Study Guide in TLED22- FOOD PROCESSING, PACKAGING AND LABELLING Module 1: Food Processing

Module No. 1
Unit 1: Food Processing

MODULE OVERVIEW

This module aims of the curriculum is to provide students a sufficient

knowledge and wisdom about food
processing and preservation. It will deal with their knowledge, skills and
attitude required to use standard
measuring devices, instruments, utensils and requiring them to apply food
safety and sanitation in the
workplace.

LEARNING OBJECTIVES

In this unit the student should be able to:

1. Understand the food processing;

2. Enumerate and identify the different standard equipment, instruments, tools and
utensils for food processing;
3. Identify role and responsibility as a member of a team;
4. Identify hazards and risks and Maintain OHS awareness; and
5. Observe safety and sanitation in a workplace.

LEARNING CONTENTS

Introduction
Malnutrition is rampant in our society especially on this pandemic crisis. Food wastage is a major
problem all over the world. This problem could be remedied if the existing food supplies are properly
handled and preserved. Preservation of foods can be a major solution to prevent food wastage and to
lengthen the shelf life of foods available at home. We call it, Food Processing which is an indispensable part
of economy.

The food processing is not easy if we are not really into it so it is very necessary to identify and be familiar
with the equipment and materials used in the process. It is also mandated to apply occupational safety and
health program for observing food safety and sanitation in helping to enhance the skills of each individual in
the food processing industry on working in a team environment.

I. WHAT IS FOOD PROCESSING?

It is the conversion of agricultural product to substances which have particular textural, sensory and
nutritional properties using commercially feasible methods. It is a way or technique that is used to convert
raw foods into well-cooked and well-preserved edible materials for humans and animals. A number of
processed products are nutritious, easy to cook and have a long shelf life.

PANGASINAN STATE UNIVERSITY 1

Study Guide in TLED22- FOOD PROCESSING, PACKAGING AND LABELLING Module 1: Food Processing

Food processing helps to: (1) destroy, inhibit or remove micro-organisms, (2) retards or prevent deterious
biochemical, chemical and physio-chemical changes, (3) maintains and generates acceptable organoleptic
properties and (4) preserves or enhances the nutritive value of the ingredient whether it is fruits and
vegetable, meat, poultry or fish.
People often try to process foods due to their interest on converting ingredients to an edible products,
preserve, extend availability and provide accessibility, provide variations and add value.

TYPES OF PROCESSING
Primary processing is the conversion of raw materials to food commodities. Milling is an example of
primary processing.
Secondary processing is the conversion of ingredients into edible products - this involves combining foods
in a particular way to change properties. Baking cakes is an example of secondary processing. A
considerable variety of products can be made using similar basic ingredients e.g. to make bread we need
flour, water and salt.
II. TOOLS, EQUIPMENT AND OTHER DEVICES

The facilities for food processing is a place where food for human consumption is:
a. Manufactured;
b. Packaged;
c. Labeled; and
d. Stored.
e.
During the various methods on food processing, there are many devices, instruments tools and
equipment is important to familiarize. In this lesson, let us identify the different materials and
which was commonly used for food processing.

1. EQUIPMENT is usually denotes a set of tools that are used to achieve a specific objective
a. Refrigerator- used for preserving food in low temperatures, to slow down decay and
natural metabolic processes. It replaced the icebox in this modern society. They are used in
maintaining the freshness of raw materials and in providing an ideal low or ambient
temperature for storing processed foods.
b. Freezer is similar device to refrigerator that maintains a temperature below the freezing
point of water
c. Gas range is most commonly used for cooking or heating which operated by a burning fuel
or using electricity.
d. Cabinet dryer is an equipment to remove moisture in food by distributing heated air in a
circular motion
e. Oven is a thermally insulated chamber used for the heating, baking, or drying of a
substance.
f. Descaler or scalers are used in removing the scales of a fish
g. Bottle capper is used to seal bottles during bottling.
h. Can sealer is a machine used to seal the lid to the can body.
i. Fermentation vat is a container for storing liquids for fermentation. It will prevent the
bacterias and other microorganism from entering.
j. Meat grinder or slicing machine is used to mince or mix raw or cooked meat
k. Salting equipment
e1. Oil drum – used as a container to keep salted fish during the process.
e2. Earthen pots are used in storing the salted products.
e3. Wooden shovel or spade is used for mixing or stirring the mixture of salt and small fish
for salting.
l. Smoking Equipment
f1. Baklad made of bamboo used in drying the fish prior to smoking
f2. Bakol is a bamboo basket used to transport smoked

