Learning Objectives:
1. Clean and sanitize equipment and tools according to manufacturers’ specifications and workplace procedures
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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
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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.
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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
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.
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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 well- organized 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'
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LO 3.3 Proper Waste Disposal
A. Waste Management in the Philippines
Waste management is defined as the handling of all wastes in the processing plant including food wastes, scratch paper, and fallen dry leaves on the ground, trim wedges and many others and transform them into useful products.
The Philippines generates about 10,000 million tons of solid waste per year and only 12 percent of the wastes are recycled and re-used. The single most dominant issue for solid waste management (SWM) is the inadequacy of disposal facilities. Presently, open dumping is still the most common waste disposal method as controlled dumpsites and sanitary landfills (SLFs) are very limited.
The opportunities presented by this serious environmental problem to suppliers of solid waste management products and equipment are enormous. The potential, however, is tempered by inadequate funds and technical capability, lack of political will and other problems. Despite the limitations, the market for SWM is still expected to grow five percent in the next three years.
The major end-users of SWM products and equipment are the local government units and their private contractors as well as private proponents of SWM projects. The equipment cost and the source of project funding are major purchase considerations of end-users.
Republic Act No. 9003 known as the National Solid Waste Management Act is issued as part of War on Waste (WOW). Its objective is to fight against waste provides that all waste matters will be recycled and reused
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into useful items. Basically it is to ensure the protection of public health and environment
B. Types of Waste from Fishery Products
• Solid waste: body parts such as heads, scales, viscera, fins, bones, blood, skin, mollusk shells, crustacean heads, exoskeleton
• Liquid waste: washed/processed water containing particles of solid waste or a suspension of solid waste, cooked water, drip and oil.
• Materials of non-fish origin: detergents, grease and oil, organic/inorganic compounds, additives, colorings and other ingredients used as processing aids, cooling water, bleaching agents, laboratory chemicals.
• Emissions: steam and water vapor, chlorine, carbon dioxide, and other gases, organic compounds with low boiling point.
The quantity of solid processing waste is directly related to the volume of raw materials being processed and the end products. The yield of meat recovery is directly proportional to the solid waste produced. The higher the meat recovered the lesser the solid waste. In production, the yield is as low as 20% of the original raw materials and 80% is being discarded in various stages of the processing.
LO 3.4 The Three R's: Reduce, Reuse and Recycle
Reduce, Reuse and Recycle – help cut down on the amount of waste
we throw away. They help conserve natural resources, landfill space and energy. The three R’s also help save money that communities use for landfalls. Setting up new landfills has become difficult and more expensive due to environmental regulations and public opposition.
REDUCE. Means using fewer resource. This is the most effective of
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REUSE. Before you recycle or dispose of anything, consider whether it
can still be used. It makes economic and environmental sense to reuse products..
RECYCLE. Recycling is the best "R"; partly because there are so
many recycling programs today (8,660 as of 2006, according to the EPA), which makes recycling and facilities easy.
Effective cleaning and sanitization of food contact surfaces of equipment and utensils serve two primary purposes:
• Reduces chance for contaminating food during processing, preparation, storage and service by physically removing soil, bacteria and other microorganisms; and
• Minimizes the chance of transmitting disease organisms to the consumer by achieving bacteriologically safe eating utensils.
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LO 3.5 Environmental Protection and Concerns Related to
Fish Processing
A. Environmental Issues and Concerns of Fish Processing Industries
Environmental issues in fish processing industries primarily include the following: Water consumption and wastewater generation, solid waste generation and by-products production, air emission and energy consumption.
A. Water Consumption. Most seafoods processors have high
baseline water use for cleaning plant and equipment. Therefore, water use per unit product decreases rapidly as production volume increases.
Major Reason for Water Consumption
Fish storage and transport Cleaning, freezing and thawing Preparation of brines
Equipment sprays
Offal transport; cooling water Steam generation
Equipment and floor cleaning.
