51 Random Sample- It is one in which all elements in the lot have an equal and independent chance of being included in the sample. Sample. It is a representative of population or group of product to be tested. Sampling Plan. A written guide on what to do and how to perform appropriate sampling procedure for a particular product. Sample Size (n). It is the number of sample units comprising the total sample drawn from a lot or production. Sample Unit- It is one of a number of individual containers, or a portion of a fish or primary container examined or evaluated as a single unit. Basic Sampling Principles, with Emphasis on Sampling Defining the Lot When dealing with fish or fish products which possess the same label, but are packaged in different styles (e.g., different sauces) consider the different styles to be of one lot. Defining a Sample Unit Define the sample unit according to the following instructions: 1. When a lot consists of pre-packaged product, each package and the package thereof constitutes a sample unit. 2. For fresh and frozen groundfish block and groundfish fillet or fresh and frozen of finfish, the sample unit shall consist of a container of fish and its contents.
52 3. Use one of the following 3 approaches when sampling from bulk packages: a. the sample shall consist of the bulk package and its contents; b. for fresh or individually frozen whole or dressed finfish or fresh or individually frozen finfish fillets, the individual fish or fillet may be considered as a representative sub-sample; and c. for scenarios other than described in section ii), a 1 kg subsample of product obtained from the bulk pack may be considered a representative sample. Note: Refer to the sampling section of the individual product standard for further guidance. 4. In lots consisting of salt or pickled fish packed in boxes or barrels, the container constitutes the sample unit. Inspect the entire contents of the container. 5. When a lot of fresh fish consists of more than one specie, all of the sample units used to form a sample shall consist of one specie type. 6. When inspecting large fish, each fish constitutes a sample unit. When an inspector has confidence a representative sub-sample may be obtained from a large, whole fish, the sub-sample becomes the sample unit. The sub-sample must be obtained in a manner that will not compromise the integrity of the sample. To obtain a representative sub-sample from large, whole fish for chemical and microbiological analysis, take 3 one-inch slices from each of the following areas: a. behind the pectoral fins; b. halfway between the first slice and the vent; and c. behind the vent. These 3 slices form the sample unit, representing the large fish.
53 When sampling for sensory analysis, the 3 slice method described above is recommended. If in the inspector's view, fewer or more slices are required to make an accurate decision on the quality of the lot, the inspector may exercise his/her discretion to decide what constitutes a representative sample unit for that fish. If the inspector decides only one slice will be required as a representative subsample from the fish, the one slice should not be taken from behind the vent because this slice does not usually exhibit signs of early decomposition. Requirements in Sampling 1. Samples should be packed with shock absorbing materials. 2. Frozen samples must remain frozen. Food products that require refrigeration should be shipped in ice. 3. Submit samples in the original unopened containers 4. Use sterile sampling tools, instrument, equipment 5. Sampling containers should be clean, dry, leak-proof, wide- mouth, sterile and to the size of the product 6. For dry materials, use sterile metal boxes, cans, bags, or packets with suitable closures 7. Label each samples. Procedure in Sampling 1. Choose representative sample. The condition of the sample product should be the same as it was before sampling. 2. Collect the most ideal sample. 3. Deliver samples immediately to the laboratory with the original storage condition maintained 4. Record the number of samples, time and date it was collected and brought/accepted in the laboratory.
54 What to PROCESS? LO 2 Collect samples In generating concrete ideas about sampling, you should identify sampling requirements in accordance with sampling plan. You should know the number of samples from a particular lot of food according to the sampling category to which a food is assigned. Generally, the assignment to a sampling or food category depends on 1) the sensitivity of the consumer group (e.g., the aged, the infirm, and infants); 2) the possibility that the food may have undergone a step that exposes it to bacteria (e.g Salmonella) during the manufacturing process or in the home; and 3) the history of the food. The selection of a sampling plan depends mainly on the first 2 criteria cited. The history of the food would be important in deciding whether to sample, i.e., whether there was a past history of contamination. Bear in mind that Sampling plan A is detailed outline of measurements to be taken which includes the objectives, outline of which measurements will be taken at what time, on which material, in what manner, and by whom. Sampling plans should be designed in such a way that the resulting data will contain a representative sample of the parameters of interest and allow for all questions, as stated in the goals, to be answered. Steps in the sampling plan The steps involved in developing a sampling plan are: 1. identify the parameters to be measured and the corresponding standard value, the range of possible values, and the required resolution 2. design a sampling scheme that details how and when samples will be taken
55 Activity 1. Make a Sampling Plan based on the steps given above. 3. select sample sizes 4. design data storage formats 5. assign roles and responsibilities Example of Sampling Plan Sampling Raw Shellfish • Examine samples of shellstock, shucked unfrozen shellfish, and live shellfish within 24 hours after collection. When analysis is unavoidably delayed beyond 24 hours, report the actual time elapsed between collection and analysis. • Use heavy plastic bags (6 mil gauge) for shellstock collection to ensure that shells do not puncture the plastic and compromise the integrity of the sample. • Take 5 units of 12-18 shellfish per unit. This number should ensure the selection of 10 sound animals suitable for shucking. Ensure the shellfish yield approximately 200 g of meat and shell liquor. • Using an aseptic technique, transfer the shellfish to the sample jar with sterile forceps; alternatively, samples of the final product may be taken in the packing cans or containers. • Consumer packages are acceptable for examination. Source: www.inspection.gc.ca/Food/fish-and-seafood/manual/standards-andmethods
56 What to REFLECT and UNDERSTAND? Research on new technology involved in sampling techniques and procedures. Activity # 2 Make a study visit in a fish Processing Plant. Observe and take note on how the Quality Controller collects, handles and prepares samples of Fishery Processed Products. Report it in class. What to TRANSFER? Now that you have all the information, are you ready to test your ability to prepare sampling procedures? If your answer is yes, your task is to prepare all the materials needed for the collection of samples and transfer the samples under controlled condition and labels according to sampling requirements. You will be evaluated using this scale. DESCRIPTORS CRITERIA CONTENT/IDEAS CLARITY MASTERY Excellent (10 points) Demonstrated/ Discussed correctly 3 ideas Presented complete and clear ideas Presented the ideas without looking at the notes Very Good (5 points) Demonstrated/ Discussed correctly 2 ideas Presented clear ideas but need details Presented the ideas while looking at the notes once in a while Good (2 points) Demonstrated/ Discussed correctly 1 idea Presented vague ideas including details Reading while presenting the ideas Needs Improvement (0) Did not discuss Did not discuss Did not discuss
57 Answer the post assessment below to determine whether there is significant increase in your understanding. Good Luck! Post-Assessment Modified True or False: Write TRUE if the statement is correct and if FALSE change the underlined word/s to make the statement correct. Write your answer in your notebook. Do not write anything in the module. ___ 1. Knowledge in sampling will help, prevent or delay self-decomposition of fish products to be evaluated. ___ 2. Samples should be handled with care after presentation to the panelists. ___ 3. Samples must be handled, packaged, and shipped in order not to compromise the identity or integrity of the sample. ___ 4. If products are in bulk or in containers that are too large for submission to the laboratory, transfer representative portions to sterile containers under aseptic conditions. ___ 5. Dry or canned foods that are not perishable and are collected at ambient temperatures should be refrigerated. ___6. Lot size is a number of units of product in a lot. ___7. For wet materials , use sterile metal boxes,cans,bags or packets with suitable closure. ___8. Sampling plan is a detailed outline of measurements to be taken. ___9. Sampling containers should be clean, dry and leak-proof. ___10. Collect the most cheap sample.
