Ohio State University Food Science & Technology Food Science and Technology 630 PRINCIPLES OF FOOD PROCESSING Winter Quarter, 2006 4 Credits U G MWF 10 a.m. in 114 Parker Food Science and R 9-12 or 1-4 in Parker 0124, Parker and Howlett Pilot Plants COURSE OBJECTIVES By the end of the course, the students should: Familiar with basic principles of several food processing methods including thermal processing, freezing, dehydration, aseptic processing, high pressure processing, pulsed electric field processing, irradiation, and extrusion. Appreciate the role of engineering, chemistry, microbiology and other disciplines and their interdependence in processing foods. Student should understand the principles of operation, be able to identify the key process parameters for microbial safety and quality, and design a basic system. Hands-on laboratory experience and ability to work in teams. Calculate some key process parameters such as D, z and process lethality by hand or using a computer. RATIONALE Most food scientists, whether they are in production, quality control, research and development, technical sales, or working as a consultant will encounter processing equipment as part of their job. While many food scientists will not need to be able to calculate exact mass and energy balances for the equipment, they do need a broad understanding of how these processes work, what can and cannot be done, and what new technologies are on the horizon. New products cannot be designed, ingredients sold, clients persuaded, or problems solved without an understanding of how the food is processed. It is important to have understanding on how various basic principles of engineering, microbiology, and chemistry are being used to process foods. This class is designed to introduce the students to food processing, to make you aware of what is available and to (hopefully) convince you that food processing is an exciting area of study. INSTRUCTOR V.M. Bala Balasubramaniam, SEQ CHAPTER \h \r 1333 Parker Food Science & Tech. 614-292-1732(voice), 614-292-0218 (FAX) E-mail: Balasubramaniam.1@osu.edu Office hours 11-11:30 MWF If these hours do not fit your schedule, drop by my office with an appointment. You may also reach me through phone or email A note on instructor’s last name-though it is a long name, if you break it down into three parts Bala- subra-maniam, you may find it easy to pronounce. Alternatively, you may simply call him “Dr. Bala”. PILOT PLANT COORDINATORS Gary Wenneker Parker Pilot Plant 247-6865 wenneker.1@osu.edu Mike Piek Howlett Pilot Plant 292-4045 piek.1@osu.edu TEACHING ASSOCIATES Loc Thai Nguyen 330 Parker 294-1059 loc.1@osu.edu Maria Villacis 144 Howlett Hall 294-5768 villacis-barrazu.1@osu.edu All Mail Boxes: 110 Parker Building REQUIRED TEXTS AND SUPPLIES P. Fellows. 2000. Food Processing Technology, Principles and Practice, Second edition. Woodhead Publishing Lmt, England. Available from the Bookstore, Millikin Rd. Additional handouts will be distributed in the class as needed. Class handouts will also be posted online (carmen.osu.edu) Supplemental reading materials are available from agricultural library reserve. Consult instructor if you would like to get any additional reading. SUPPLEMENTAL READING Additional reference materials are on reserve at the Agriculture Library (Room 045, Agriculture Administration Building, 2120 Fyffe Road) Most books are on open reserve under FST 630. Note that this is not an exhaustive list. Other books on these topics are also available. You may find journal articles as additional valuable resources. R. P. Singh. 1996. Computer applications in food technology. Academic Press. A complete course in canning (13th ed) 1996. Canning trade, Inc. Baltimore, MD Chapter 10, Equipment and Sanitary Design, Microbiology and engineering of sterilization processes. J. Pflug. Environmental sterilization laboratory, Minneapolis. Chapter 14 Designing microbial-control processes, some general considerations in selecting the microbiological input. Chapter 15, The design of microbial control processes Chapter 16, The mathematical method of heat sterilization process evaluation Aseptic processing: Willhoft, E. M. A., ed. 1993. Aseptic processing and packaging of particulate foods. Blackie Academic & Professional Glasgow Singh, R. P. and Heldman, D. R. 1993. Introduction to Food Engineering, 2nd ed. Academic Press, Inc. San Diego Chapters on Filtration, aseptic processing and packaging. Irradiation: Status summary. 1998 Irradiation of Food Satin, Morton. Food irradiation : a guidebook Extrusion: Chapter 1, Food extruders and their applications in Mercier, C., Linko, P. and Harper, J. M., eds. 1989 Extrusion cooking American Association of Cereal Chemists, Inc. Cheryan, M. 1986. Ultrafiltration handbook Technomic Publishing Co., Lancaster. GRADING The grading breakdown (%) is: Homework assignments Group term project Laboratory report & participation Mid term exams (2; 15% each) Final Exam (cumulative) Attendance 10% 15% 15% 30% 30% (-1% per day) The class is graded on a straight scale: 100-93 = A, 92.9-90 = A-, 89.9-86 = B+, 85.9-83 = B, 82.9-80 = B-, 79.9-77 = C+, etc. It is possible (and desirable) for the entire class to receive As, if you earn them. Attendance will be checked randomly. For each day you are not present, 1% will be deducted from