to find a convenient space to operate it. Place the dehydrator near an
electrical outlet so that extension cords are not necessary. You should have
room to open the door and easily load and rotate the trays. When deciding
where to put the dehydrator, keep these points in mind:
 The food will give off humidity

 The fan will create noise
 The appliance will give off heat
Heat control
The dehydrator should allow you to select heat settings from 85–160 degrees F
and should have a thermostat to maintain the selected temperature. The
113
heating element should be enclosed so that it does not present a shock or burn
hazard. Some models have timers and automatic shutoffs. Controls should be
located on the front of the dehydrator. Check the instructions to see how often
the trays need to be rotated. Requirements for frequent rotation can mean
uneven heat in the dehydrator.
Air flow
As much food surface as possible should be exposed to warm, dry, moving air.
Good air flow is extremely important in removing moisture from food. Some
dryers use natural convection only; others use a fan. The addition of a fan will
make even air circulation more likely. A fan with two speeds is desirable. High
speed is used at the beginning of the drying period when moisture is readily
available at the surface. Low speed is then used to slowly remove the remaining
moisture.
The two basic kinds of air flow systems are horizontal and vertical. Horizontal
flow moves air across the top and bottom of food and is considered the best
system. Vertical air flow is more easily blocked by food shelves.
Trays
Tray edges should be a quarter- to a half-inch high to prevent food from spilling
or falling off and to allow air to circulate. Trays should slide easily in and out.
There should be four to 10 open-mesh trays of sturdy lightweight plastic for

drying. The mesh size of the screening material should be large enough to allow
air to circulate yet small enough to prevent food falling through.
Finally, the trays should be easy to clean and lightweight.
Door
The door should be easy to open and close. Doors may swing up or down, right
or left. Some are removable. When open, the door should not interfere with
traffic passing by the dehydrator. You may need both hands to load and unload
the food trays so the door should stay in an open position by itself. It should
seal well and have strong hinges and latches that will withstand repeated use
as well as heat and humidity.
Cabinet
The cabinet should be built of a material that does not warp or get hot when in
use—double-wall construction of metal or plastic. It should be nonflammable
and easy to clean.
Safety
Look for the UL label and a grounded plug.
Service and warranty

Review the service and warranty information to find out who can service the
appliance. Check the length of the warranty and what it covers. A one-year
warranty is recommended. Also, verify that replacement parts are available.
Capacity
Use common sense. If the capacity of the dehydrator does not look large
enough to accommodate the size of the loads you will dry frequently, it will not
be a good buy.
114
Procedures for oven drying
When using the oven drying method, it is important to know if your oven can
maintain the appropriate temperatures. Use an oven thermometer to test the
temperature of the oven at its lowest setting. Many ovens cannot maintain a
temperature below 200 degrees F. If your oven cannot, it is too hot for
successfully drying food, so alternative drying equipment must be used.
Tray placement
Trays upon which the food is placed must be at least 1½ inches narrower than
the inside of the oven to allow for air circulation. Allow at least 2½ inches
between trays and 3 inches of free space at the top of the oven for good air
circulation.
Arranging food layers

About 4 to 6 pounds of food can be dried in an oven at one time. Place food on
drying trays, or on wire cooling racks covered with cheesecloth or nylon
netting, to allow easy removal of dried food. Pieces of food should be in a single
layer. Do not place food directly on oven racks. Cookie sheets are acceptable
only for fruit leathers, which do not require good air circulation.
Setting the temperature

Place an accurate, easy-to-read thermometer on the top rack toward the back.
Preheat oven to 150 degrees F. For gas ovens, if temperature cannot be
maintained below 200 degrees F, it may be possible to use only the pilot light.
For electric ovens, use only the bottom element, disconnecting the broiler
element if necessary. Arrange trays in the oven to allow for adequate air
circulation. Prop oven door open at least 4 inches.
Ventilation
Place a fan outside the oven door to aid air circulation. Move it from side to
side occasionally. The room also should be well ventilated. Oven drying,
particularly if a fan is used, should be done with caution if small children are
around.
Maintaining the temperature
Maintain the temperature at 140 degrees F. Watch the temperature even more
carefully toward the end of the drying process. To prevent scorching, lower
temperature to 120 degrees F if possible. Examine the food often and turn
trays frequently, removing foods as they dry.
Procedures for drying in a dehydrator