Factors Affecting Water Use
Type of product processed Scale of the operation Process used
Level of water minimization practices in place (Environment Canada, 1994a).
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General cleaning contributes significantly to total water demand that’s why smaller-scale sites tend to have significantly higher water use per unit of production.
B. Energy Consumption. Seafoods processing industries consume
large quantities of electrical energy.
For fish and fish meal processing, energy is required for cooling, cooking, sterilizing, drying, evaporation, can cleaning, fork-lifting.
Effluent Discharge. Effluent is also known as liquid waste. Effluent
streams generated from seafoods processing contain high loads of organic matter due to the presence of oils, proteins and suspended solids. They can also contain high levels of phosphates and nitrates.
Fish processing industries have been known to pollute nearby beaches and shores by releasing wastewater containing oils. Since oil floats on water, it can end up on the surrounding coastline.
Resources for Effluent Discharge from Fish Processing
Handling and storage of raw fish prior to processing Fluming of fish and product around the plant
Defrosting Gutting Scaling
Portioning and filleting of fish Washing of fish products.
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.Resources for Effluent in Discharge Canning Operations Draining of cans after precooking
Spillage of sauces, brines and oil in the can filling process Condensate generated during precooking
Factors Affecting Effluent Quality
Type of fish being processed Type of processing undertaken
Effects of Effluent Discharge
Eutrophication (the process by which a body of water becomes
rich in dissolved nutrients from fertilizers or sewage, thereby encouraging the growth and decomposition of oxygen-depleting plant life which harm other organisms)
Oxygen depletion. This is a condition wherein the level of
Oxygen is not adequate leading to adversed effect on the living organism
D. Odor. Odor is often the most significant form of air pollution in fish
processing.
Major Sources of Odor
• Storage sites for processing waste
• Cooking by-products during fish meal production • Fish drying processes
• Emissions during filling
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Fish quality may deteriorate under the anaerobic conditions found in onboard storage in fishing processing facilities. This deterioration causes the formation of odorous compounds such as ammonia, mercaptans, and hydrogen sulphide gas [National Pollutant Inventory. June, 1999].
E. Noise Pollution. Noise is not a significant problem in seafood
industries. Noise may be generated during cutting, pre-cooking, filing and weighing the can, can seaming and sterilization. The noise measurements at any sources in the process do not exceed the standard of Maximum Sound Level (140 dB) [Ministry of Interior, 1976]
F. Solid waste generation. Solid waste is mainly in the form of
organic wastes generated in the production processes. It consists of fish shells and heads from the seafood processing. Seafood processing activities generate potentially large quantities of organic waste and by-products from inedible fish parts and endoskeleton shell parts from the crustacean peeling process.
The waste generation depends on the species and the process.
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LO 3.6 Manufacturer’s Requirements
Uses of Manufacturer’s Specifications
Equipment, tools and utensils that are purchased are accompanied by a manual containing specifications as to how they are used, manipulated or operated, cared for and stored to lengthen their serviceability.
When using any equipment, tool or device, it is important to read and understand the manufacturer’s specifications in order to properly or accurately use or manipulate them and prevent any accident due to ignorance or lack of information on their correct use. Familiarity with all information pertaining to food processing equipment results in systematic, orderly, and accurate accomplishment of tasks.
A food processor, however, must know the essential information regarding the equipment in terms of how it must be operated or used in accordance with the manufacturer’s specifications.
Before operating any equipment, it is important to be familiar with the manufacturer’s specifications, which include:
• Handling requirements • Operating requirements • Discharge label • Reporting • Testing • Positioning • Refilling
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How to Read Manufacturer’s Specifications
Food processing equipment when sold are provided with a manual containing the manufacturer’s specifications and a necessary reminder to the processor in the form of a sticker or Warning Label. This label attached to the equipment itself as an assurance that the equipment/machine or tool is in excellent condition as it has passed quality control.
The specification usually gives a detailed description about the equipment dimensions, materials, and other relevant information regarding the equipment or machine.
The dimension is the measurement of the size of an object in terms of length, width, or height of the equipment/machine or tool.