58 Module 4. INSPECT AND SORT RAW MATERIALS AND PRODUCTS (IS) This module deals on how to inspect and sort raw materials and products (IS) in Fish Processing. This includes preparing equipment and tools, inspecting and sorting the materials and product, and complete inspection and sorting activity. Content Standard Performance Standard The learner demonstrates understanding of inspecting and sorting raw materials and products to be used. The learner demonstrates how to inspect and sort raw materials and products to be used. LO 1. Prepare Equipment and Tools Learning Objectives; 1. Prepare equipment and tools for inspection and sorting in accordance with manufacturer’s specifications and workplace requirements 2. Check, clean and sanitize equipment and tools in accordance with manufacturer’s specifications and workplace requirements 3. Prepare office equipment and materials/supplies needed in accordance with approved specifications
59 Pre-Assessment Read and understand the questions below. Select the best answer for each item then write your choice on your answer sheet. Do not write anything in the Module. 1. Which of this statement implies the removal of dirt and organic substances, such as fats and protein particles from surfaces of walls, floors, tools and equipment? a. Cleaning b. Inspection c. Sanitation d. Sorting 2. Which of the following is not a type of sanitizer? a. Acid based sanitizer b. Chlorides chlorine peroxide c. Hypochlorites acid d. Quarternary ammonium 3. The objective of inspection prior to using of any reusable container is to see to it that a. they are new b. they are not damaged c. they are of correct dimension d. all of the above 4. The objective of regular checks and inspection of tools, machines and equipment is to see to it that they are a. clean and free of any residue, including water b. treatment is continuous c. they have undergone preventive maintenance d. products have not been contaminated
60 5. Which of the following is the key component of the HACCP Plan? a. cleaning b. monitoring c. sorting d. recording information 6. It refers to tidiness and proper removal of waste. a. Book keeping b. Household services c. Housekeeping d. Cleaning 7. Which of the following is not an example of Food Safety Practices and Principles? a. Prevention of contamination b. Following Law c. Minimizing contamination. d. Maximizing contacts from human or animal feces 8. It is a preventive food quality management system. a. HACCP b. Hazard Analysis c. Sanitation d. GMP 9. It is a type of anti-microbial that kills germs that are present in places where tools, utensils and equipment are treated and kept. a. Chlorine b. water c. oil d. perfume
61 10. Which of the following is not the purpose of inspection? a. To determine the condition of the equipment. b. To calibrate the tools and equipment c. To buy a new one d. To ensure safety. What to KNOW ? LO 1 Prepare Equipment and Tools LO 1.1 Preparation of tools for inspection and sorting The purpose of an inspection is to identify whether work equipment can be operated, adjusted and maintained safely – with any deterioration detected and remedied before it results in a health and safety risk. Not all work equipment need formal inspection to ensure safety and, in many cases, a quick visual check before use will be sufficient. However, inspection is necessary for any equipment where significant risks to health and safety may arise from incorrect installation, reinstallation, deterioration or any other circumstances. The need for regular inspection and frequency of inspection should be determined through risk assessment. The result of the inspection should be recorded and this record should be kept at least until the next inspection of the equipment. Records do not have to be made manually in writing but, if kept in another form (e.g.in a computer), these should be held securely and made available upon request by any enforcing authority. Work equipment that requires inspection should not be used, unless inspection has taken place.
