151 A. The Importance of Packaging The usefulness of packaging can be summarized as follows: a. Adequate packaging facilitates distribution. b. Rapid and reliable distribution helps reduce malnutrition, removes local food surpluses and allows the consumer more choice in the foods available. c. Packaging and distribution reduce post harvest losses, and with a larger market allows producers to increase their income. d. Attractive packages appeal to the consumer/buyer. e. Good packaging material complete information about the product helps customers decide about the product. f. It is easy to handle, open, use and dispose. g. Easy storage Therefore, inadequate packaging in developing countries has profound effects on the whole pattern and total amount of food consumed. B. Uses of Packaging Packaging is a means of providing the correct environmental conditions for food during the length of time it is stored and/or distributed to the consumer. A good package has to satisfy the following requirements: 1. It must keep the product clean and provide a barrier against dirt and other contaminants. 2. It should prevent losses. Its design should provide protection and convenience in handling, during transport, distribution and marketing. In particular, the size, shape and weight of the package must be considered.
152 3. It must provide protection to the food against physical and chemical damage (eg water and water vapor, oxidation, light), insects and rodents. 4. It must provide identification and instruction so that the food is used correctly and have sales appeal. LO 1.4 Packaging Materials There are various types of packaging materials used in Fish processing industry. Tthe most commonly used are: (1) hard plastic; (2) Films, and (3) plastic box. These come in various shape and sizes. (1) Hard Plastic is not flexible or elastic and can be used for retail packaging in the production of trays and form-fill packs fishery products. Likewise, they are light, strong and durable and resistant to corrosive substance and water. The following are types of hard plastic : 1. Polystyrene – transparent with low obstruction to water vapor and gases. 2. Expanded Polystyrene – they are produced in cellular shape and used for tray molding. 3. Polyvinyl chloride (PVC) – there are two types of PVC, namely: plasticized and rigid. Plasticized PVC are soft plastics and used in making films while Rigid PVC is hard and is used in the production of trays because of its water proofing and gas barrier properties. (2) Films are web materials that that are 0.25 mm thick, materials more that 0.25mm are called sheet. In choosing plastic film for packaging, properties such as tensile strength, puncture resistance, flex/crack resistance, water vapor and gas barrier, light transmission, clarity and gloss, and heat sealability are also considered. Films are classified: into
153 Basic Films and Laminates: Basic Films are single layered films, which are seven types of basic films. a. Polyethylene (PE). is the most commonly used material because of its low cost, relative strength and flexibility even in low temperatures (Hermes, 1998). b. Polylpropylene (PP). has good protective properties due to resistance to high temperature but becomes brittle when exposed to low temperature. c. Polyamide (PA). is commonly called nylon PA manufactured by condensation of diacid and diamine. It is tough, grease resistant, less permeable to gases and with permeability to moisture. It is elastic and stable at all degrees of temperature, thus, it can be used for boil-in bag pouches production. d. Polyester (PET). It can be used in all degree of temperatures, has excellent gloss, low gas permeability, low moisture transmission, and with high tensile strength. e. Polyvinylchloride (PVC). hard and glossy, but greased resistant and brittle at all degree and temperature. f. Polyvinylidine chloride (PVDC). commercially known as Saran or Crovacs and is produced as a copolymer with vinyl chloride. It can be made into shrinkable forms with low temperature stability. g. Ethylene-vinyl acetate (EVA). has good impact strength, good permeability and high cling attributes. This is used in the lamination of frozen products.
154 Laminates are made up of two or more films attached together by adhesives, to provide better protection to food as a result of improved barrier properties. a. Boil-in-bag. The best material for this type of container is the modified polyethylene with polyester or nylon lamination, which are commonly used for light cooking fishery products. b. Retort pouch pack. is made from layers of polyester/aluminum film and polyolefine like polyethylene bonded together with glue of high performance. The shelf-life of this pack is almost the same canned products, yet it is preferable due to less heat damage of texture and nutrient. (3) Plastic Box. Plastic is used to characterize wide range of materials such as polyethylene and polypropylene that are used in the manufacturing of modern day containers. Plastic box packaging container are classified into: Polyethylene. has excellent toughness; resistant to chemicals, oil and grease; inert to food; and has extremely low water vapor transmission properties (Hermes, 1998). The high density polyethylene best for chilling fish, they can resist extreme heat and cold because they can retain coldness inside. Polypropylene is very light plastic, resistant to grease and to most chemicals, provides good barrier to water vapor and can withstand high temperature because of its low softening point, low density (around 0.9202 g/cm3) and superior processibility. Polystyrene or styrophore is resistant to weak acids like bases and vegetable oils, can penetrate to water vapor, oxygen and carbon dioxide and has low water absorption (around 0.04% to 0.05%) (PalerCalmorin, 2006). In the Philippines styrophore boxes are popular for transporting fish from the wharf to market or processing plant.