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Study Guide in TLED22- FOOD PROCESSING, PACKAGING AND LABELLING Module 1: Food Processing

f3. Bistay is a bamboo basket for collecting sun dried fish

f4. Dinarayan is a smoking tray made of wood
f5. Panakip is a bamboo cover used to keep fish submerged in the brine while boiling
f6. Panandok is a big metal ladle to scoop up the cooked fish from the boiling brine
f7. Bamboo poles used to hold the baklad with brine cooked fish while drying.
f8. Pugon is a concrete heat source used when pre-cooking fish in a brine

2. MEASURING DEVICES/APPARATUS are instruments that show the extent or amount of

quantity or degree of what we measure in food processing

a. Weighing scale
a.1. Triple beam balance is for measuring small quantities like spices, preservatives, etc.,
while the heavy duty scale is for measuring fish, salt, etc.
a. 2. Checkweigher scale is a digital weighing scale used to get the weight of food like
meat, fish, vegetables, fruits, etc
a. 3. Clock Type weighing scale is usually used for food measured into kilograms.
This can be also associated with check weighing scale but it is a manual type.
b. Thermometers indicate the degree of hotness or coldness of a thing or body. It measures
how high or how low the temperature is.
b.1. Salinometer is used to measure the salinity of a brine
b.2. Psychrometer is used to measure the relative humidity of the air when sun drying
b.3. Anemometer is used to determine the velocity of the wind in sun drying.
b.4. Refractometer is used to measure the sugar concentration of sap and syrup for food.
b.5. Ph Meter is an instrument used to measure acidity and alkalinity.
b.5. Hydrometer is used to measure relative density of liquids based on the concept of
buoyancy.

c. Beaker are used for measuring liquid ingredients like milk, vinegar, fish sauce, etc. It is a
kitchen utensil used primarily to measure the volume of liquid or powder-form cooking
ingredients such as water, milk, juice, flour,
Measuring cups can be in plastic, glass and stainless. From mini shot measure to measuring
pitcher and batter bowl.
d. Measuring spoons is a spoon used to measure an amount of a substance, either liquid or
dry, when cooking. Measuring spoons may be made of plastic, metal, etc.
e. Measuring cups Measuring cups for solid ingredients like flour, salt, minced garlic,

3. TOOLS are handheld devices used to carry out particular functions. Utensils are tools,
containers, or other materials used for household task like cooking.
HERE ARE THEOTHER UTENSIL AND MATERIALS:
a. Cutting board is where fish or meat are cut; ingredients are sliced or minced.
b. Cutting implements/knives is used for cutting or slicing fish or meat; for scaling fish
c. Basin is a container that holds water and is used for washing
d. Food tong is used for picking up or handling food
e. Kitchen scissor is used for trimming – off fins of fish

III. WORK IN A TEAM ENVIRONMENT

No man is an island. The common technique to reach the goal is to work in a team efficiently and
effectively. Processing foods may be easy for an expert processor but it may take a hard time for those who
are novice in this endeavor. So here is the formula for calibrating a team in order to achieve such task
successfully:

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Study Guide in TLED22- FOOD PROCESSING, PACKAGING AND LABELLING Module 1: Food Processing

TEAM= individuals + group mission statement + group skill

Many task may be given to an individual and may fail if she/he just work alone. Building a team with
positive environment is a very good idea but may cause a bit of struggle due to diversity. Hence, this will
become easier if we know the proper formula. An individual is very important on a team. Example, you
cannot eat if your hands do not want to do so. Being in a team is like a man which has a body and has
different parts with various functions. You need each other to accomplish your purpose with efficiency. In
addition, your action as a group will be in vain or become wasted if you do not have your mission statement.
All parts or members of the group shall be aware and committed of such mission and vision. When one of
the member failed to be in his or her function, the remarks of your goal will be a failure. The group shall
have collaboration, cooperation, communication and consideration on the individual skills of all the
members. With that, as you deliberate and understand the various skills of each member, the group may
identify the tasks that is relevant on such individual to whom will be effective and efficient.

When we are involve in a group, everyone shall have communication and will be able to apply SMART.
Specific, this is very necessary to clear out all things and assumptions will become out of the group.
Measurable, this will help the team to know if when they will achieve their goal. It must be meaningful and
motivating. Achievable, it will give the team to take their goal with great excellence. The group shall have
the consensus on agreeing with such goal that can be attainable by all members. Relevant, the group
members and leader shall set a realistic goal so they will feel motivated and has a positive work attitude.
Example, a writer has an expertise on writing. You cannot give her the task on food processing because the
forte of that individual is not relevant and applicable to her. Every specific goal shall be reasonable,
realistic, resourced and results-based. Time Bound, It will associate with beating the deadlines and
submitting the demand of the product on time. This will always bound to time, answering the questions, “Is
it timely? Is our time limited?”