your final grade. Reasonable medical excuses are acceptable, provided you document them. Late assignments/term papers are penalized at a rate of 10% loss in points per day late including weekends. During the first day of the class, we will discuss about grading policy and revise the grading breakdown and mid term exam dates if necessary. ACADEMIC MISCONDUCT Academic misconduct is defined in the Code of the Student Conduct (3335-23-04, http://studentaffairs.osu.edu/info_for_students/csc.asp) and the Rules of the University Faculty (3335-31-02, http://www.acs.ohio-state.edu/offices/oaa/procedures/1.0.html). Academic misconduct will not be tolerated. If you have questions on this point, please refer to the above web sites or ask an instructor. Some examples of misconduct are: 1. Using a report from a previous year as the whole or a portion of your report. 2. Copying another student’s answers during a quiz. 3. Including material from internet without providing proper citations Collaboration is expected and required in this course. Students are allowed to work on their lab reports together, but each student must write their own report in their own words. Discussion of laboratory methods and interpretation of results is encouraged (but report should be written independently). This does not constitute academic misconduct. COURSE ORGANIZATION The course consists of three lectures and one three-hour laboratory/tutorial sessions per week. Attendance is required. TENTATIVE LECTURE SCHEDULE Lecture Monday, Wednesday, Friday 10.00-10.48 Students are highly encouraged to read the indicated lecture and reference materials available through Carmen (carmen.osu.edu) so that you could actively participate in the classroom discussion. You may also provide anonymous feedback to the instructor using Carmen. Chapters and page number indicate the corresponding material from Fellows Text book, 2nd edition. Week 1 (Jan 3-6) Review of basic principles (Chapter 1, 1-59) Week 2 (Jan 9-13) Why do we process food? Properties of foods Thermometry Importance of sterility, D, z Processing by application of heat (Chapter 10 and 11, 233-249) Continue lethality discussion Blanching Pasteurization Week 3 (Jan 16-20) Heat Sterilization (Chapter 12 250-276) JAN 16 - Martin Luther King Day observed--no classes, offices closed Week 4 (Jan23-27) Retort processing Heat penetration studies Aseptic Processing Heat processing by advanced thermal processes (Chapter 18.1, and 18.2, 365-377) January 27th 2005 Ohmic heating Microwave heating Review - mid term 1 Mid term exam 1 . Week 5 (Jan30-Feb3) Complete lectures on advanced thermal processes as needed Week 6 (Feb6-10) Processing by removal of heat-Food freezing (Chapter 21, 418439) Minimal/nonthermal food preservation methods (Chapter 9, 210222) High pressure processing Pulsed electric field processing Week 7 (Feb13-17) Processing using hot air – dehydration (Chapter 15, 311-339) Extrusion processing (Chapter 14, 294-308) Week 8 (Feb20-24) Continue lectures and review for midterm 2 Feb 24, 2005 Mid term exam II Week 9 (Feb27-March3) Separation and concentration of food components (Chatper 6, 140168) Week 10 (March 6-10) Food Irradiation (Chapter 8 196-208) Wrap up & review March 10 (Friday) Last day of regularly scheduled classes Week 11 (March 13-16) Final Exam Week March 19 Winter Commencement TENTATIVE LABORATORY SCHEDULE During the lab session, we will complete assigned pilot plant exercise or process calculation tutorial, or equipment demonstration. The labs will be held in the pilot plant in the Howlett Hall or in Parker Hall (or) instructor will let you know. The class will meet at Rm 124 Parker Lecture hall before the pilot plant activities unless otherwise specified by the instructor. Wear shoes suitable in pilot plant wet environment. Wherever possible, students will be divided into small groups and perform lab projects together. Lab reports are due one week after the lab date. Some laboratory exercises will require longer periods of time than allocated for the laboratory. In such cases, one person from that group must be present in the lab at all times during that day. All members of lab group must be present during regularly scheduled lab period. Date January 5, 2006 Activity Location Howlett / Parker Pilot Plants Pilot plant safety Student photographs Team term project selection Tour of parker and Hewlett pilot plants January 12, 2006 Thermometry lab Parker Teaching lab January 19, 2006 Canning lab Heat penetration studies Demonstration of Technical Software Howlett Pilot Plant January 26, 2006 February 2, 2006 February 9, 2006 February 16, 2006 Demonstration of USDA pathogen modeling software Thermal process calculation tutorial Aseptic lab Ohmic pilot plant tour (tentative) Parker Pilot Plant & 135 Ag Eng. Dehydration lab High pressure lab demonstration Howlett Pilot Plant Freezing lab PEF pilot plant demonstration (tentative) Parker & basement Parker February 23, 2006 Extrusion lab (or extrusion industry tour) Howlett Pilot Plant March 2, 2006 Irradiation tour OSU Nuclear Reactor Lab, 1298 Kinnear Road, Columbus March 9, 2006 Term project class presentation RECOMMENDED FORMAT FOR LAB REPORTS 1. State the title of the lab, date and your name. 2. Abstract: Provide a 300 word abstract (one page maximum) stating objective of the lab exercise and key findings. 