155 What to PROCESS? Activity 1. Identify the different transporting and packaging materials used in the following food/fishery products. Food/Fishery Products Transporting Material Packaging Material 1. Fish Paste 2. Shellfishes like shrimp, crabs 3. Rice 4. Bread 5. Frozen Meat 6. Canned Milkfish 7. Noodles 8. Drinks 9. Vegetables 10. Fruits What to REFLECT and UNDERSTAND? Activity1. Discuss the advantages and disadvantages of using the following packaging materials. Type of Packaging Materials Advantages Disadvantages 1. Glass Jars 2. Tin Cans 3. Laminates 4. Cartons 5. Styrofoam
156 What to TRANSFER? There are various types of packaging materials used in Food (Fish) Processing Industry. The most commonly used are the: (1) hard plastic; (2) Films, and (3) plastic box. These come in various shape and sizes. Your task is to demonstrate how to package food/fishery products. You will be evaluated using this scale. 1-Poor 2 - Fair 3 - Good 4 – Very Good 5 – Excellent Indicator 5 4 3 2 1 Packaging smoked fish Wrapping dried fish Placing fish in plastic Placing fish in glass jar Placing shell fish in styrophore 6. Plastic Bottles 7. Polyethylene bag 8. Rigid plastic Container 9.Retort Pouch Pack 10. Thermoplastics
157 Post-Assessment Multiple Choice. Choose the best answer among the given options and write the letter of the correct answer on your answer sheet. 1. Which of the packaging materials can resist extreme temperature and retain coldness inside? (a.) Polyamide (c.) Polyethylene (b.) Polyestene (d.) Polypropylene .2. Which packaging material is used for the lamination of frozen food products? (a.) Ethylene-vinyl acetate (c.) Polyester (b.) Polyamide (d.) Polyvinyl chloride 3. Styrophore as a packaging material is also known as (a.) Polyamide (c.) Polypropylene (b.) Polyethylene (d.) Polystyrene 4. Which packaging container does not belong to the group? (a.) Polyester (c.) Polypropylene (b.) Polyethylene (d.) Polystyrene 5. It is popular for the transporting of fish from the wharf to the market or processing plant. (a.) Polyamide (c.) Polypropylene (b.) Polyethylene (d.) Polystyrene 6. Which is not considered important in packaging? a. protecting the goods for transport b. enhancing product market appeal c. lessening production cost d. advertising the product
158 7. Which is the best packaging material for fish processed through canning? a. tin can c. thermoplastics b. polyethylene bag d. paper board 8. If you are assigned to select packaging materials, which of these factors should be considered? a. appearance c. composition b. reliability d. capacity 9. If you are to pack fermented fishery products, what do you think is the most ideal packaging material? a. plastic bottles c. tin cans b. bottles with plastic caps d. plastic laminates 10. When selecting packaging materials for dried and smoked fish which of these characteristics will you consider? a. odor and gas proof b. sturdy c. elastic d. colorful LO 2. Prepare Raw and Packaging Materials and Supplies Learning Objectives; • Accomplish washing cleaning of materials according to required specifications • Prepare raw and packaging materials and supplies according to Specifications • Complete records according to workplace requirements
159 Pre-Assessment Matching Type. Match Column A with the word/s in Column B that will describe the different packaging materials/containers. Write your answer on your sheet. Column A Column B _____ 1.Tin cans a. easy to dispose _____ 2. Glass Jars b. ease of opening ______3. Paper Sheets c. transparent ______4. Cellophane d. odor protection ______5. Cartons e. durable ______6. Plastic Bottles f. tamper- proof ______7. Laminates g. fragile ______8. Polyethylene Bags h. elastic ______9. Aluminum Foils i. grease proof ______10. Styrophore j. heat-sealed What To KNOW? LO 2.1 Washing and Storing Raw Materials and Ingredients A. Things to Remember when Washing and Sorting Raw Materials and Ingredients Washing (Stansby, 1963). Use clean water in washing the raw materials and ingredients for processing to remove dirt and prevent
160 contamination of the products. Washing can be manual or mechanical by using sprayers, tanks and conveyor belts. These systems must be properly maintained and kept clean and sanitary just like other equipment. Storing (Stansby, 1963). The final part of this section of the GMP requires that food, ingredients, and packaging materials be stored in a way that will protects them from contamination and minimize their deterioration. Proper storage conditions for each food or ingredient should be pre-determined (Canham, 1956). Dry food should be stored in containers or in an environment that protects them from moisture and high humidity conditions. Food and ingredients that have been refrigerated preciously should be placed in refrigerated storage. You should also consider how to protect food and ingredients from other foods and from the plant environment, foods should never be left on the floor but be stored in protective containers or packages to protect them from contamination.
