Value-Added Food Products

Potential Processing
• Value-
Value-added food products are raw or pre-
pre-
Technologies for Value- processed commodities whose value has
Added Fruit & Vegetable been increased through the addition of
ingredients or processes that make them
Products more attractive to the buyer and/or more
readily usable by the consumer.
Yanyun Zhao
Dept. of Food Science & Technology
Oregon State University

The New Food Entremanuer Conference, April 1-

1-2, 2005

Adding Value to Your Products Food Processing Technologies

Physical Methods
– High temperatures (canning)
– Low temperatures (freezing)
Product ideas – Remove of water (drying)
– High hydrostatic pressure
Processing technologies – Use of ionizing radiation
Package design Chemical Methods
– Use of sugar (jams, jellies)
Marketing and advertising – Fermentation and salting (natural fermentation)
– Treatment with acids (addition of vinegar)
Short-
Short-term Processing Methods
– Refrigeration
– Cold storage and packaging with modified or controlled
atmosphere
– Chemical treatments

Freezing Fruits and Vegetables Freezing Methods

Freezing is a quick and Air freezing
convenient way to preserve – air-
air-blast freezer (-
(-30~-
30~-45oC, air velocity 10~15m/sec)
fruits and vegetables. The Indirect contact freezing
extreme cold slows the – food placed on cold plates, trays, belts, separated
growth of microorganisms from refrigerant
and the chemical changes Immersion freezing
that affect quality or cause
– immersion in cold air - fluidized bed
spoilage. Correctly frozen
– immersion with cryogenic liquid (liquid N2 & CO2) -
foods maintain excellent
boiling temp. of liquid N2 is -196oC, CO2 is -79oC
color, flavor, texture, and food
value.

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 Air-blast Freezer Fluidized Bed Freezer
A modified version of an IQF
system.
Very high convective heat transfer
coefficients.
Product pieces must be relatively
small to establish and maintain a
fluidized bed.
The limits to use of the process are
based on efficiency: energy
requirements necessary to
maintain the fluidized condition.
The primary product parameter
influencing energy required for
Tray Freezer Spiral Freezer fluidization is size or mass of the
product.

Indirect Contact Freezer

Immerse Freezer
- Plate Freezer
The product is exposed to a liquid
refrigerant that is undergoing phase
change as the freezing process
occurs.
The common refrigerants used for
immersion freezers -nitrogen,
carbon dioxide, and Freon-
Freon-must be
approved for food product contact.
Very rapid freezing is achieved,
resulting in superior product quality
when rate of ice crystal formation
influences quality.
Overall process efficiency is
influenced by recover expensive
refrigerant as the freezing process
is complete.

Quality Control of Frozen Fruits Application (Market) of Frozen

and Vegetables Fruits and Vegetables
Rapid freezing (>4
(>4oC/min) to have small
small regular
ice crystals As end products for direct consumer
Maintain low and stable storage temp. (– (–18 ~ – usage
23oC) to prevent re
- crystallization, high drip loss,
etc. Ingredients in ice cream, frozen yogurt,
Prevention of freezing burn during storage – fresh and frozen baked goods and other
appropriate packaging materials and prevent frozen dairy and non-
non-dairy products
temp. fluctuation during storage
Blanching before freezing of some fruits and
vegetables to inactivate natural enzymes for
preventing discoloration and quality loss

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 Drying Fruits and Vegetables Drying Methods
Drying is the oldest Sun (raisins)
method of preserving food
by removing water from Belt oven (vegetable pieces, crackers,
food (reducing water cookies)
activity). Advantages
include: Roller or drum (mashed potatoes)
-Make product safe Spray (coffee, infant formula)
-Convenience
-Increase shelf life Freeze (coffee, strawberries)
-Reduce weight
Osmosis (infusion)

Batch and Continuous Air Drying Drum Drying

Freeze Drying Freeze Drying

Components in freeze
• Water removal by sublimation drier
• Under vacuum (27- 133 Pa) – Freeze-
Freeze-dryer
– Heater
– Vacuum pump
Best nutrient quality
Best product quality
(shape; rehydration)
rehydration)
Most expensive
Good control

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 Process Control in Osmotic
Infused Dried Fruits and Vegetables Dehydration
Place solid food, whole or in pieces, in sugars
or salts aqueous solutions of high osmotic Pre
- treatments –
pressure blanching, SO2
At least two major simultaneous counter- Temperature control;
current flows
– water flow out of the food into the solution
Type of sugar or salt
– transfer of solute from the solution into the food Agitation
Major advantages Final drying
– Soft texture
– Enhanced flavor and taste
– Energy saving and others