3. Lab Report (up to 15 pages): Provide brief introduction and discuss the industrial relevance of the lab. Describe what your objective was and how you did experiments. Describe what the results were, why they happened, what they should have been and why they are important. If the results were unexpected, describe why they occurred. Refer to figures and tables in the appendix, but explain them in enough detail that the reader doesn’t have to look at them. Explain the theory behind what happened and the implications. Include the information asked for in the lab handout. Be sure to reference all figures that you include. The reference should not be the subject or object of the sentence. Be sure to include any observed quality changes in the products and what caused them. References must be properly cited. List references at the end of the paper in the format used by the Journal of Food Science. For internet citations, please provide web address of the page containing cited material and last time you access the information. 4. Appendix: Attach tables, graphs and raw data if applicable. Make certain you report to the correct number of significant figures. You will be graded on correctly labeling axes, units, legends and titles. You will also be graded on deciding how to graph the results so that they show meaningful results. HOMEWORK ASSIGNMENTS There will be a set of homework assignments (problems or web reading materials) on Fridays. Homework is due one week after the assignment date at the time of class. FIELD TRIPS We may have up to 2-3 scheduled field trips (within OSU campus area) during lab periods. It is essential that students arrive on time to allow sufficient time for travel and touring the facility. The tour will leave from Parker front hall and volunteers are needed to drive. A brief report not to exceed one double-spaced typed page is required for each field trip, indicating what was learned during the trip. Each student will write a separate report. Reports are due one week after the trip. COMPUTER TUTORIAL Some days, there will be process calculation tutorial. Please read the assigned material before coming to the class and ready to participate in a group discussion. Bring a calculator. Carmen Lecture and laboratory handout materials available online at carmen.osu.edu. Carmen is the primary web-based course management system supported by the Office of Information Technology (OIT) at the Ohio State University. To log into Carmen and see your online courses, first use your web browser to open a link to carmen.osu.edu. A login box is on the left side of the screen that appears. Type your username and password and click on the Log In button. In most cases, your Carmen username is the same as your OSU Internet username (the name you use for checking your e-mail, etc.). For example: doe.999. When entering your username, be certain your caps lock is off and that you type it all in lowercase. If you are having problems please contact Carmen at (614)688-HELP (4357) TERM PROJECT At the beginning of the quarter, first Thursday you will form groups and choose a topic. You will have all quarter to work on the project, but you must turn in a brief progress report (one-two paragraphs) every Friday listing what each person did and signed by all group members. The second to last week of class each group will turn in a 20 page term paper, and give a 15-minute oral presentation. Be certain the paper includes a table of contents. You may use any resources you can find, and present in any manner. Since you have a time limit, present only the highlights. The presentation and paper will receive one grade, which will be multiplied by the score given to the individual by their group members. Thus each individual’s grade may be higher or lower than the presentation grade, based on how well their peers thought they worked with the group. The key issue is to explain WHY you chose the particular ingredients/equipment/ packaging. Highlight the relevance of engineering, microbiological and chemistry principles. Each project should include sample process calculations (show some sample calculation steps) and microbiological/chemical reactions or composition and how this is important to your process. The oral presentation should be not longer than 15 minutes. Additional five minutes will be allowed for questions. The preferred format for this presentation is using PowerPoint with the video projector. Assistance with preparing the PowerPoint presentation is available from the instructors or TAs. Scanners and digital cameras are available with assistance from instructors or TAs. Please plan ahead if you will require assistance. For each of the group presentations (including your own) you need to submit 2 questions. Write general concept questions since some of these will appear on the final exam. Also bring handouts (6 slides per page) of your presentation for the class. If you get the presentation to me in advance I will print the handouts, otherwise you need to make copies for the whole class. The presentation will be evaluated on the basis of the following: Presentation skills (good audience eye contact, not reading from paper, good voice projection) Visual aids (pertinent, understandable) Answering questions (direct answers, effectiveness, command