PROCESSING PR)
This module deals with the properties of different packaging materials. The technical properties of the different materials and actual use will depend mostly on the cost and availability in a particular area. Furthermore, there may be practical marketing reasons for choosing a certain type of package.
Content Standard Performance Standard
The learner demonstrates understanding of preparing raw and packaging materials and supplies for
food processing.
The learner prepares raw and packaging materials and supplies for
food processing.
LO 1. Select Raw and Packaging Materials and Supplies for
Processing
Learning Objectives
1. Record the availability of raw and packaging materials and supplies for Food (Fish) Processing according to production requirements
2. Handle raw and packaging materials and supplies for Food (Fish) Processing according to workplace and OHS requirements
3. Apply proper procedures in putting raw and packaging materials and supplies for Food (Fish) Processing in the receiving bin according to required specifications.
146
Pre – Assessment
Direction. Choose the best answer among the given options and write the letter of the correct answer on your answer sheet.
1. Which of these packaging materials can resist extreme temperature and retain coldness inside?
a. Polyamide c. Polyethylene
b. Polyestene d. Polypropylene
2. Which of the following packaging materials 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 of the following packaging containers does not belong to the group?
a. Polyester c. Polypropylene
b. Polyethylene d. Polystyrene
5. Which of the following is commonly used for transporting fish from the wharf to the market or processing plant?
a. Polyamide c. Polypropylene
147
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
7. What 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 will you consider?
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 proofing b. shelflife
c. immobility d. colourful appeal
148
What to KNOW?
LO 1.1 Selecting and Confirming Raw/Packaging Materials
and Supplies and Their Availability
Quality Control includes all phases of processing, from the selection of raw materials to the final processed products.
The composition and if appropriate, the conditions of use of packaging must:
a) comply with the requirements specified in the current REPUBLIC ACT NO. 10611 known as the “Food Safety Act of 2013″;
b) be determined by the operator for suitability, based on an analysis of hazards and other risks.
If compliance with this specification is achieved by meeting the requirements of sub- clause (1) (a) or (b), the risk management programm must state the full reference to the regulation, part, section or standard with which the packaging complies.
If the packaging is damaged such that suitability for processing of seafood products or fitness for the intended purpose is affected, the product must be appropriately disposed of or handled in a manner that contamination until may be minimize the damage to the packaging is rectified. Reused and recycled packaging should not be a source of contamination to the product.
149
LO 1.2 Receiving and Handling Raw/Packaging Materials and
Supplies
A. Receiving and Storing
1. Operators must obtain a written guarantee from the supplier stating that packaging meets mandatory requirements for composition and conditions of use.
2. All packaging and product contact containers must be on received in a good condition.
3. Once accepted into the premises, all packaging and product contact containers must be handled in a manner that would prevent
contamination and deterioration.
4. Containers and packaging held in a warehouse-type store must be securely wrapped and stored above the ground (e.g. on pallets) to minimize contamination from dust and vermin.
B. Handling of Packaging Materials
1. Containers and packaging must be unwrapped stored, handled or transported only in a support area or processing area. The risk management program must document in full the regulation, part, section or standard with which the packaging complies.
2. Operators must ensure that opened cartons are re-closed and covered during storage to prevent dust contamination. Any wet plastic packaging must be disposed of rather than stored.
3. Only containers or packaging required for immediate use may be held in an area where seafood products is processed or packaged.
4. New packaging and containers must be clean and undamaged at the time of use.
150
5. All packaging materials must be removed from the processing area or adequately protected before any cleaning and sanitizing operations are carried out.
6. Re-usable containers used for transporting or storing product must be cleaned and sanitized before use at a frequency specified in the cleaning and sanitation program. The frequency of cleaning and sanitation must take into account the areas in which the containers are used and whether or not product comes into direct contact with the container.
7. Re-usable containers that have been cleaned must be protected from contamination.
LO 1.3 Packaging of Fishery Products.
Packing of fishery products may be defined as wrapping or enclosure of fishery products in attractive and colorful materials as of protection and preservation of the product as well as an appeal to the customers.
The most common material used for manufacturing containers for fish products are
Tin plate Tin free steel (TFS) Aluminum alloys Enamel coatings Lacquered steel plate Glass jars
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%) (Paler- Calmorin, 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
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
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
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 compatiblewith 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 Ease of Disposal Size, shape, weight
limitation; low cost Appearance and
Printability
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 warehouse- type 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:
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