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IQF food manufacturing app

IQF Food processing app
IQF Food processing app for simple food manufacturing food processing and food quality control.

IQF Food processing app

Food processing app

Food processing is the transformation of agricultural products into food, or of one form of food into other forms. Food processing includes many forms of processing foods, from grinding grain to make raw flour to home cooking to complex industrial methods used to make convenience foods. Some food processing methods play important roles in reducing food waste and improving food preservation, thus reducing the total environmental impact of agriculture and improving food security.

Primary food processing is necessary to make most foods edible, and secondary food processing turns the ingredients into familiar foods, such as bread. Tertiary food processing has been criticized for promoting overnutrition and obesity, containing too much sugar and salt, too little fiber, and otherwise being unhealthful in respect to dietary needs of humans and farm animals.

Food processing app
Food processing app

Food processing app for food safety

Manufacturing Outlook: Food and Beverage Manufacturers Cautiously Optimistic

Our annual survey about manufacturing issues looks at concerns about hiring and retention, food safety, capital spending and more.

Food manufacturers are feeling at least moderately optimistic about their prospects for 2021, according to our annual Manufacturing Outlook Survey.

Asked directly how they view the new year, 21% of our 158 respondents said they were “very optimistic” and another 37% said they were “somewhat optimistic.” Only 13% were pessimistic to any degree, and the remaining 29% said they were neutral or not sure.

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The survey had two other questions that can be taken as indicators of optimism. Asked about staffing plans, 41% said their companies plan to add staff, and 44% said they probably will maintain current staffing levels. Asked about what will happen to production levels at their companies, a plurality of 41% said the plan was to increase production by adding lines or plants, while 35% said they will probably stay the same.

This optimism, however moderate, echoes the attitudes of American business as a whole, according to the economic advisory service IBISWorld. Its “business sentiment index,” defined as a gauge for “the overall health of the business environment,” will increase 5.7% in 2021, as consumer confidence improves with an end to the pandemic in sight.

The pandemic, of course, is the overriding concern of pretty much every business and institution. We asked how respondents were coping with it, giving them multiple answers to choose from (more than one if they wanted). The most popular answers were “we had to change production scheduling to meet changes in demand” (59%) and “we make workers stand farther apart on the plant floor” (52%).

Some respondents included comments about the pandemic that were not part of the options provided: “We have to sanitize all the areas every few hours”; “Delays in receiving supplies”; “Tremendous focus on worker education on how to stay safe and healthy”; “Hard to see vendors”; and, simply and sadly, “Fallen morale in workers.”

Food processing app:  What’s most important?

We gave respondents a list of 10 manufacturing issues to rank in order of importance. The top four finishers: food safety, cost control, worker safety and changes due to COVID. (The latter two obviously can be conflated.)

Of course, there are more than 10 manufacturing issues facing the industry, so we allowed respondents to specify their own. Here are some of the more interesting ones:

“How to improve training to deal with poor practices and reduced labor available.”

“Less paper, more computer-based tech.”

Food processing app functionality:

Our 2021 Manufacturing Survey was conducted in November 2020 and included the responses from more than 150 food and beverage professionals. Download your copy of the survey results to get access to the data.

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“Employees quitting early rather than finishing seasonal work because they qualify for unemployment and receive government checks because of COVID-19.”

From someone in Baltimore: “Safety on the grounds immediately outside of our manufacturing facilities due to civil unrest.”

We asked respondents about food safety, their No. 1 issue. Given a choice of options, the most overwhelmingly popular response, at 71%, was employee training. The next most popular ones were “more/improved sanitary equipment” (42%); a HACCP plan (33%); and third-party certification (32%).

Automation is an ongoing issue in food manufacturing, and it’s something we always ask about. One of the biggest issues that arise in automation is hiring people who can handle it.

“I think one of the major reasons why food and beverage have been slow to automate is that they’re having difficulty finding the technical workers needed to design, program and operate automation solutions,” says Tyler Noesser, technical director of Alliantgroup, a provider of specialty tax services.

“It seems counterintuitive because we assume automation will take jobs, but in fact automation ends up creating a demand for technical workers,” he continues. “The fact is, even if a food and beverage company wants to automate, there just is not a large enough pool of technical workers versed in automation.”

We asked respondents to rank 10 strategies for dealing with personnel issues related to automation. Their top three choices (with multiple answers allowed): Expanding in-house technical training, 42%; recruiting maintenance technicians, 33%; adding in-house engineering capabilities, 31%. A quarter said they were “not addressing the issue.”

A couple of respondents alluded to the need for training. One said, “We are seeking a variety of ways to help train and educate students in the field of automation and mechatronics.” Another said, “Working with outside consultants to assess and implement automation and train staff.” One gave the simplest possible explanation for not having to worry about automation: “We’re still making hand-twisted pretzels.”