62 Regular checking and inspection of equipment and machines will facilitate Preventive Maintenance which includes the following: 1. Machine temperature- checking to avoid overheating. 2. Hydraulic fluid – checking to guarantee that equipment/machine which is operated by water or other liquids moving through the pipes under pressure will function. 3. Wear and surface condition- to make sure no machine parts are deteriorating or defective due to everyday use. 4. Crack - to see to it that there are no broken parts which will cause the breakdown of the machine or as source of leak 5. Leak detection –to prevent accidental release of gas, water, oil from the machine. 6. Vibration – checking to determine if there is an instance of shaking or moving back and forth rapidly which will affect the performance of equipment or machine. 7. Corrosion – checking to minimize wear and tear of parts by washing, drying and lubricating parts. 8. Electric insulation – checking to guarantee that there are no live wires exposed during the operation of an equipment which may results in short circuit, electrocution, or even fire. Who Should Carry Out the Inspection of Work Equipment? Equipment can be inspected by someone who has sufficient knowledge and experience to determine: • what to look at • what to look for • what to do in case there is a problem
63 Guide for Inspection of Tools, Utensils and Equipment The required level of competence will vary for inspections according to the type of equipment and how or where it is used. The nature of these inspections does not have to be determined by the same competent person who undertakes them. This can often be done in-house by experienced workforce, taking account of: • the manufacturer's recommendations • industry advice • their own experience of the equipment, its use, the particular factors of the workplace and the people using the work equipment Things to remember during inspection All precautions for inspecting items must be carefully observed prior to sterilization. Check specifically if instruments are: • clean and free of any residue, including water • in good working order - joints or jaws not stiff • complete and all parts present in a multi-part instrument • undamaged - not out of alignment • meet designed according to specifications regarding tension and grip. When checking multi-part instruments it is necessary to re-assemble them to ensure that they are working correctly. This is also a good way of checking that all the parts are there, but remember they need to be disassembled again prior to sterilization.
64 LO 1.2 Checking, Cleaning and Sanitizing of Tools and Equipment A. Cleaning is the removal of dirt and organic substances, such as fat and protein particles from surfaces of walls, floors, tools and equipment. Through the cleaning procedures, large number of microorganisms (90% and more) present on the mentioned objects will be removed. However, many microorganisms stick very firmly to surfaces, in particular in tiny almost invisible layers of organic materials, called biofilms, and will not entirely be removed even by heavy cleaning but persist and continue multiplying. The maintenance of cleanliness in a fish processing plant requires frequent and continuous cleaning as well as at the end of every shift. This will keep wastes from accumulating during the operating day, which not only improves sanitation but reduces the time needed for end of shift cleaning. Waste could be removed by brushing away or wash away with water with aid of appropriate cleaner. Factors affecting Cleaning a. Soil type (organic, inorganic and other source) b. Soil condition ( Infestation of microorganisms) c. Water temperature d. Surface being cleaned e. Type of cleaning agent f. Agitation or pressure g. Length of treatment
65 A clean surface is defined as being free from soil (e.g. food residues), free from bad odors, non-greasy to the touch and having no visible oxidation (e.g. rust). A sanitized clean surface is defined as a surface that is substantially free from pathogenic microorganisms and undesirable number of spoilage microorganisms. Cleaning prior to sanitizing is recommended as it increases the effectiveness of the sanitizing step. Effective cleaning and sanitation programs are required to achieve the correct level of hygiene in food handling or production facilities. If these are not adhered to there is a greater risk of food becoming contaminated by pathogenic or spoilage microorganisms. B. Sanitation in Fish processing Plant Sanitation in Fish Processing Plants may be defined as the planned maintenance of the work and product environment to prevent or minimize hazards of product contamination and condition that are visually unpleasant to the consumer, and to provide clean, healthy and safe working condition. The use of sanitizing agents leads to effective sanitation of tools, equipment and utensils. Sanitation with the use of physical and chemical sanitizing agents will kill residual microorganisms that remain after cleaning. Cleaning by washing with soap and water is very important as it ensures the removal of dirt or debris by physical and/or mechanical means. Clean water is to be used to finally wash and rinse all utensils, tools and equipment. Sanitizing or disinfecting, on the other hand, rids of or reduces the number of micro-organisms on surfaces where food comes in contact with. It cannot be accomplished until surfaces where food are processed are clean. Moreover, it cannot be effective without a good pest control program. Cleaning alone by washing will not be capable of totally eradicating microbes, germs and viruses, hence the need to use sanitizing agents. Chlorine is one
66 of the cheapest and most easily available sanitizers in the market. It is popularly used in the treatment of water for both household and plant. Likewise, chlorine is also used to sanitize processing equipment. Importance of Sanitation 1. Prevents pest infestation 2. Kills bacteria already present 3. Reduces potential for cross contamination 4. Helps increase shelf- life 5. Minimizes chance for injury 6. Helps create a more pleasant work environment Sanitizer is a type of antimicrobial that kills or irreversibly inactivates at least 99.9 percent of all bacteria, fungi, and viruses (called microbials, microbiologicals, microorganisms) present on surfaces, tools, utensils and equipment. Types of Sanitizers • Quaternary Ammonium Chlorides • Acid-based sanitizers • Chlorine dioxide • Hypochlorites Recommended Level of Using Sanitizer (ex. Chlorine) Area/Materials to be Sanitized Volume of Water Volume of Chlorine Time Hand Dip 5 gallons 10.8 ml 2-5 minutes Equipment 5 gallons 54 ml 2-5 minute Floor 5 gallons 125 ml 20 minutes
67 Categories of Sanitation for Fish Processing Plants • Housekeeping. Refers to tidiness and proper removal of waste. • Rodent elimination. Knowledge of the characteristics of rodent and permannent control through structural changes in building, removal of possible shelter and food, and supplementary poisoning and trapping is needed. • Insect pest elimination. Recognition of serious infestations and identification including the knowledge on habits and ecology is required. Control may be the safer way of using insecticidal chemicals, building structure is required, equipment and other process change. • Cleaning. Cleaning of Fish Processing Plant and equipment involves careful organization, training work schedule and use of the best available equipment, methods and materials. • Microorganism. The types and significance vary with product and type of operation. The microorganisms found in dried and salted fish differ from canned fishery products. • Construction and maintenance of buildings and equipment. This may simplify sanitation maintenance and reduce cost and contamination hazards. • Employee’s facilities. Rest rooms, locker rooms, drinking water, eating facilities and working environment must be well maintained for the comfort and safety of the workers for proper motivation and efficient performance and for excellent production and product quality. • Water. Must be potable and safe for the product and other plant uses. • Waste. Convert fish waste into fish value-added products such as burger, polvoron, spread, embotido, fish ball, meat loaf, luncheon meat, sausage and many others. This will eliminate environmental pollution and promote food security and economic security.