Application (Market) of Dried Fruits

and Vegetables Canning
Dried fruits as snack Canning can be a safe and
economical way to preserve
Fruits - salads, brownies, muffins, cookies, quality food. Canning
breads, bagels, cereals, rice dishes, practices remove oxygen;
entrees, etc. destroy enzymes; kill and
prevent the growth of
Vegetables - dry soups, breads, bagels, undesirable bacteria, yeasts,
stuffing and rice mixes, pasta dishes, and molds; and help form
boxed dinner kits, etc. a high vacuum in cans.

pH Scale and Classification of

High Acid Foods
Foods According to Their Acidity
Berries, fruit, tomatoes, sauerkraut

Only vegetative cells must be destroyed

because spores won’t germinate

Boiling water bath or hot fill may be used

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 Acidified Foods Low Acid Foods
Food with pH above 4.6 may be acidified and pH > 4.6
then processed as a high acid food Toxins produced by some organisms can be
• Blanch in acidified water lethal
• Blanch in water, then pack in acidified brine
Cannot be made commercially sterile in boiling
• Direct adjustment of batch pH with acid
water bath
• Predetermined amount of acid added to each
individual container Must be processed under pressure
• Add high acid food to low acid food FDA and USDA regulations
Final EQUILIBRATED pH must be below 4.6 Requires a Better Process Control School
FDA regulated certified supervisor

If you’re really going to use any of High Hydrostatic Pressure

these canning processes.....

High hydrostatic pressure is

GO TO BETTER a novel food processing

technology where foods are
subjected to high isostatic
PROCESS CONTROL pressure, generally in the
range of 100-600 MPa, at or
SCHOOL around room temperature.

High-Pressure Processing Food Commercialization

Novel, non-
non-thermal food
processing, pressure is applied Product: jams & fruit
uniformly, in all directions
Extremely high pressures toppings
– Kills vegetative microorganisms Elimination of yeasts and
– Retains flavors and nutrients
– Extends shelf life moulds
Food has higher quality than Producer: Meidi-
Meidi- ya,
a, Japan
thermally processed foods and
is safe Market Introduction: 1991
Food is not crushed
Product characteristics virtually
unchanged

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 Commercialization Commercialization
Guacamole, refrigerated
Fresh orange juice, refrigerated
Prevention of browning by
Deactivation of pectin methyl
deactivation of polyphenol
esterase ensures cloud stability
oxidase
Reduction of microbial load
(yeasts, lactic bacteria) Reduction of bacterial load
Producer: Avomex,
Avomex, Keller, TX
Producer: Ulti,
Ulti, Pernod-
Pernod-Ricard,
Ricard,
France, www.pernod-
www.pernod-ricard.com Market Introduction: 1997
Market Introduction: 1995 New products: chipotle sauce,
salsa, pico de gallo

Jam and Jelly Terms

Jelly - a mixture of fruit juice and sugar that is clear
and firm enough to hold its shape.
Jam and jelly are gelled or
Jam - made from crushed or chopped fruit. Jam holds
thickened fruit products
its shape, but is less firm than jelly.
with a low pH, cooked and
preserved with sugars. Conserves - jam-jam-like products that may be made from
Products include fruit a mixture of fruits. They may also contain nuts, raisins,
butters, jellies, preserves, or coconut.
jams and similar products. Preserves - made of small, whole fruits or pieces of
fruits in a clear, thick, slightly gelled syrup.
Marmalades - soft, transparent fruit jellies that contain
small pieces of fruit or citrus peel.
Fruit butters - made from fruit pulp cooked with sugar
until thickened.

Essential Ingredients
Pectin
in Jellies and Jams
Pectin content in fruits
Fruit or fruit juice – Highly variable within and among commodities
Pectin - make fruit juice to gel – Some fruits contain sufficient native pectin for
gelation,
gelation, e.g. plum
Acid - for gel formation and flavor – Citrus pectin often added to form gel
Sugar Pectin grade
– Parts of sugar that one part pectin will gel under
– proper proportions with pectin and acid to standard conditions, pH = 3.2-
3.2-3.5; sugar = 76-
76-70°Brix
make a good gel – Commercial pectin sold as 100 or 150 grade
– prevent the growth of microorganisms Pectin types
– contributes to the taste – High-
High-methoxyl (Rapid-
(Rapid-set, Slow-
Slow-set)
– Low-
Low-methoxyl

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Standard Identity and Regulations Principles of Preservation
Fruit jellies - 45 parts by weight of the fruit juice Add sugar to increase osmotic pressure to
ingredient to each 55 parts of the sweetener solids prevent microorganism development (~60%
(45:55). The finished soluble solids content of a jelly is sugar)
not less than 65%. In food preservation with sugar, water activity
Fruit preserves and jams can’
can’t be reduced < 0.845- sufficient for
– Berries - 47 parts by weight of the fruit component to bacteria and neosmophile yeast inhibition, but
55 parts of the sugar does not prevent mold attack.
– Pomes - 45:55
Other means are used to avoid mold
– Finished product is not less than 65% solids development:
Title 21CFR Part 150 – Finished product pasteurization
http://www.accessdata.fda.gov/scripts/cdrh/cfdocs/cfCFR
– Use of chemical preservatives
/CFRSearch.cfm

Vegetable Pickling &

Fermentation
Pickled or Fermented
products cure for
several weeks. Curing
changes the color,
flavor, and texture of
the product. Lactic acid
produced during
fermentation helps
preserve the product.