When using a dehydrator, load food on trays in single layers so that pieces do
not overlap. This arrangement allows air to circulate through the trays. A
constant temperature of 140 degrees F is necessary for dehydrator drying.
Large pieces, such as apricot halves, should be turned halfway through the
drying time. Pieces near the sides of the tray should be moved to the center.
Stir small pieces with your fingers (make sure they're clean) every one to two
hours, separating bits that stick together. It may be necessary to rotate the
trays within the dryer at least once during the drying period. Vegetables
usually take six to 16 hours to dry. Fruits can require up to 48 hours.
Never dry sulfured fruits in an oven or dehydrator, because the sulfur dioxide
fumes can be irritating. Use sulfite dips or steam, water or syrup blanching in
place of the sulfur treatment.
115
Separating foods
Different foods requiring similar drying times and temperatures can be dried
together. Vegetables with strong odors or flavors (garlic, onion and pepper)
should be dried separately. Don't dry strong-smelling vegetables outside in an
electric dehydrator, because dehydrators are not screened and insects may
invade the food.
Choosing a dehydrator
Because an electric dehydrator can be an expensive investment, choose a
specific brand or model carefully. Refer to the sidebar for features to look for
and evaluate before making your investment.
When is it dry?
Judging when food is dry requires experience. It is better to overdry than to
underdry. When in doubt, continue drying for an additional 15–30 minutes.
Check for doneness. Allow the product to cool before testing.
Vegetables are sufficiently dried when they are leathery or brittle. Leathery
vegetables will be pliable and spring back if folded. Edges will be sharp. Corn
and peas will shatter when hit with a hammer.
Fruits are adequately dried when moisture cannot be squeezed from them, and
if they are tough and pliable when cut. Fruit leathers may be slightly sticky to
the touch but should separate easily from the plastic wrap.
Meats should be extremely dry unless they are to be refrigerated or frozen for
long-term storage. Meat is sufficiently dried when it is dark-colored and fibrous
and forms sharp points when broken.
Herbs are dried when brittle. Their leaves shatter when rubbed together.
After drying
Even when a food tests dry, it may not be uniformly dry. Also, there is a chance
of contamination of dried foods, especially if racks have been exposed to the
open air for any time. Therefore, conditioning and pasteurizing should be done
before storing.
Conditioning is the process used to equalize, or evenly distribute, moisture left

in the food after drying. It is usually done to fruits, herbs and seeds to improve
storage, because it decreases the chance of spoilage, especially by molds. To
condition a food, follow these steps:
 Cool foods on trays.

 Pour into a large, nonporous container of food-grade material; fill to
about two-thirds full.
 Cover container and place in a convenient, warm, dry place. Shake
container daily or stir contents at least once a day for 10–14 days.
 Check for condensation on the lid and any signs of spoilage. If
condensation occurs, return food to the dryer to finish the product.
Recondition after it is dry.
 Cool thoroughly before packaging.
Caution
If any sign of mold growth occurs, destroy the product.
Freshly dried fruit can be added to the conditioning batch within the first five
days. Conditioning time will need to be lengthened to accommodate the
additional food.
116
Pasteurizing is recommended for foods that have been contaminated before or
during storage. It can be used as a second treatment for vegetables held in
storage if the vegetables do not have any mold on them. Keep in mind that this
treatment can cause quality changes. To pasteurize, use one of the two
following methods:
 Freezer—Seal dried food in a heavy, plastic bag after drying (and

conditioning, if necessary). Place in a freezer at zero degrees F for a
minimum of 48 hours.
 Oven—Place the food in a single layer on a tray or in a shallow pan. Place
in an oven, preheated to 160 degrees F, for 30 minutes. Cool and
package for storage.
Packaging dried foods

Package dried foods in glass jars, food-grade plastic storage containers, or
plastic food-storage bags. Make sure the package has an airtight seal. It is a
good idea to package dried foods in small amounts, because after the package
is opened, the food can absorb moisture from the air and quality deteriorates.
Storing dried foods safely