Food processing app:  The digital age

Closely related to automation is the issue of digital technology in general. Of the 10 alternatives we gave, the most popular responses were (with multiples permitted): “Replacing paper records with electronic” (52% of responses); “Replacing analog devices with digital sensors and meters” (38%); “Shifting from local servers to cloud computing” and “Providing more remote access to machine controls” (tied at 35%).

The last option usually has to do with allowing access to equipment manufacturers or other third parties to diagnose problems. One respondent was wary: “Due to cybersecurity risks, less remote access, no OEM access.”

Food processing app
Food processing app

We also asked about maintenance issues. Of a list of 10 strategies to optimize asset use, the most popular response, at 53%, was “On-the-job training programs are being added to expand maintenance workers’ skill sets.” The next most popular were “Routine maintenance duties are being assigned to machine operators” (47%) and “additional maintenance technicians are being hired” (35%).

Capital spending related to manufacturing was another topic. A plurality of 32% didn’t know what their companies’ plans are for 2021. Of the rest, 25% said they expected it to stay about the same, while 27% expected it to go up anywhere from 5% to more than 10%.

Food processing app
Food processing app

We asked respondents to rank what how think their companies will be investing that money. The top three options: process equipment, packaging equipment and plant/worker safety.

We also asked them to mention any capital expenditures that were not on our list. This drew a spate of mentions of specific equipment like blanchers, chillers, dehumidifiers, etc.; several mentioned moving to larger quarters. Some of the more interesting individual responses included: “Installing dust shields over parts of equipment where food is exposed”; “Creating a video ad for trade shows/website”; “Buying cannabis extraction equipment.”

What is a food processing app?

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

What are the methods of food processing apps?

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

Canning

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

Fermentation

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

Food processing app
Food processing app

Freezing

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

Modified atmosphere packaging

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

Pasteurisation  

Food is heated and then quickly cooled down to kill microorganisms. For example, raw milk may contain harmful bacteria that cause foodborne illnesses. Boiling it (at home) or pasteurising (on a large scale) is crucial to ensure it is safe to consume. Apart from dairy products, pasteurisation is widely used in preservation of canned foods, juices and alcoholic beverages.

Smoking

A process of heat and chemical treatment of food to help preserve it by exposing it to smoke from burning material such as wood. Smoked foods usually include types of meat, sausages, fish or cheese.

Additives

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

What are the reasons and consequences of food processing?

Makes food edible

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

Safety, shelf life, and preservation

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

Food processing app
Food processing app

Nutritional quality

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

Convenience

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

Price

Food processing can decrease the cost of foods. For example, frozen vegetables have a similar nutritional value as fresh ones, but at a lower price, as they have already been prepared, do not contain inedible parts, can be bought in bulk, and can last longer. This way, processing increases the shelf life of food, and decreases the amount of waste, reducing thereby the overall costs of food production.

More examples of the impact of food processing can be found in our infographic on the basics of food processing.

How does processed food fit into a healthy diet?

A healthy diet means eating a variety of nutritious foods from different food groups, including fresh fruits and vegetables, grains and cereals (opting for wholegrains when possible), proteins, dairy and healthy fats. Most foods consumed nowadays are processed at least to some degree, but not all processed foods are the same. For example, fruit canned in fruit juice will be a better option than fruit canned in a sugary syrup. Therefore, when chosen mindfully, processed foods can be incorporated into a healthy and balanced diet.

Less processed foods such as frozen fruits and vegetables provide valuable sources of nutrition, with greater convenience and lower price. Chopped, frozen, and canned foods in natural juices (fruit) or water (veg or fish), are therefore good alternatives for busy people having limited time to shop for or cook from a fresh produce.

Some processed foods that contain less fibre, and higher levels of (saturated) fat, added sugar and salt, are best consumed occasionally. For example, canned savoury foods and cured meats are often high in salt. In fact, the World Cancer Research Fund advises to eat very little, if any, processed meat (such as ham, salami, bacon and some sausages, including frankfurters and chorizo). For more information, read our science brief. Similarly, it helps to be mindful of foods like biscuits, chocolate bars, burgers, pizzas and alike, and make them an occasional addition to, rather than a basis of our diet.

For more information please see:

EUFIC (2016). Understanding perceptions of processed food among UK consumers. A qualitative consumer study by EUFIC. EUFIC Forum n° 7.