68 • Laboratory tests. This is important to the sanitation control program in the Fish Processing Plant; it must be understood and utilized to its best advantage. LO 1.3 Cleaning and Disinfection Procedure Cleaning and disinfection are the most frequent operations in modern food processing. Carelessness may cause considerable economic loss, and loss of reputation on the market. The hygienic standards respected in processing plants depend on kinds of production. For example, in the cannery they will be stricter than in plants where fish is only gutted and stored in ice and its shelf life is rather short. Regarding all other technological operations and processes, cleaning and disinfection procedures must follow detailed instructions and responsible personnel be assigned. Steps/Procedure in Cleaning and Disinfection of Tools, Equipment and the Laboratory Area Various steps should be included in a complete cycle of cleaning and disinfection (Huss, 1994): 1. Remove food products; clear area from bins, containers, etc. 2. Dismantle equipment to expose surfaces to be cleaned. Remove small equipment, parts and fittings to be cleaned in a specified area. Cover sensitive installations to protect them against water, etc.
69 3. Clear the area, machines and equipment of food residues by flushing with water (cold or hot) and by using brushes, brooms, etc. 4. Apply the cleaning agent and use mechanical energy (e.g., pressure and brushes) as required. 5. Rinse thoroughly with water to completely remove the cleaning agent after the appropriate contact time (residues may completely inhibit the effect of disinfection). 6. Control cleaning. 7. Sterile thru chemical disinfection or heat. 8. Rinse off the sterilant with water after the appropriate contact time. This final rinse is not needed for sterilants, e.g., Hydrogen Peroxide based formulations which decompose rapidly. 9. After final rinsing, reassemble equipment and allow it to dry. 10. Control cleaning and disinfection. 11. In some cases it will be good practice to re-disinfect (e.g., with hot water or low levels of chlorine) just before production to begin again. As mentioned above, only agents and disinfectants permitted by adequate regulations can be used for cleaning and disinfection operations. During their use, precautionary measures must be observed and this requires proper training of personnel.
70 LO 1.4 Food Safety Principles and Practices 1. Preventing contamination. Prevention of microbial/chemical contamination of foods/fishery products is better than relying on corrective actions once contamination has occurred. 2. Minimizing contamination. To minimize microbial/chemical food safety hazards in fresh produce, producers and others involved in production should use good agricultural and management practices in those areas over which they have control. 3. Minimizing contacts from human or animal feces. The major sources of disease-causing microbes are human or animal feces. 4. Ensuring a safe water supply. Whenever water comes in contact with produce, its source and quality are directly linked to the potential for contamination. 5. Using manure and municipal sewage safely. Incomplete composted organic fertilizers may contain disease-causing microorganisms from animal or human feces. 6. Focusing on worker health and hygiene. There is a direct correlation between poor personal hygiene and food-borne disease. 7. Following the law. Follow all applicable local, state, and national laws and regulations. 8. Being accountable. Accountability at all levels of the agricultural environment (farm, packing facility, distribution center, and transport operation) is important for a successful food safety program.
71 LO 1.5 Awareness of Codes or Regulations such as Hazard Analysis Critical Control Point (HACCP) and Good Manufacturing Practice (GMP) Hazard analysis is a preventive food quality management system which identifies, evaluates and controls the hazards significant to food safety specific to a product. Critical control point is a point in time or a physical location at which failure of control or preventive measures will expose the consumer to unacceptable health risks. HACCP is a national standard for fish and fishery aquatic products. Major Concepts of Hazard Analysis Critical Control Point (HACCP) • Preventive system of control for biological hazards • System approach to identify risks in food production and food safety measures. • Universally recognized system as the most effective way to prevent food-born diseases • Scientific-based system to identify specific hazards and measures control to ensure food safety • Capability of accommodating change such as equipment design, processing procedure or technological development • Applicability to establishments that produce, process, treat, pack, trade, transport, serve or are involved in food production • Food safety • Safety programs such as Good Manufacturing Practices (GMP) and Sanitation Standard Operating Procedure (SSOP)
72 Seven Principles of Hazard Analysis Critical Control Point 1. Conduct a Hazard Analysis The application of this principle involves listing the steps in the process and identifying where significant hazards are likely to occur. 2. Identify the Critical Control Points A Critical Control Point (CCP) is a point, step or procedure in which control can be applied and a food safety hazard can be prevented, eliminated or reduced to acceptable levels. 3. Establish Critical Limits A Critical Limit (CL) is the maximum and/or minimum value to which a biological, chemical, or physical parameter must be controlled at a CCP (Critical Control Point) to prevent, eliminate, or reduce to an acceptable level, the occurrence of a food safety hazard. The critical limit is usually a measure such as time, temperature, water activity (Aw), pH, weight, or some other measures that are based on scientific literature and/or regulatory standards. 4. Monitor Critical Control Point Monitoring procedures should describe how the measurement will be taken, when the measurement will be taken, who will be responsible for the measurement, and how frequently the measurement will be taken during production. 5. Establish Corrective Action Corrective actions are the procedures that are followed when a deviation in a critical limit occurs. This usually includes identification of the problems and the steps taken to ensure that the problem will not occur again.