Store containers of dried foods in a cool, dark, dry area, such as a basement or
cellar. Exposure to humidity, light or air decreases the shelf life of foods. The
lower the temperature, the better: Foods stored at temperatures under 60
degrees F will keep about one year. At 80–90 degrees F, the food begins to
deteriorate within several months. The shelf life of fruits increases three to four
times for every 18 degrees F drop in temperature.
117
Unit of Process foods by thermal application

competency
Module Title Processing foods by thermal application
UNIT OF COMPETENCY : Process foods by thermal application
118
UNIT DESCRIPTOR : This unit deals with the knowledge, skills and attitudes
required to process foods by thermal application thru pasteurization, canning
and bottling.
High Pressure Thermal Application in Food Processing
Both heat and pressure have long been used independently as means of
preserving food. For example, high pressure processing (HPP) at low or ambient
temperatures can prevent the growth of bacterial spores, and is an effective
means of preservation in moderate and high acid foods. However, low acid
foods (LAF) remain impervious to standard pressure processing at these
temperatures, which allow the Bacillus and Clostridium strains of bacteria to
flourish, and have traditionally been preserved through thermal processing.
But this technique requires relatively long periods of heating to ensure that all
the food within the target pack has been heated to the minimum temperature –
and the longer the heating period is, the greater the risk of degradation to the
food quality attributes (flavor, texture, nutrient content and color). How HPT
works food products are put through a pre-heating, holding and cooling
process in order to achieve the desired result. The equipment used is designed
to enable maximum compression heating which is vital for bacterial spore
inactivation. It must be able to maintain temperatures of up to 90°C, at
pressures of 600-800 MPa or higher (up to 1,500 MPa).
Firstly, the food product is placed in a holding unit and heated to a set
temperature.
The holding unit is then pressurised, and the temperature is increased. The
extent of these increases depends upon the composition of the food product
and its reaction to heat.
Once the required temperature has been reached it is maintained for a period
of time long enough to inactivate bacterial spores.
119
Decompression then takes place which cools the food product quickly, avoiding
degradation in terms of colour, taste, texture and nutritional value.
The advantage of HPT processing lies in the reduced thermal load applied to
products due to:
the accelerated heating/cooling times of food products during

(de)pressurization; and potentially reduced processing temperatures and/or
times through the synergistic effect of heat and pressure on bacterial spore
inactivation.
c. How successful is HPT? The results show that HPT processing is effective at
preventing reactivation in most – but not all – types of pathogenic
bacteria. Spore reaction Bacteria spores show different responses to HPT
processing – even between strains of the same species. For example,
proteolytic Clostridium botulinum strains were more HPT resistant compared to
the nonproteolytic strains. Curiously, those bacterial spores which are heat-
resistant differ in their response to the combined application of heat and
pressure.
The very heat-resistant Bacillus amyloliquifaciens strains are highly pressure

HPT-sensitive.
The very heat-sensitive Bacillus coagulans strains are the most HPT-resistant
under a variety of conditions.
While Clostridium thermosaccharolyticum strains are generally more than 10-

fold more heat-resistant than C. botulinum, with the introduction of pressure
they become far less HPT-resistant.
The intrinsic properties of the underlying food also play a part; research
suggests that spore inactivation may be affected by the food’s water content, or
its pH levels. Impact of packaging The effect of HPT processing on food
products also varies according to the barrier properties used. Ideally, food
packaging needs to be able to withstand changes in volume, (de)compression,
and temperature without any degradation of its aesthetic appeal. However, HPT
processing causes degradation to a certain extent in all forms of food packaging
this is more visible in barrier materials such as vapor-deposited nylon and

oxide film, but aluminum foil and PVDC-MA film are the least affected.
Further work is needed The use of HPT processing to sterilize low acid, shelf-
stable foods remains a long term research challenge, although a more realistic
goal is that of prolonging the shelf life of low acid chilled foods. Further work
needs to be undertaken into bacterial spore inactivation in these chilled LAFs,
in particular into the non-proteolytic C. botulinum strain, which can germinate
and produce toxin at refrigeration temperatures. Other areas to be addressed
include:
 improving pressurisation equipment to ensure optimum temperature