EUFIC Review (2010) The greatest thing since sliced bread? A review of the benefits of processed foods

Food Processing

Ruth MacDonald, Cheryll Reitmeier, in Understanding Food Systems, 2017

Abstract

Food processing requires a knowledge of the chemistry, microbiology, and physical composition of foods. Early types of food processing included cooking, smoking, fermentation, and drying. These methods have been refined but are still in use today. New technologies have been developed, including irradiation, high-pressure, extrusion, and freeze-drying, that have generated new products and enhanced food safety and quality. The reasons for processing foods and the role of additives, preservatives, and packaging are presented. Government regulations and food industry procedures that assure food safety and labeling requirements are explained. The benefits and concerns surrounding food processing in the context of human health are addressed, including the role of artificial colors, salt, sugar, and fats in processed foods.

Food processing app
Food processing app

Food Processing Technologies and Value Addition for Improved Food Safety and Security

Emanuel O. Alamu, Ackson Mooya, in Smart Technologies for Sustainable Smallholder Agriculture, 2017

Food processing and value addition are key steps in the food value chain. Developing food processing technologies that are environmentally friendly and efficient can substantially contribute to the food value chain and to mitigating the energy crisis that the southern African region is experiencing. Some methods of food processing have been challenged in the recent years but food processing cannot be circumvented entirely because of the ever-growing human population that has to be nourished. The increase in global population during the past two centuries has made food processing one of the most deliberated subjects in the food value chain. The need for processed food is expected to increase even further when the global population increases further. Environmental concerns related to food processing that require consideration, such as the use of fossil fuels and the disposal of residual matters of food processing, will have to be reviewed. This chapter will provide strategies that can be used by industries to enhance the use of environmentally friendly technologies for food processing and enhance value addition.

Food Processing Facility Design

Timothy J. Bowser, in Handbook of Farm, Dairy and Food Machinery Engineering (Third Edition), 2019

Abstract

Food processing facilities add value to a food product. Design of a food processing facility includes many complex steps. This chapter provides an overview of the design of a food processing facility. Key design issues fall into three broad categories: products, cost, and prints. Each category is described and potential design issues are listed. Ten crosscutting (found in all three categories) design issues, critical for project success, are identified and described. Interacting issues (found in two categories) are listed and discussed. Typical drawings rendered during the food processing facility design are listed and explained. Important project phases of planning, conceptual, preliminary, and final design are described with expected results. Construction and startup phases are briefly explained.

Advances in anaerobic systems for organic pollution removal from food processing wastewater

Yung-Tse Hung, ... Lawrence K. Wang, in Handbook of Water and Energy Management in Food Processing, 2008

Food processing wastewaters are generated mainly from food-processing industries, food services and retail establishments. The characteristics of food processing wastewater are extremely varied. The biochemical oxygen demand (BOD) ranges from as low as 100 mg/L to as high as 100 000 mg/L. While suspended solids can be as high as 120 000 mg/L, in some wastes they almost completely absent. The wastewater may be highly acidic (pH 3.0) or highly alkaline (11.0). Food processing wastewaters usually contain organic matter either in dissolved or colloidal form. The concentration of organic matter, varies between different types of food processing wastewater. In generally, food processing wastewaters have high ratios of volatile solids/ total solids (VS/TS), which indicate high energy content. The volume of wastewater also varies widely, some sources generating only a small amount and others one or more million gallons per day.

Biological treatment is accepted as the most appropriate approach to food processing wastewater, the method used depending on the characteristics of the wastewater to be treated. Among the aerobic and anaerobic treatments available, the most effective methods include activated sludge, biological filtration, anaerobic digestion, oxidation ponds, lagoons, and spray irrigation. The most widely used anaerobic treatment for food processing wastewater is anaerobic digestion. A key advantage of anaerobic digestion over other conventional methods is the ability to convert organic matter to energy-rich biogas that can be used as a fuel or upgraded for use in clean fuel vehicles.

Anaerobic digestion technology is an efficient, odor-free method to reduce waste volume, mitigate greenhouse gas associated with organic waste decay, and produce a valuable soil conditioner.

Food processing app
Food processing app

Microbial Enzyme in Food Biotechnology

Poonam Singh, Sanjay Kumar, in Enzymes in Food Biotechnology, 2019

2.5 Future Aspects of Enzymes in Food Processing

Food and feed processing areas are having great success using biological agents like enzymes and microorganisms for the manufacturing of valuable food products (Pedro, 2010). In the future, recombinant strains will be playing a significant role in the production of industrial enzymes, but currently there is some hesitation applying them to genetically modified food products. There is no doubt that the genetically engineered production culture is superior to the wild strain. The sophisticated fermentation techniques and downstream processing will also provide support to the manufacturing of pure and large-scale food processing enzymes. There is a need to develop a novel food processing technology to reduce the cost and time of manufacturing processed food items. Therefore, more advanced research is needed in the area of recombinant DNA technology for improvement of production strains, commercially viable enzyme production, and the development of new food-processing techniques for maximum cost-effective product formulation.