The capacity specifies the measurement of the amount, which a device can hold or contain as in boilers, cooker, or steamers or a weighing scale.
The manufacturer’s specifications are usually contained in the manual, which accompanies the equipment. The food processor must thoroughly read and understand all the information contained in the manual especially if the equipment is to be electrically operated. Aside from knowing the correct operation of the equipment or machine, it is also important to know the following:
• Basic safety precautions to follow when using the equipment • Warning labels which specify proper operation of an equipment • Instructions on the proper care of the equipment/machine • Instructions on the correct operation of the equipment
The manufacturer’s specifications must be thoroughly read and understood by the food processor.
It is Important to follow manufacturer’s instructions for safety and to protect the product or purchase. Some instructions are warnings while others
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are instructions on how to use the product. Warning instructions like “do not place in contact with fire” reminds the user that the product is flammable and may cause explosion resulting to injuries if not followed carefully.
Below are some examples of manufacturer’s specifications, which must be properly read and interpreted to ensure accurate and safe operation/manipulation of an equipment/machine:
How to Seal Tin Cans with Hand Automatic Can Sealer
Fasten sealer firmly to table or armchair using clamp. Attach crank to worm shaft and tighten set screw.
Adjust the chuck, height washers, and levers to the size of can to be sealed.
Lower base plate by turning can lifter handle as far as possible to the left.
Place cover on can and set can on base plate.
Place the first operation roll and rivet in the first adjusting lever.
Raise can until it is clamped firmly between base plate and chuck. Turn crank clockwise (eleven turns) until the first operation roll is
through half sealing. After half – sealing, the cans are placed in the pressure cooker for 15 minutes exhausting to form vacuum.
After exhausting the cans, remove first operation roll and put the Second operation rolls and rivet in the adjusting lever.
Turn crank clockwise (ten turns) until the second operation roll returns to its normal position away from the chuck.
Release sealed cans by turning can lifter handle as far as possible to the left. The machine is now ready to receive another can for sealing.
Can Sealer
www.cansealer.com
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Directions for Use of the Hydrometer
Clean the hydrometer thoroughly and dry before using it each time. Handle with clean dry hands or with clean cloth.
Use with fluid juices, otherwise if the liquid to be tested is thick or slimy, the resting point of the hydrometer will be uncertain.
Pour a small quantity of the juice into a glass cylinder and drop the hydrometer carefully.
Make sure that the instrument is floating freely and touches neither the bottom nor the sides of the cylinder.
To read correctly, set eye level with the surface of the liquid.
Since the specific gravity of juices varies with temperature, bring the juice to the standard temperature for which the hydrometer is adjusted usually 16 C or 60 F or make the necessary corrections in the reading. Add 0.1% for every 3 above the standard and subtract 0.1% for every 3 .
What to PROCESS?
Activity 1.
Collect and make a list of brochures/manuals of different equipment. Study the different Manufacturer’s Specification. Mark a comparison of the brochure collected.
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Activity 2.
Make a survey on how waste from fishery products are disposed by fish processor in the locality.
Waste Materials
Reduce
Recycle
Re use
1. Fish scales Fertilizer Home
Decorations
What to REFLECT and UNDERSTAND?
Research on new techniques involved in cleaning, sanitizing and storing tools and equipment following the manufacturers’ specifications and workplace procedures.
Activity 3.
Make a work plan on how to keep complete records of reports according to workplace procedures with emphasis on proper waste disposal and environmental protection. Follow the format below.
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Waste Disposal Work Plan
Objectives Time Frame
Activities Personnel Remarks
1. Clean the canal of the processing plant/area
Daily 1. Remove the dirt and debris in the canal. 2. Use low pressure water unit. 3. Use sanitizer 1. Staff/utility/ja nitor
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What to TRANSFER?
Now that you have all the information, are you ready to test your ability to clean and keep equipment and tools according to manufacturer’s specifications and workplace procedures? If your answer is yes, your task is