73 6. Establish Verification Procedure Those activities, other than monitoring, that determine the validity of the HACCP plan and ensure that the system is operating according to the plan. 7. Establish Recordkeeping Procedure A key component of the HACCP plan is recording information that can be used to prove that food was produced safely. The records also need to include information about the HACCP plan. Record should include information, product description, flow diagrams, the hazard analysis, the CCPs, Critical Limits, Monitoring System, Corrective Actions, Recordkeeping Procedures, and Verification Procedures What are Good Manufacturing Practices? Good Manufacturing Practices (GMPs) are the minimum sanitary and processing requirements necessary to ensure the production of quality food. Categories of Good Monitoring Practices 1. General maintenance of physical facilities 2. Cleaning and sanitizing of equipment and utensils 3. Storage and handling of clean equipment and utensils 4. Pest control 5. Proper use and storage of cleaning compounds, sanitizers, and pesticides 6. Employee training 7. Plant design 8. Quality assurance assessment
74 Things Needed to Meet Requirementd For Good Manufacturing Practices To meet the general GMP requirements for inspecting and storing raw foods and ingredients, you need to: Develop consistent procedures for receiving food or ingredients that describe how they will be evaluated, separated, and cleaned if necessary, and then stored. Inspect every delivery to make sure that all items are clean and suitable for use as food. Separate any contaminated item and filthy or damaged containers from safe items. Reject food or containers that are spoiled, contaminated with filth, or otherwise unsuitable for food, and properly dispose them in a sanitary manner. Wash items as necessary if they are acceptable for use, and then repack for storage. Water should be potable. Store all food and ingredients in containers or in ways that will adequately protect them from contamination from other foods or the plant environment, and allows for routine monitoring for damage, contamination, or intrusion by pests.
75 Monitor and clean and sanitize mechanical systems including conveyors to make sure that they do not contaminate food. Monitor and inspect every delivery of food, ingredients, or packaging materials. What to PROCESS? Activity 1. Classify the following tools, utensils, equipment in accordance with their uses and classification. Select your answer from the pictures below. Write the words/terms only. Pressure Cooker Wooden Vat Measuring Cups Baklad Knives Measuring Glass Salinometer
76 Activity 2. Prepare a sanitizing solution and apply the steps in sanitizing tools, utensils, equipment, and laboratory table used in Making Fish Nuggets. Making Fish Nuggets • Tools, utensils and equipment needed • Mixing bowl • Utility cups • Measuring cups and spoons • Range • Model • Pan • Casserole • Ladle • Spoon and Fork • Working table • Chopping board and knife • Basin MEASURING TOOLS/devices TOOLS, UTENSILS, EQUIPMENT FOR FISH PROCESSING CUTTING IMPLEMENTS SALTING EQUIPMENT Smoking EQUIPMENT
77 Ingredients: • 1 kg Fish • 1 medium size potato( grated) • 1 medium size carrot( grated) • 1 medium size egg • 1 cup all purpose flour • 2 cups bread crumbs • 1 tsp garlic powder • 1 tsp white pepper • 1 tsp salt • 1 tsp seasoning • 1 tsp basil leaves • 1 tbsp chopped bell peppers For the Sauce: • cup corn starch • 2 cups water • 3 tbsp sugar • 1 tbsp vinegar • 1 tsp chopped onion • 1 tsp white pepper • 1 tbsp chopped bell pepper Procedure: 1. Debone the fish then slice it into cubes. 2. Marinate the chopped fish in white bell pepper , salt, garlic powder basil leaves and seasoning. 3. Add the flour, egg and grated potato and carrot in the marinated fish.
78 4. Mix well all the ingredients until they become sticky. 5. Form the shape that you want, then roll it over the bread crumbs. 6. Fry, garnish and serve with sweet and sour sauce. What to REFLECT and UNDERSTAND Show and tell to the class the result in Activity 1. Name of Tools Operational Non-Operational Remarks 1. 2 3 4 5 6 7 8 9 10 Activity 3 Research on the latest techniques involved in checking, cleaning and sanitizing of equipment and tools in accordance with manufacturer’s specifications and workplace requirements.
79 What to TRANSFER? Now that you have all the information, are you ready to prepare tools, utensils, equipment for inspection and sorting? If yes, follow on the procedures given in the Task Sheet below Task Sheet Title: Prepare, clean and sanitize fish processing tools, utensils, equipment for inspection and sorting Performance Objectives: Given the available fish processing tools, utensils, equipment and sanitizer prepare them for inspection and sorting Supplies/Materials: • Sanitizer • Cleaning aid Equipment: Available fish processing tools, utensils, equipment Steps/Procedures: 1. Gather the available tools, utensils and equipment as well as the sanitizers and cleaning aids. 2. Follow the procedure on how to check, clean and sanitize the fish processing tools and equipment. 3. Observe precautionary measures while doing the activity. Assessment Method: Direct observation Demonstration
80 Answer this post-test to enable you to find out what you already know. Write your answer in your test notebook. 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 Checking, cleaning & sanitizing of tools Application of procedures Safety work habits Speed/time Appearance of finished output Post – Assessment Read and understand the questions below. Select the best answer for each item then write your choice on your answer sheet. Do not write anything in the Module. 1. Which of the terms implies the removal of dirt and organic substances, such as fats and protein particles from surfaces of walls, floors, tools and equipment? a. Cleaning b. Inspection c. Sanitation d. Sorting 2. Which of the following is not a type of sanitizer? a. Acid based sanitizer b. Chlorides chlorine peroxide c. Hypochlorites acid d. Quarternary ammonium
81 3. What do you think is the purpose of inspection prior to reusing reusable container? a. to see if they are new b. to see if they are not damaged c. to see if they are of correct dimension d. all of the above 4. What conditions of tools, machines and equipment should be considered during regular checking and inspection? a. clean and free of any residue, including water b. length of treatment c. preventive maintenance d. products contamination 5. Which of the following is the key component of the HACCP Plan? a. cleaning b. monitoring c. sorting d. recording information 6. It refers to tidiness and proper removal of waste. a. Book keeping b. Household services c. Housekeeping d. Cleaning 7. Which of the following is not an example of Food Safety Practices and Principles? a. Preventing contamination b. Following Law c. Minimizing contamination. d. Maximizing contacts from human or animal feces
82 8. It is a preventive food quality management system. a. HACCP b. Hazard Analysis c. Sanitation d. GMP 9. It is a type of anti-microbial that kills germs that are present on surfaces where tools, utensils and equipment are kept or stored. a. Chlorine b. water c. oil d. perfume 10. Which of the following is not the purpose of inspection? a. To determine the condition of the equipment. b. To calibrate the tools and equipment c. To buy a new one d. To ensure safety. LO 2. Inspection of Packaging Materials Learning Objectives: a. Receive and handle raw materials and products according to standard operating procedures. b. Conduct inspection and sorting according to required specifications, OHS requirements and workplace procedures. c. Inspect raw materials and products for visible signs of defects according to processing and purchasing specifications. d. Sort raw materials and products in accordance with physical property specifications