Here are the Activities that is primarily takes place within a team:

1. Exchanging information internally and externally. Two heads are better than me. The expertise and
experience of an individual may not be available in the other member of the group. The skills that
you cannot do may be available by the other member. So, it is very necessary to ask for an opinion
and suggestions to others to come up with a high quality idea that a group shall attain.
2. Distributing works is somehow hard for some individuals due to having a hard time working in a
group. Therefore, disseminating and assigning each member in a group on such task is the key
technique of successful institution. As every member receive their task, they will give their best
even to the smallest detail of their function. A fish cannot be able to be call as a fish without its
scale.
3. Building internal and external relationships is helping to have motivation on their functions. There
is no success if there is division in a group.
4. Making decision is considered as the hardest part of task in a group. Identifying the authority is the
very important step to create a wise decision that will be follow by all of the members. Being in the
dilemma of choosing what is best for the group is not an easy thing to do but can be justified if the
decision maker has the integrity to walk the talk and will meet his/her standard no matter what
happen and whosoever may hinder them.
5. Generating new ideas is applicable for changes. When changes is eternal, the group shall be
required to always prepare contingency plans. The group shall be always ready to provide a new
and unique ideas that can be their next goal if their first try did not succeed.

PANGASINAN STATE UNIVERSITY 4

Study Guide in TLED22- FOOD PROCESSING, PACKAGING AND LABELLING Module 1: Food Processing

In food processing, proper skills and ideas must always be generated because there are many competitors in
the industry that can make a better and greater ideas to their products that can defeat/your processed foods.
With these industry, the processor must not be complacent on what she/he just know today. There shall be a
continuous learning and exploring of innovative ideas to improve your product. Consequently, the members
of the group shall not work solely but must always be in a group work.

IV. OCCUPATIONAL SAFETY AND HEALTH

An occupational safety and health program is a planned system of working to prevent illness and injury
where you work by recognizing and identifying hazards and risks. You cannot tell what will happen
every day so an ounce of prevention is better than cure. In this lesson, you are required to understand
the safety in a workplace. Safety is the protection from any physical injury and mental well-being of the
individual. Your health is wealth that is why during various methods in food processing, it is necessary
to protect your body and mind against all illness to have a continuous operation. The welfare of the
workers must be the primary goal of an institution or a food processing company to take care. Why?
The workers are the jewels of the food processing company. It is not easy to find their substitute so the
company must make sure that they can provide facilities that will maintain the health and well-being of
every food processor in the workplace. If there is an effective workplace safety and health programs, the
group may save the lives of every member of an institution. It will also result to positive effects on both
worker’s morale and productivity and can save employer’s money.

Here are the three think safe steps to get rid of from any danger:

1. Spot the hazard

In hypothesis, you cannot find a solution to the problem if you don’t know the problem. So, don’t forget
to be in the very first step. You need to identify the hazard in your workplace. A hazard is anything that
could hurt you or someone in such place. Example, a knife can be a hazard so the food processor must
be aware on the possible event may happen.

Types of Hazards

a. Physical hazard are substances or activities that threaten your physical safety such as
conditions that can cause injury, illness and death. The most common physical hazards are
temperature, air quality, mold, noise or radiation. Companies must ensure the right
equipment, monitoring and training is provided, and workers have to proactively
communicate with each other.
b. Mechanical hazard are created as a result of either powered or manual (human) use of tools,
equipment or machinery and plant. An example of a mechanical hazard is: contact and/or
entanglement with unguarded moving parts on a machine
c. Chemical hazard at the workplace can range from cleaning products to chemical
production. When chemicals are not used, stored or handled properly, they can cause injury,
illness, fire or even explosions at the extreme. Ways that chemicals can harm workers can
include contact with the skin, inhalation or ingestion; the impact can take place immediately
or overtime over prolonged exposure.

PANGASINAN STATE UNIVERSITY 5

Study Guide in TLED22- FOOD PROCESSING, PACKAGING AND LABELLING Module 1: Food Processing

d. Biological hazard is a biological substance that poses a threat to the health of living
organisms, primarily humans. This could include a sample of a microorganism, virus or
toxin that can adversely affect human health.
e. Ergonomic hazard are present in work environments from offices to construction sites; this
includes injuries or strains from repetitive strains, strains from lifting/pushing/pulling,
standing, shiftwork or slips and falls. Ways to manage ergonomic hazards include making
sure that workers have the right equipment and tools to do their jobs comfortably, designing
the workplace to be more ergonomic, and empowering workers to perform exercises or
stretches to prevent musculoskeletal disorders.