Developed by Ministry of Agriculture, Fisheries and Food, BC, Canada

http://www.agf.gov.bc.ca/busmgmt/budgets/budget_pdf/value_added/VA2.PDF

Principles of Fermentation Benefits of Fermentation

Preservation of the product - acid produced may
Breakdown of carbohydrates under prevent spoilage of food.
anaerobic conditions Add, remove or alter existing flavors
Alter chemical characteristics of the food
Allow growth of non-
non-pathogenic – Sugar to ethanol
microorganisms to produce acid or alcohol – Ethanol to acetic acid
– Sugar to lactic acid
Two ways
Production of foods or ingredients by
– natural acidification
microbial cultures – artificial acidification

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 Natural Fermentation Artificial Acidification

A predominant lactic fermentation

Addition of organic acids
– Lactic acid bacteria succeed in overcoming the – Acetic
accompanying microorganisms and lactic acid is – Lactic
formed to reach pH < 4.1
– Citric
Encourage the multiplication of select M.O.’
M.O.’s
– Addition of acid foods
and their metabolic activities in foods
Raw material is put into a brine without
previous heating

Cucumber Pickles - 3 major

Combined Acidification
categories
Involve as a preliminary processing step
Brine stock ( fermented)
a weak lactic fermentation followed by
– Genuine Dills
acidification (vinegar addition) – Sweet Gherkins
Classes of vegetables preserved by – Dill Chips
natural acidification (fermentation) Fresh Pack (acidified and pasteurized)
– Sauerkraut – polish dills
– Cucumber Pickles – Bread and Butter

– Green Olives Refrigerator Pickles ( acidified and refrigerated)

– Claussens

Fruit Juice
Juice without pulp (clarified or not
clarified)
Juice with pulp
Nature juice – product from one fruit
Mixed juices - products from mix of 2 or
3 juices from different fruit species or
by adding sugar

Developed by Ministry of Agriculture, Fisheries and Food, BC, Canada

http://www.agf.gov.bc.ca/busmgmt/budgets/budget_pdf/vegetables/pklgcuke.pdf

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 FDA SINGLE STRENGTH JUICE Major Steps for Fruit Juices
VALUES Without Pulp
Washing and sorting
http://pdlab.com/juicex.htm
http://pdlab.com/juicex.htm Crushing/grinding/disintegration step
– Crushing for grapes and berries;
Juice Type Brix – Grinding for apples, pears;
– Disintegration for tomatoes, peaches, mangoes, apricots.
Acerola 6.0 Enzyme treatment – optional step to improve
improve extraction
yield, juice color and finished product taste
Apple 11.5 – Add 2-
2-8% pectolitic enzymes at ~ 50° 50° C for 30 min
– For fruit naturally rich in pectic substances, this may result
Apricot 11.7 "exhausted" material
Heating
Banana 22.0 – An optional step used for some fruit to facilitate pressing and color
fixing; sometimes, protein coagulation takes place.
Blackberry 10.0

Steps for Fruit Juices Without Pulp Major Steps for Fruit Juices with
Pulp
Pressing to extract juice
Juice clarifying Process at industrial scale in two
– Centrifugation or enzyme treatment.
– Centrifugation at a speed of 6000 to 6500 RPM.
categories of operations:
– Enzyme – adding pectolitic enzyme in 0.5 to 2 g/l,g/l, last 2 a. Processing for obtaining juices;
to 6 hr at room temp, or <2 hr at 50°
50°C
– Controlled by checking juice viscosity, or is completed
b. Juice conditioning for preservation.
with a step called "sticking" by adding 5-
5-8 g/l of food
grade gelatin.
Pasteurization
– Water baths at 75°
75° C until juice reaches 68°
68° C
– Rapid pasteurization at about 80°
80° C, over 10-
10-60 sec.,
followed by cooling