83 e. Weigh and keep inspected and sorted raw materials and products in accordance with standard operating procedures f. Report rejected/sub-standard raw materials and products to appropriate person and/or disposed according to organizational guidelines. Pre- Assessment Identify the answers found inside the boxes to the questions below. 1. It is a vital component of the visual quality of fresh foods. 2. It is the application of tests and measuring devices to compare products and performance with specified standards. 3. It is carried out on the basis of individual physical properties. 4. It is the assessment of the overall quality of a food using a number of attributes. 5. It is the combination of properties which determine product quality and process effectiveness. Grading Sorting Color Inspection Functional Property Geometric Property Shelf life Nutrition Facts Flavor External Force Internal Force
84 6. It is the duration or period wherein a fishery product remain in consumable quality. 7. It is a rather subjective property which is difficult to quantify. 8. It is the result of mechanical injury to fish. 9. It arises from physical changes such as variation in temperature and moisture content of fish. 10. This is found in the label of the fishery products. It serves as source of info to the customer to guide them on what they are eating What to KNOW? LO 2.1 Types of Raw Materials and Fishery Products and its Properties The selection of raw materials is a vital consideration to the quality of processed products. The quality of raw materials can rarely be improved during processing, and while sorting and grading operations can aid by removing oversize, undersize, or poor-quality units, it is vital to procure materials whose properties most closely match the requirements of the process. Quality is a wide-ranging concept and is determined by many factors. It is a composite of those physical and chemical properties of the material which govern its acceptability to the ‘‘user.’’ The latter may be the final consumer, or more likely in this case, the food processor. Geometric properties, color, flavor, texture, nutritive value, and freedom from defects are the major properties likely to determine quality.
85 Properties of Raw Materials The main raw material properties of importance to the processor are geometric, and functional properties. A. Geometric Properties Food units of regular geometry are much easier to handle and are better suited to high-speed mechanized operations. In addition, the more uniform the geometry of raw materials, the less rejection and waste will be produced during preparation operations such as peeling, trimming, and slicing. Color Color and color uniformity are vital components of the visual quality of fresh foods, and play a major role in consumer choice. However, it may be less important for processing. For low-temperature processes, such as chilling, freezing, or freeze drying, the color changes little during processing, and thus the color of the raw material is a good guide to suitability for processing. Texture The texture of raw materials is usually changed during processing. Textural changes are caused by a wide variety of effects, including water loss, protein denaturation which may result in loss of water-holding capacity or coagulation, hydrolysis, and solubility of proteins.
86 Flavor Flavor is a rather subjective property which is difficult to quantify. Flavor quality of horticultural products is influenced by genotype and a range of pre- and postharvest factors. Optimizing maturity/ripeness stage in relation to flavor at the time of processing is a key issue. Again, flavors are altered during processing, and following severe processing, the main flavors may be derived from additives. Hence, the lack of strong flavors may be the most important requirement. B. Functional Properties of Raw Materials The functionality of a raw material is the combination of properties which determine product quality and process effectiveness. These properties differ greatly for different raw materials and processes, and may be measured by chemical analysis or process testing. Specifications of Raw Materials In practice, processors define their requirements in terms of raw material specifications for any process on arrival at the factory gate. Acceptance of, or price paid for, the raw material depends on the results of specific tests, to wit: Fish Freshness – physical characteristics of fresh fish-bright red gills, few slime, bright eyes, scales adhere to the skin, fish odor and pH of 6.0 to 7.0 using a pH meter or sinks when soaked in a basin water. Species of Fish– It is important that we are familiar with the different species of fish so that we can process them well. We can use them in preparing minced products like sausage, burger, fish ball, embotido, spread, luncheon meat, meat loaf, etc
87 Color- color is important to determine the freshness of the raw materials. e.g., red eyes when stale; red gills when fresh. Flavor – Most the products with good aroma or odor have likewise good flavor. Texture – Texture is an important factor in assessing the quality of the fishery and fishery by-product. Moisture content – The moisture content of the fishery products vary which could be influenced further by the processing method employed. This is the amount of water in fish that could be utilized by microorganism for growth. Shelf-life – This is the duration or period wherein a fishery product remains in consumable quality. Generally, fish and fishery products vary but could be influenced by the processing method employed; thus the longer the shelf-life the better. Exception to this is the pickled fishery product, a semipreserved type of processed product. Nutrition facts – this is found on the label of the fishery product. It serves as source of info to the customer to guide them on what they are eating. LO 2.2 Procedures and Techniques in the Inspection and Sorting of Raw Materials and Products Inspection is the application of tests and measuring devices to compare products and performance with specified standards. It determines whether a given fishery product falls within specified limits of variability and therefore, acceptable or unacceptable (defective). Acceptance inspection or screening, cannot determine good quality in a product; it merely identifies non-acceptable units after defects have occurred. By determining substandard work during and after processing, however, inspection helps
88 control quality by providing the fish processor useful information in determining causes of defective product. Purposes of Inspection 1. Accept or Reject – good quality products are accepted based on the set of specification as to formulation like color, flavor, texture, weight, nutritive values, microbial test, and shelf-life. 2. Evaluate average quality – Sampling evaluation of the product is more practical than undertaking 100 percent evaluation/inspection. To give equal chance, the products sampling must be taken at random. 3. Determine uniformity – if all of the 31 kilos of smoked fish are uniform as to their formulations, color, flavor, texture, weight, nutritive values, microbial test, and shelf-life, then they meet the standards and are acceptable for commercialization and human consumption. LO 2.3 Grading of Raw Materials or Products In grading raw materials needed in Fish processing, the following qualities should be observed: 1. The skin of freshwater fish has a bright color. 2. Scales adhere strongly to the skin. 3. Gills are bright red and covered with clean slime. 4. The flesh is firm and elastic. 5. The body is rigid, stiff and belly walls intact, not ruptured. 6. It sinks in water, although some tend to float if gassy. 7. The skin is shiny and bright. 8. Eyes are clear, full, not sunken.