161 LO 2.2 Prepare Raw/Packaging Materials and Supplies According to Specifications A. Important Requirements for Packaging Materials/ Containers The following are among the more important general requirements and functions of food packaging materials/ containers PACKAGING MATERIALS/ CONTAINER Non Toxic and compatible with specific foods Sanitary Protection Moisture and fat protection Gas and odor protection Light protection Resistance to impact Transparency Tamper- proof Ease of Opening Pouring Features Reseal Features Size, shape, weight Ease of Disposal limitation; low cost Appearance and Printability Special Features
162 LO 2.3 Complete Records According to Workplace Requirements A. Monitoring and Recording What to monitor? The responsible person must regularly check compliance with documented procedures during sanitation and cleaning adequate protection for the food when brought to the processing room once cleaning and sanitation has been complete, ready for the next processing shift. Monitoring options for packaging and containers include: • Checking once the food has been delivered to confirm they have not been damaged in transit, and show no visual signs of contamination. • checking to confirm they are clean and suitable for use. • weekly checks to confirm proper storage. Made up cartons may be protected from dust by covering the top layer switching the topmost carton to its opposite side. Ideally, outer pallet wrapping should be removed before entering the processing area. However, if this is not practical, covering can be removed in the processing area provided effective controls are in place to minimize any risk of contamination to surrounding seafood products or product contact materials. Unused containers and packaging may be returned to a warehousetype store provide the packaging is re-wrapped to minimize contamination from dust and vermin.
163 The operator must keep relevant records of compliance with documented procedures. These must include monitoring, problems identified and corrective action taken. Examples of other records that can be used to demonstrate compliance are: 1. register of packaging and/or suppliers 2. supplier statements/guarantees for product contact packaging and containers 3. daily & weekly check sheets B. Importance of Recording and Documentation 1. It gives a reference data on the materials used and their correct magnitude. 2. It determines the economic viability of the product. 3. Records serve as a basis for planning. 4. Records greatly help in making right decisions Steps in recording and documenting production: 1. Weigh all materials and ingredients needed. 2. Make a necessary listing in your notebook of all the materials and ingredients used. It is important to note how much or how many. 3. Follow the correct format in documenting and recording. Sample of Production Report Product Name: Pickled / Marinated Milkfish Production Date: November 6, 2013 Description of Materials: Fresh Milkfish 1000 g
164 Other Ingredients: Distilled vinegar 250 g Calamansi juice 125 g Soy sauce 125 g Salt 75 g Sugar 75 g Black pepper 15 g Minced garlic 15 g Input: 1680 g Output: Marinated Fish 1200 g Wastage 480 g Percentage Yield 71 % Problem Encountered: NONE C. Occupational Health and Safety Requirements Occupational health and safety during the operational phase should focus on: 1. Physical hazards that may cause unexpected damage to the operations include falls caused by slippery floors and stairs; equipment safety issues associated with filleting knives and other sharp tools; and cuts from sharp dges on process equipment (e.g. stainless steel basins). 2. Biological hazards in manual gutting, skinning, and general handling of fish and shellfish include infections and or allergic reactions to humans resulting from exposure to the fish itself, or bacteria on the fish. Water spraying processes may result in the formation of aerosols with bacteria that can be inhaled. 3. Workers can be exposed to lifting, carrying, repetitive work, and unhealthy work posture. Many of the manual operations in less mechanized fish processing plants include lifting heavy boxes of raw materials. Repetitive strain injuries may result from manual filleting and trimming operations.
165 4. Exposure while in handling chemicals such as chlorine, lye, and acids during cleaning operations and disinfection in process areas. 5. Exposure to heat and cold is common in air-conditioned plants under low temperature, even in tropical locations. Improper work clothes in combination with stationary work locations may result, in respiratory and musculoskeletal ailments. The employer shall be responsible for adequate and proper maintenance of Personal Protective Equipment (PPE) used in his workplace. He shall at his own expense furnish his workers with protective equipment for the eyes, face, hands and feet, protective shields and barriers depending on the nature of the process or environment. All personal protective equipment shall be of the approved design and construction appropriate for the exposure and the work to be performed. Examples of Personal Protective Equipment Apron Hairnet Towel Gloves
166 What to PROCESS? Activity 1. Ask the students to collect 10 samples of packaging materials. Make a record of the type of packaging materials and the type and name of food/fishery products being packed. Follow this format. Product Information Brand Name: Product Name: Name and Address of the Manufacturer: Ingredients: Product Specifications: Type of Packaging Materials: Description of the Product as packed: Storage Condition Requirements: Date it was packed: Expiry date: Food Application: Code Number: What to REFLECT and UNDERSTAND? Research and investigate on the techniques of proper handling of raw and packaging materials and supplies in any processing plant available in the vicinity. Visit a Food (Fish) Processing Plant near your locality. Evaluate possible hazards and think of ways on how to eliminate or reduce these hazards in the work place.