2. Assess the risk

This is to work out how hazards will harm someone and how serious the harm could be.
3. Make the changes
For example, you can pick up things from the floor and put them away to eliminate a trip hazard. As
you identify the hazards and the risk in a workplace, make sure to remove them immediately to
prevent such accident.

SAFETY GUIDELINES

1. Protect people from injury

2. Protect equipment from damage
3. Protect the environment from contamination

Hazard Analysis Critical Control Point (HACCP)

HACCP allows processors/regulator to look at what happens during the process to ensure safety.

Major Concepts of HACCP

1. A preventive system of control particularly on biological hazards

2. A system approach for estimating the risk in producing a food product
3. Universally recognized system as the most effective way to prevent food borne illness
4. Science - based systematic, identified specific hazards and measures for their control to ensure
food safety
5. Capable of accommodating change, such as advances in equipment design, processing
procedures, or technological developments that can be applied throughout the food chain from the
primary producer to the final consumer
6. Applicable to establishments that produce, process, treat, pack, trade, transport, serve, or involve
in food production

Seven (7) HACCP Principles

1. Hazard analysis
2. Identify critical control points
3. Establish Control limits
4. Monitor critical limits
5. Establish corrective actions in case of deviation from established critical limits

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Study Guide in TLED22- FOOD PROCESSING, PACKAGING AND LABELLING Module 1: Food Processing

6. Establish verification procedure to ensure that the system is consistent

7. Establish record keeping procedures

V. FOOD SAFETY AND SANITATION

The correct practice of food safety and sanitation can greatly improve efficiently, keep productivity up,
workers safe and consumer confidence high, as well as meeting or surpassing standards and thus
avoiding untoward incidents such as having not only non-compliance fines or a potential shutdown.

Due to the pandemic crisis we are experiencing, safety and sanitation is highly required on any
institution especially in food industry. Remember the following:

1. Wear Personal Protective Equipment

Personal protective equipment are checked according to manufacturer’s specifications
They are worn according to the job requirement. Personal Protective Equipment may include but
not limited to:
1.1 Apron/laboratory gown
1.2 Mouth masks
1.3 Gloves
1.4 Rubber boots/safety shoes
1.5 Head gears such as caps, hair nets, earl plug

2. Observe Personal Hygiene and Good Grooming

Personal hygiene and good grooming is practiced in line with workplace health and safety requirements

3. Implement Food Sanitation Practices

Sanitary food handling practices are implemented in line with workplace sanitation regulations.
Safety measures are observed in line with workplace safety practices.

4. Render Safety Measures and First Aid Procedures

Safety measures are applied according to workplace rules and regulations

First aid procedures are applied and coordinated with concerned personnel according to workplace
standard operating procedures.

Safety measures may include but not limited to:

4.1. 1 labelling of chemicals and other sanitizing agents
4.1. 2 Installation of fire fighting equipment in the work area
4.1. 3 Installation of safety signage’s and symbols
4.1. 4 Implementation of 5S in the work area
4.1. 5 Removal of combustible material in the work area

First Aid Procedures may include but not limited to:

4.2.1 Mouth to mouth resuscitation
4. 2.2 CPR
4. 2. 3 Application of tourniquet

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Study Guide in TLED22- FOOD PROCESSING, PACKAGING AND LABELLING Module 1: Food Processing

4. 2. 4 Applying pressure to bleeding wounds or cuts

4. 2. 5 First aid treatment for burned victims

5. Implement housekeeping activities

Work area and surroundings are cleaned in accordance with workplace health and safety regulations.
Waste is disposed according to organization’s waste disposal system. Hazards in the work area are
recognized and reported to designated personnel according to workplace procedures.

Every individual shall be independent and responsible for their Personal Behaviour or Habits.
People engaged in food handling activities should refrain from behaviour that could result in food
contamination, such as Smoking, Spitting, Chewing or eating, Sneezing or coughing over unprotected
food.

Personal effects such as jewelry, pins or other items should not be worn or brought into food handling
areas if they pose a threat to the safety and suitability of food.

Visitors in food manufacturing, processing or handling areas should, where appropriate, wear protective
clothing and adhere to the other personal hygiene provisions.

LEARNING POINTS
Enough knowledge and skills are required to become an effective and
efficient food processor. So, the students shall be in their fullest potential to
understand and familiarized the different equipment, tools and devices used
in food processing. Let us also learn to be comfortable on working with a
team because it is easier to access the achievement if everybody is working
for this.
Every member of such group shall be committed and ready to give all what is
needed for the company. Being part of the implementing body of occupational
safety and health program to apply and observe food safety and sanitation in
workplace has a big impact for the result of the group’s performance.