89 LO 2.4. Defects of Raw Materials Damage to Raw Materials Damage may occur at any point from growing to the final point of sale. It may arise from external or internal forces. • External forces result in mechanical injury to fish, fruits and vegetables, cereal grains, eggs, and even bones in poultry. They occur due to rough handling as a result of careless manipulation, poor equipment design, incorrect containerization, and unsuitable mechanical handling equipment. • Internal forces arise from physical changes such as variation in temperature and moisture content, and may result in skin cracks in fruits and vegetables, or stress cracks in cereals and for Fishery products due to longer chilled storage the eyes structure become concave. The scales will get removed and the skin becomes bare which is undesirable and not economic. Weight loss in shrimps occurs due to leaching of amino acids and vitamins from the fish body when the ice melts. Color change in the fish occurs when chilled. Either internal or external damages leave the material open to further biological or chemical damages including enzymic browning of bruised tissue, or infestation of punctured surfaces by molds and rots.
90 LO 2.5 Physical Properties for Sorting Foods A. Difference Between Grading and Sorting Sorting and grading are terms which are frequently used interchangeably in the food processing industry, but strictly speaking they are distinct operations. Sorting is a segregation based on a single measurable property of raw material units, while grading is ‘‘the assessment of the overall quality of food using a number of attributes.’’ Grading of fresh produce may also be defined as ‘‘sorting according to quality,’’ as sorting usually upgrades the product. Virtually all food products undergo some type of sorting operation. There are a number of benefits, including the need for sorted units in weight filling operations, and the aesthetic and marketing advantages in providing uniform-sized or uniform-colored units. In addition, it is much easier to control processes such as sterilization, dehydration, or freezing in sorted food units, and they are also better suited to mechanized operations such as size reduction, pitting, or peeling. B. Basis of Sorting: By weight- the most precise method of sorting, as it is not dependent on the geometry of the products. By size– is less precise because it requires a number of physical parameter but is considerably cheaper. By shape– useful in cases where the food units are contaminated with particles of similar size and weight, particular in grains that may contain other seeds.
91 By density– can also be a marker of suitability; density of peas correlates with tenderness and sweetness, while the solid content of potatoes which determine suitability of manufacture of crisps and dried products relate to density. It can be achieved using flotation in brine at different concentrations. By photometric properties– this make use of photocell which compare reflectance food unit to preset standard that make it very expensive. By color- is often a measure of maturity, presence of defect or degree of processing. What to PROCESS? Activity 1. Each group will choose raw materials to bring to class, either fish or shellfish and sort and grade it according to the prescribed qualities for fish processing.
92 What to REFLECT and UNDERSTAND? Conduct actual inspection in some backyard fish Processing Plants in your locality. Observe and make personal interview on how they inspect and sort the raw materials used. Activity 2. Make a summary report based on the interview conducted following the format given below and report it on the class. Name of Practitioner:_____________________________ Kind of Business:_______________________________ Address:_______________________________________ Date Conducted:________________ Time:__________ Please check the corresponding indicators if it is observed or not observed. Put some remarks if there is additional information during the conduct interview. A. Raw materials ( Fishery Products) Indicator Observed Not observed Remarks Signs of being spoiled or damaged Indication of insects or vermin attack Good quality raw materials are used Suitable for their intended purpose Dust or dirt as a result of poor storage and handling practices. B. Inspection of Tools, utensils and equipment used Well sanitized Not damaged In good working condition Meet manufacturers specifications Suitable for their intended purpose
93 What to TRANSFER? Now that you have all the information, are you ready to test your ability to inspect and sort the materials and products in accordance with physical property specifications? If your answer is yes, follow the procedure stated in the Task Sheet below. Task Sheet Title: Inspect raw materials and products for visible signs of defects according to set processing and purchasing specifications. Performance Objectives: Given the available fish processing raw materials and products, inspect these fish processing raw materials and products for visible signs of defects according to set processing and purchasing specifications. Supplies/Materials: • Raw materials and Products Equipment: None Steps/Procedures: 1. Gather all the necessary materials needed for the task. 2. Inspect the raw materials and products for visible signs of defects according to set and processing and purchasing specifications that you have learned 3. Submit your work to your teacher. Assessment Method: Direct observation Demonstration
94 Answer this post-test to enable you to find out what you already know. Write your answer in your test notebook You will be evaluated using this scale. 1-Poorly performed 2 - Slightly 3 - Fair 4 - Good 5 - Procedures properly followed Indicator 5 4 3 2 1 Reported 15-20 rejected/sub-standard raw materials and products for visible signs of defects according to set processing and purchasing specifications. Reported 9-14 rejected/sub-standard raw materials and products for visible signs of defects according to set processing and purchasing specifications. Reported 5-8 rejected/sub-standard raw materials and products for visible signs of defects according to set processing and purchasing specifications. Reported 1-4 rejected/sub-standard raw materials and products for visible signs of defects according to set processing and purchasing specifications. Post- Assessment Identify the answers found inside the boxes to the questions below. Grading Sorting Color Inspection Functional Property Geometric Property Shelf life Nutrition Facts Flavor External Force Internal Force
95 1. It is a vital component of the visual quality of fresh foods. 2. It is the application of tests and measuring devices to compare products and performance with specified standards. 3. It is carried out on the basis of individual physical properties. 4. It is the assessment of the overall quality of a food using a number of attributes. 5. It is the combination of properties which determine product quality and process effectiveness. 6. It is the duration or period wherein a fishery product remain in consumable quality. 7. It is a rather subjective property which is difficult to quantify. 8. It is the result of mechanical injury to fish. 9. It arises from physical changes such as variation in temperature and moisture content of fish. 10. This is found in the label of the fishery products. It serves as source of info to the customer to guide them on what they are eating LO 3. Complete Inspection and Sorting Activity Learning Objectives: 1. Clean and sanitize equipment and tools according to manufacturers’ specifications and workplace procedures 2. Complete and report records according to workplace procedures.