distribution,
 developing food packaging to better withstand HPT processing, and
 better understanding the kinetics and mechanisms of spore inactivation
through HPT.
120
Self Check 5.1
Write T if the statement is correct and F if incorrect.
____1. Thermal application requires relatively long periods of heating to ensure

that all the food within the target pack has been heated to the minimum
temperature – and the longer the heating period is, the greater the risk of
degradation to the food quality attributes
____2. The process of pre-heating, holding and cooling process are not necessary
to for food to achieve the desired
121

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COMPETENCY BASED LEARNING MATERIAL

Sector Processed Foods and Beverages

Qualification Title FOOD PROCESSING NC II

Unit of Process Food by Salting, Curing and Smoking

Module Title Processing Food by Salting, Curing and Smoking

The units of competency, “Process Food by Salting, Curing and

The module, Processing Food by Slating, Curing and Smoking,

In this module, you are required to go through a series of learning

UNIT OF COMPETENCY: Process Food by Salting, Curing and Smoking

1. Prepare equipment tools, materials and utensils

LEARNING OUTCOME 1 Prepare equipment tools, materials and

Information Sheet # 1.1

Food Processing- is a process of food preservation that improves the texture

Food Processing by Salting, Curing and Smoking

Smoking: In this procedure, smoke is used to preserve the meat. Smoking is

Common Equipment, Tools, Materials and Utensils and Their Uses

1. Cooking range (Gas range or oven)- is the most

2. Refrigerator- a piece of equipment that uses

3. Chiller- an equipment used to store semi-perishable

1. Weighing Scale- an instrument used to take the weight or mass of raw

2. Measuring Cups- a measuring tool used to measure dry ingredients of

3. Salinometer-an instrument for measuring the amount of salt or brine

5. Refractometer- an instrument used for reading the salinity or

6. Impulse Sealer- a device used in sealing purposes especially plastics

1. Grater and Shredder- for grating and shredding vegetables, lemon

2. Wooden barrels- containers made of wood where salted fish are

3. Double Boiler- a cooking utensil used to simmer foods

4. Scissors and shears- used for cutting fins of fish

6. Saucepan-a cooking utensil usually with handle used for heating

7. Strainer- a receptacle used for draining food items like fish,

8. Wooden Ladle- a stirring utensil made of wood in order to prevent

9. Steamer-a cooking utensil used to steam food and other raw

10. Mortar and Pestle- made either of wood or marble used in

13. Knives- used to cut ingredients

15. Cutting/Chopping Board- made either of plastic or wood used to

16. Basin- a container used in preparing brine and other curing

17. Smokehouse- a building, place or any construction used for

18. Soaking containers- used in preparing brine solution or for

D. Materials for Salting, Curing and Smoking

2. Fresh fish, meats, poultry and eggs (common raw materials)

3. Smoking materials like fuel, e chips, charcoal, hush

4. Flavoring and tendering ingredients like salt

E. Personal Protective Equipment (PPE)

PPE is specific safety gear, which workers may be advised or required to

1. Laboratory Gown- a clothing with sleeves worn as protection from

2. Face Mask- used as a mouth covering

3. Hand Gloves- used to protect workers hands in food handling

4. Splashers/working shoes- worn by workers to protect them from

Self Check 1.1

1. Give examples of food items that are commonly processed and

2. What is the importance of using PPEs in food processing?

3. Identify what is being asked

b. _____ a building, place or any construction used for smoking fish

c. _____ made either of plastic or wood used to place a food material

d. _____ A cooking utensil used for cooking, stewing food and in

g. _____ a device used in sealing purposes especially plastics

h. _____ an instrument for measuring the amount of salt or brine in a

i. _____ an equipment used to store semi-perishable foods in a low

Answer Key 1.1.1

2. PPEs are important to be worn to protect the worker from dirt

Sanitation in Food Processing

Product safety and quality are highly dependent on sanitation, as improper

Considerations for Effective Cleaning

Chemical Functions. Another important factor to consider when setting up