LEARNING ACTIVITIES

Exercise 1
Name: _______________________________________ Date:
________________
Year & Section: _______________________________ Score:
_______________

1. Fill in the missing words. Write your answer in a white pad paper.
_______________ is the conversion of an agricultural product into substances with
particular __________, __________ and __________ properties by means of different

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Study Guide in TLED22- FOOD PROCESSING, PACKAGING AND LABELLING Module 1: Food Processing

feasible ___________. (E.g. milling)

Primary processing is the conversion of _______________ to food commodities.
Secondary processing is the conversion of _______________ to _____________ products.
(e.g. baking)

2. Match.
__1. Pilot plant a. is the conversion of ingredients into edible
products. __2. Secondary processing b. is when the appearance, odour, taste and
texture of the product are being assessed
__3. Testing idea on a small scale c. is when several versions of the product are made,
using slightly different ingredients or processes.
__4. Full-scale production d. is a small version of the equipment used in
manufacture.
__5. Primary processing e. is the conversion of raw materials (crops) to food
products.
__6. Sensory evaluation f. is manufacturing of a product on a production line.
__7. Product development is the process g. often organized in unit operations.
__8. The aim of product development h. of making new / modified food products.
__9. The manufacturing process i. is to increase the company’s sales.
_______________________________________________________________________________

Exercise 2
Identify the following. Write your answer on the space provided.
______________1. It is a device used to measure the strength of brine solution.
______________2. It is a device used to Measures the sugar content of sap and
syrup.
______________3. It means to set or determine the accuracy of the measuring
device.
______________4. It is the cheapest and most easily available sanitizer in the
market.
______________5. It is used in measuring the volume of liquid.
______________6. It is a device used to measure liquid ingredient in small
quantity.
______________7. It is the type of water used in calibrating the refractometer.
______________8. It is a device used to measure the temperature of fish/food.
______________9. It is a device used to measure the weight of fish / food.
_____________ 10.How many drops of sap or syrup sample are needed in
testing the
refractometer?
______________ 11. It is use for cutting or slicing fish or meat; for scaling fish.
______________ 12. It is use for trimming of fins of fish.
______________ 13. It is use for picking up or handling food.
______________ 14. It is where fish or meat are cut; ingredients are sliced or
minced
______________ 15. It is use in storing the salted products.

Exercise 3
Write TRUE if the statement is correct and FALSE if the statement is wrong.

PANGASINAN STATE UNIVERSITY 9

Study Guide in TLED22- FOOD PROCESSING, PACKAGING AND LABELLING Module 1: Food Processing

Write your answer a white pad paper

________ 1. Hazards analysis is the identification of selective ingredients,

critical process points, and relevant factors as the key to product safety.
________ 2. Environmental hazards include flood, chemical spill, fire, pollution,
brownout, red tide, and food poisoning.
________ 3. A product can be subjected to contamination after processing and
before packaging.
________ 4. Keep your emergency kit wet and dangerous
________ 5. Wearing of jewelries and keeping objects pockets by employees
should be encouraged.
________ 6. Spitting of employees on the floors and walls as well as smoking
are allowed.
________ 7. Washing facilities should be placed near the toilets and in the
washing area.
________ 8. There must be regular bacteriological and periodical chemical
examination of water supply.
________ 9. There must be a provision of necessary tools like emergency kit in
case of flood and other emergencies.
________ 10. Fire is not only hazardous to health but also a threat to economy.

REFERENCES

Laboratory Manual for Food Processing II (2002). E. Dizon & C. Capareda. University of the Philippines Los Banos
4031 College, Laguna. UPLB-CA Publications Office

Meat processing for small and medium scale operations (1983). P. Ibarra. Institute of Animal Science of UP Los
Banos, College of Agriculture, College of Laguna

https://www.google.com/search?rlz=1C1CHBF_enPH851PH851&ei=WrhUX-
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file:///D:/1st%2020-21/fppl/kto12fishprocessinglearningmodule-130822015015-phpapp01.pdf
https://public.wsu.edu/~rasco/fshn4202005/Intro%20to%20Food%20Processing82905.pdf

https://www.slideshare.net/MarjorieValdez3/food-fish-processing-tools-equipment-166382051?qid=514a9ba9-
3481-4375-92a1-df9a0151109c&v=&b=&from_search=1

https://www.5stoday.com/what-is-5s/

Prepared by: Aileen DG. Catungal

PSU-SC San Carlos City,Pangasinan

PANGASINAN STATE UNIVERSITY 10