167 What to TRANSFER? Prepare five empty bottles for packaging fish bagoong according to required specifications. You will be evaluated using this scale. 1-Poorly performed 2 - Slightly 3 - Fair 4 - Good 5 - Procedures properly followed Discussion 5 4 3 2 1 Preparation of tools and raw materials Application of procedures Safety work habits Speed/time Appearance of finished output Post-Assessment Matching Type. Match the words inColumn A with the word/s in Column B that will describe the different packaging materials/containers. Write your answer on your activity sheet. Column A Column B _____ 1.Tin cans a. easy to dispose _____ 2. Glass Jars b. ease of opening ______3. Paper Sheets c. transparent ______4. Cellophane d. odor protection ______5. Cartons e. durable ______6. Plastic Bottles f. tamper- proof ______7. Laminates g. fragile ______8. Polyethylene Bags h. elastic ______9. Aluminum Foils i. grease proof ______10. Styrophore j. heat-sealed
168 GLOSSARY OF TERMS Contamination. The unintended presence of potentially harmful substances, including microorganisms, chemicals, and physical objects in food. Control Measure. Any action or activity that can be used to prevent, eliminate, or reduce an identified hazard. Control measures determined to be essential for food safety are applied at critical control points in the flow of food. Critical Control Point (CCP). An operational step in food preparation process at which control can be applied and is essential to prevent or eliminate a food safety hazard or reduce it to an acceptable level. Critical Limit. One or more prescribed parameters that must be met to ensure that food safety hazards are controlled at a CCP. Food Borne Disease. Illness resulting from the consumption of food or beverages contaminated with disease-causing microorganisms, chemicals, or other harmful substances. Hazard. A biological, chemical, or physical property that may cause food to be unsafe for human consumption. Hazard Analysis and Critical Control Point (HACCP). A prevention-based food safety system that identifies and monitors specific food hazards that can adversely affect the condition of food products. HACCP Plan. A written document that is based on the principles of HACCP and describes the procedures to be followed to ensure the control of a specific process.
169 HACCP System. The result of the implementation of the HACCP plan. A HACCP system includes the HACCP plan and all the prerequisite programs. Microorganism. A form of life that can be seen only through a microscope including bacteria, virus, yeast, and single-celled animals. Monitoring. The act of observing and making measurements to help determine if critical limits are being met and maintained. Pathogen. A microorganism (bacterium, parasite, virus, or fungi) that causes disease in humans. Person in Charge. The individual present at a food establishment who is responsible for the operation at the time of inspection. Prerequisite Programs. Procedures such as Standard Operating Procedures (SOPs) that address basic operational and sanitation conditions in an establishment. Risk Control Plan (RCP). A concisely written management plan developed by the retail or food service operator with input from the health inspector that describes a management system for controlling specific out-of-control risk factors. Standard Operating Procedure (SOP). A written method of controlling a practice in accordance with predetermined specifications to obtain a desired outcome.
170 REFERENCES A. Books Anon, A.. Sanitation for the Food Preservation. New York. McGraw-Hill Book Co. 1952 BFAR,. Philippine Fisheries Prime. Quezon City, Bureau of Fisheries and Aquatic Resources. 1981 Canhan, R.A. 1965. “Current Trends in Handling Canning Wastes.” Presented at the 5th Annual Water Symposium Water Pollution. Louisiana State University on February 22, 1956 Calmorin, Espejo – Hermes L.P. Post Harvest Fisheries, Quezon City, National Bookstore Inc., 2006 Cortez, 1990, Processing and Preservation of Freshwater Fish, Quezon City, National Book Store, Inc., Saturno, J.O. 2011. Module 6: Tilapia Processing and Value – Adding. Tilapia Production and Entrepreneurship Training Manual. Saturno, J.O. 2010. Lecture Manual in Fish Processing Technology. Department of Aquatic Post Harvest, College of Fisheries, Central Luzon State University, Science City of Muňoz, N.E., 99 pp. Stansby, M.E. Industrial Fishery Technology., New York: Robert E. Crier Publishing Company ,1963. Vera Cruz, A., DT., Saturno, Porciuncula, Recto, Rafael and Laggui, Central Luzon State University, Science City of Muňoz, Nueva Ecija, CLARRDEC, CVARRD and PCARDDD – DEVT. 87 – 127. Villaluz D.K, Fish Farming in the Philippines. Manila, Philippines, Bookman Inc,.1953
171 Online References 1. www.inspection.gc.ca/food/fish-and-seafood/manual/standardsand-methods/esg/1348608971859 2. http://www.inspection.gc.ca/about-the-cfia/newsroom/food-safetysystem/haccp/eng/1346306502207/1346306685922