Processing for Obtaining Juices Juice Conditioning for Preservation

Berries (strawberry, wild berries, etc.)
Washed, sorted, crushed, preheated and then introduced in
extractor.
To avoid browning and undesirable taste, add 0.05% ascorbic
acid.
Stone fruits (apricots, peaches, cherries, etc.)
Washing, sorting, submitted to steam in a continuous heater
Warm fruit mass is passed through a pulper and then an
extractor.
Pomaces (apples, pears)
Washed, sorted, and crushed in a colloid mill;
Fruit puré
purée is passed through a screw type heating equipment
Warm fruit mass is treated in a pulper with a 2 mm screen and
then through an extractor
ƒ Use continuous centrifugal separator to partially
eliminate cellulose
ƒ Juice is processed to adjust sugar and acid content for
viscosity
ƒ Sugar (about 8-8-10%) is added as a syrup
ƒ Acidity is adjusted with citric or tartaric acid
ƒ Juice is deaerated under vacuum at about 40° C for
avoiding oxidative reactions and vitamin C loss
ƒ Homogenization to obtain particles with dimensions
below 100
ƒ Pasteurization in plate heat exchanger at ~ 130° C,
cooled down to ~ 90° C and aseptically packed

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 Fresh-
Fresh-Cut Fruits and Vegetables

Developed by Ministry of Agriculture, Fisheries and Food, BC, Canada

http://www.agf.gov.bc.ca/busmgmt/budgets/budget_pdf/value_added/VA30.PDF

Fresh-
Fresh-Cut Fruits and Vegetables Modified Atmosphere Packaging
Key controls Replacement of air with a single gas or mixture of gases
– Preparation (cutting, trimming, sorting, No further control over initial composition
washing, etc.)
Gases:
– Disinfection
CO2: Anti-microbial agent, inhibit lipid oxidation
– Temperature control
O2: Maintain fresh bright red meat color
– Packaging (MAP)
Inhibit growth of pathogenic anaerobic bacteria
– Shelf- life and microbial safety
N2: Inert gas, as a packaging filler
Inhibit aerobic bacteria growth

How to Access Kitchen Incubator

A shared-
shared-use commercial kitchen where caterers, street
University Extension Service cart vendors, farmers, and producers of
– Workshops/short courses specialty/gourmet food items can prepare their food
products in a fully licensed and certified kitchen.
– Communication Often sponsored by an umbrella nonprofit organization
or existing business incubator, provide start-
start-up
– Contracted work businesses the opportunity to explore food production
without the high cost of buying their own equipment or
Licensed facility constructing their own building.
– Incubator kitchen Usually offer technical assistance in food production as
well as general business management skills, networking
– Co- packs opportunities among entrepreneurs, and the opportunity
to form shared services cooperatives for marketing,
distribution, and supply purchasing.
http://www.gjincubator.org/incubatorfacility.html
http://www.gjincubator.org/incubatorfacility.html

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 Kitchen Incubator in OR Kitchen Incubator in WA
Incubator Creative Group Applied Process Engineering Laboratory
Cheshire Richland www.apel.org
Oregon Association of Minority Ellensburg Business Incubator
Ellensburg
Entrepreneurs Ctr Military Technology Contracts Incubation Center
Portland (360) 377-
377-0191
Oregon Innovation Center Bremerton
Bend Tri-
Tri-Cities Enterprise Center
Portland Business Accelerator Richland
Portland Tri-
Tri-County Economic Development District
Colville
University of Oregon William M Factory Small Business Incubator
Eugene Tacoma

Co-Packing Find the Right Co-Packer

Existing food processors to make your Gather name
product according to your specifications Check for quality
Co-
Co-packers usually sign a non-
non-disclosure Compatibility
agreement, promising not to copy, – Level of Involvement
disclose, or use your recipe or formula – Supplies
except in your own products. – Ingredients
Check “Thomas Food Industry Register”
Register” – Volume
for co-
co-packers in different states – Case Amount

Technical manual on small-scale

Resources processing of fruits and
vegetables

“Food Processors Handbook” developed FOOD AND AGRICULTURE

ORGANIZATION OF THE UNITED
by ODA NATIONS

FDA, USDA, and State website on the Gaetano Paltrinieri

federal ad state regulations Senior Food Technology and
Agroindustries Officer, FAO
Technologies – University food science Fernando Figuerola
Food Science and Technology Expert
Extension website Loreto Rojas
Food Technology Expert
Equipments – “Food Manufacturer”
Manufacturer” FAO REGIONAL OFFICE
http://www.foodmanufacturing.com/ FOR LATIN AMERICA AND THE
CARIBBEAN
Small scale food processing - http://www.ssfp.ca
http://www.ssfp.ca// Santiago, Chile
1997

http://www.fao.org/documents/show_cdr.asp?url_file=/DOCREP/x0209e/x0209e00.htm

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Small-Scale Food Processing:
A Directory of Equipment and
Methods
Edition: 2nd - Author(s): Azam-
Ali, Sue; Ali, Sue Azam; Battcock,
Mike; Fellows, Peter; Judge,
Emma

ISBN: 1853395048
Format: Paperback
Pub. Date: 5/1/2003
Publisher: Stylus Pub Llc

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