96 Pre-Assessment A. Select the letter of the best answer .Write your answer on your notebook 1. It lowers the amount of waste produced. a. Recovery b. Recycle c. Reduce d. Re use 2. If you are going to pack processed foods in tin cans, why do you need to seal it with a can sealer? a. a can sealer is the appropriate equipment. b. cans are made of metal c. cans cannot be sealed manually d. tin cans are difficult to seal 3. What might happen if you didn’t use mechanical cleaning aids? a. food-borne disease will break b. money, time and energy can be saved c. will not be sanitized d. work will be easier 4. It means “ To throw away all rubbish and unrelated materials in the workplace. a. Seiri or Sort b. Seiso or Sanitation c. Seiton or Set d. Shitsuke or Sustain
97 5. Which of the following is not an example of solid waste? a. ammonia b. fish shells c. mercaptans d. spillage of sauces, brines and oil B. Identify What are being asked. Write your answer on your notebook. _________1. It is essential for continuous cleaning of floor. _________2.It produces a jet of hot water at a somewhat lower pressure when mix with water or detergent solution. _________3. It is used to remove stubborn or dirt. _________4. It is useful for removing rust or paint. _________5. It is useful to wipe the walls of the laboratory as well as lavatory and working tables. What to KNOW? LO 3.1 Cleaning and Storing Equipment and Tools after Use The importance of proper cleaning can be appreciated when one realizes that contaminated equipment (equipment and utensils which are not clean) can be a cause of food-borne disease outbreaks. Cleaning comprises many operations in the food establishment, and the process is usually specific to the type of cleaning necessary. No cleaning task in the food establishment is as important as the cleaning and sanitization of food contact surfaces of equipment and utensils.
98 Types of Mechanical Cleaning Aids The use of mechanical cleaning aids is highly desirable to reduce the time and increase the efficiency of the cleanup. These mechanical cleaning aids are (a) brushes, (2) brooms, (3) mops, (4) scrapers, (5) sponges, (6) water hoses, (7) low pressure and high temperature units, (8) high pressure water units, and (9) steam guns. .1. Brushes- come from various types and essential for general cleaning purposes. Synthetic fiber brushes and epoxy vinyl brushes are very useful. Brushes with wire bristles are not advisable as they may break off and many equipment surfaces may be scratched off by the wire. Moreover, they are useful for removing rust or paint. 2. Brooms – are desirable as they usually fit the contour of the surfaces being cleaned. They have handles long enough for the user to reach the surfaces easily. 3. Mops – are essential for continuous especially of well to avoid accident and to maintain neatness and cleanliness 4. Scrapers – are used to remove stubborn dirt.
99 5. Sponges –are useful to wipe the walls of the laboratory as well as the lavatory and working tables. 6. Water hoses – water is the best cleaning tool. Hoses equipped with automatic shutoff valves can be of great help. There are various types of nozzles for valve outlets according to cleaning purposes: for cleaning deep cracks, use a small jet type; flat surface, use a fin type; for cleaning around and use bent type while the spray-head brush combination type is for cleaning surfaces where combined brushing and washing are needed. 7. Low pressure high temperature units – usually consist of a detergent tank which is steam heated and pump capable of creating a pressure of about 50 pounds per square inch (psi) and hoses that are lightweight and with adjustable nozzles. Both portable and stationary units are used depending on plant conditions. They are used with strong detergents for high pressure cleaning in removing grease, oil, and others. 8. High pressure water units – may either be movable or stationary. Movable units are generally small and are well adapted for small areas while stationary units are installed with high pressure lines piped to the various departments for cleaning. Some are equipped with mechanism for mixing detergent solutions with water, others with hot water with or without detergent, while others with air.
100 9. Steam guns –that produce a jet of hot water at a somewhat lower pressure when mixed with water or detergent solution is best for cleaning purposes. LO 3.2 Principle of “ 5S” "5S" is a structured program to systematically achieve total organization, cleanliness, and standardization in the workplace. A wellorganized workplace results in a safer, more efficient, and more productive operation. It boosts the morale of the workers, promoting a sense of pride in their work and ownership of their responsibilities. The "5S" was invented in Japan, and stands for five (5) Japanese words that start with the letter 'S': Seiri, Seiton, Seiso, Seiketsu, and Shitsuke. Table 1 shows what these words mean. An equivalent set of five 'S' words in English have likewise been adopted by many, to preserve the "5S" acronym in English usage. These are: Sort, Set (in place), Sanitize, Standardize, and Sustain. Table 1. Meaning of “5S” Japanese Term English Equivalent Meaning in Japanese Context Seiri Sort Throw away all rubbish and unrelated materials in the workplace Seiton Set Set everything in proper place for quick retrieval and storage Seiso Sanitization Clean the workplace; everyone should be a janitor Seiketsu Standardize Standardize the way of maintaining cleanliness Shitsuke Sustain Practice 'Five S' daily - make it a way of life; this also means 'commitment'