Advances in aerobic systems for treatment of food processing wastewater

Jerry R. Taricska, ... Kathleen Hung Li, in Handbook of Water and Energy Management in Food Processing, 2008

Publisher Summary

Food processing wastewater exhibits extreme variation in characteristics due to the amount of organic materials it carries. The concentration of organic matter in food processing wastewater varies with each type of processing, but generally the Volatile Suspended Solids (VSS) concentration for food processing wastewater is high due to the carryover of food product from processing into the wastewater stream. The wastewater contains various levels of bacteria, viruses, and other pathogens, depending on the food manufacturing process, type of food, and the facility. Treatment of food processing wastewater utilizes a combination of chemical, physical, and biological processes. Each food processing wastewater stream's characteristics, flow rates, and regulatory requirements will determine which physical, chemical, and biological treatment processes will be needed. Physical processes can include screening, clarification, and filtration. Chemical processes may consist of neutralization, enhanced coagulation, and precipitation. The biological treatment processes include both aerobic and anaerobic processes, such as aerobic suspended growth processes, aerobic and anaerobic attached growth processes, and aerobic and anaerobic digestion processes. The major advantages of aerobic processes as compared to anaerobic processes include a generally higher treatment rate and fewer obstacles to meeting effluent dissolved oxygen regulatory requirements.

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Emerging Food Processing Technologies

Gargi Ghoshal, in Food Processing for Increased Quality and Consumption, 2018

Abstract

Food processing is a series of unit operations to convert unprocessed food-to-foodstuffs with prolonged shelf life and enable storage that abolishes or reduces time or effort spent in culinary procedures for increased consumption. The principle of food processing in the majority of developing countries helps to modify taste, aroma, and texture to enhance shelf life and aesthetic properties and to improve the nutritional value of foods. High-quality foods in greatest demand are also highly perishable foods. Fortunately most perishable foods can be preserved by the judicious use of present technology. With the successful application of commercial food preservation technologies, the availability of perishable foods can be extended, thereby contributing to human welfare. In spite of increasing demand for new processed products, the basic principles of food processing remain the same for sustainable availability during scarcity. The processed food industries struggle to accomplish consumer expectations for making nutritious, enjoyable, convenient, safe, easily available, and affordable supreme quality various food items. The objectives of this chapter are to discuss the necessity and perspectives of food processing and preservation, history of food preservation, food spoilage, conventional and modern methods of food processing and preservation, characterization, its evaluation, industrialization to address food safety issues, food waste management, food security, and response to consumers changing demand and so forth.

Food processing app
Food processing app

Food Processing and Foodborne Illness

Maria Vitale, Domenico Schillaci, in Reference Module in Food Science, 2016

Abstract

Food processing is fundamental to counteract food spoilage by microorganisms and enzymes and to make a huge variety of products, from raw to ready to eat food. Package and label ensure safety and contain useful information to trace the foodstuff, to appropriately handle and to alert for the presence of allergens. Foodborne illness related to chemical hazards and toxins from different sources are briefly described. Biofilm communities responsible of microbial persistency in food-processing establishments are also summarized. Common and severe complications symptoms of main pathogenic infection and the examples of Campylobacter, Salmonella, and Listeria monocytogenes are reported.

Food Allergies

S.L. Taylor, in Reference Module in Biomedical Sciences, 2014

Effects of Processing on Allergenicity

Food processing operations have little effect on the allergenicity of most foods since the allergenic food proteins tend to be remarkably stable to food processing conditions (Besler et al., 2001). Food-allergic individuals react to processed foods so allergens must be stable to food processing with a few exceptions. For example, some of the allergens in fruits and vegetables are heat-sensitive. Additionally, food allergens tend to be resistant to proteolysis allowing these proteins to survive digestive processes and arrive in the intestine in immunologically active form (Astwood et al., 1996). Thus, food allergens may survive, in whole or in part, the acid and enzymatic hydrolysis methods used to prepare protein hydrolysates often used as food ingredients. Hypoallergenic infant formula can be manufactured with extensive hydrolysis of milk proteins but that is one of the few examples where processing has an effect on allergenicity. The removal of protein in edible oil refining serves as another example.

Rheology of Food Materials: Impact on and Relevance in Food Processing

Jason R. Stokes, Yuan Xu, in Reference Module in Food Science, 2019

Abstract

Food processing deals with rheological complex and structurally sensitive materials, which impacts operational parameters, process system design and energy usage. The rheology of non-Newtonian fluids and soft solid foods also has a critical relevance in product design, stability and sensory properties. Here, a review on several important rheological aspects in food processing is provided, which includes relevant food rheological properties and consideration for their dependence on microstructure as well as shear and thermal history. In addition, the impact of non-Newtonian fluids in the analysis on viscous friction losses in pipe flow using the mechanical form of energy equation, and heat transfer, is also reviewed.


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