of subject) Content meaningful PARTICIPATION Your active participation in both class and laboratory activities is encouraged. Participation means you will attend lectures and field tours and being on time equal partner in the activities of your lab group participate in class discussion LABORATORY SAFETY POLICIES Laboratory and pilot plant safety is everyone’s responsibility. Use common sense and work carefully at all times. Try to prevent an accident from happening -- think before you act! IF YOU ARE NOT SURE, ASK BEFORE OPERATING OR USING ANY PIECE OF EQUIPMENT. If you observe some unsafe activity, please bring it to instructor attention. Don’t hesitate to ask questions. GOOD SAFETY PRACTICES Lab coat, hair net must be worn in the lab. Do not wear rings, earrings, bracelets, wristwatches, or jewelry in the vicinity of operating machinery and power tools. Long full beards, unrestrained long hair, and loose clothing (such as lab coat) can become caught in tools or machinery and cause serious personal injury. Do not stick hands, fingers or any utensil into any machine while it is operating or even while it is plugged in. Eye and ear protection must be worn when instructed. Be very careful with water sprays especially around electricity. Do not try to catch falling knives or glassware. Don't even try to catch or reposition fruits/vegetables entering running machinery Floors will be wet and SLIPPERY. Be careful as you move around the pilot plant and wear appropriate footwear. No open-toed shoes. Hot surfaces, hot product, hot water and steam are all primary hazards in the pilot plant. Protective equipment (gloves, etc.) will be provided and must be used. Exercise caution when lifting and moving heavy objects. The two main hazards are injuring your back or dropping something heavy on yours (or someone else’s) foot. Ask for help when you need to move something heavy. You will receive safety instruction for every piece of equipment that you will operate. If you are unsure, ask! Report all accidents and unsafe conditions or actions to the instructor or pilot plant supervisor. Instructor: TAs: Pilot Plant Supervisor: Dr. Sheryl Barringer Shantanu Yousuf Debby Cokro Maria Bebko Mike Piek 317 Parker Hall 266 Parker Hall 330 Parker Hall 320 Parker Hall Pilot Plant, Howlett 688-3642 247-7135 688-8243 688-8243 2924045 barringer.11@osu.edu yousuf.2@osu.edu deapple@hotmail.com bebko.2@osu.edu pi ek.1@osu.edu 292-0218 FAX Office hours: drop by anytime, or make an appointment Laboratory Exercises: Laboratories will be done in the pilot plant of Howlett Hall. We will be using real processing equipment, so remember that accidents can happen. Report ALL accidents to the instructor or a TA immediately. No high heels, open toed shoes or shoes with slippery soles are allowed in the pilot plant. No loose, dangly jewelry or sleeves. Do not wear nice clothes to the lab. Laboratory aprons will be provided as needed but you may still get wet or dirty. Exercise caution when working around equipment that is in motion. Week 3 (Enzyme lab) you will need to bring a lab coat. Be certain you read the lab before coming to class. For each laboratory exercise, a written lab report is required. This report is due a week later, at the beginning of the class. If you are late to lab, your report will be counted late. Reports must be neat and readable or they will not be graded. Late lab reports will lose 10 pts if up to one day late, 20 pts if up to two days late and will not be accepted after a week. There are no make up labs except with a verified medical excuse, in which case an essay may be assigned. The information needed to answer the questions should have been given in lecture, but if you need more information, feel free to ask Dr. Barringer. Remember to clean up after each lab exercise. This includes hosing down all equipment, taking apart and cleaning equipment where necessary, discarding any garbage and wiping down all surfaces. Any students who leave before the entire area is clean, or do not help with the cleaning, will have points taken off of their lab reports. Students will divide into groups at the beginning of each lab and chose a leader. The leader will be in charge of making sure all of the work is done, results are reported to the rest of the class, and everything is clean before leaving. Everyone must lead a group at least once. Make sure you understand what the other groups did. Ask questions at the end of the lab if you are unsure. Exams: There will be 2 exams and a cumulative final. Exam hints: If you are asked for 4 reasons, give at least 5. You can get full credit for using excellent logic but coming to the wrong final answer. However, if you don’t explain your reasons you can’t get partial credit. Grading: The grading breakdown is: Lab reports, homeworks and quizzes 30% Exams 20%, 20% and 30% Attendance (-1%) With each exam you will be given a list of the questions. You have 24 hours (due at noon) to return the list with the correct answer for any question you feel you answered incorrectly on the exam. Correct answers on the original exam will not be regraded down. You may do this by email, fax, in my mailbox or under my door. You will receive 1/3 credit for each question answered correctly, that was previously wrong. The class is graded on a straight scale: 100-93 = A, 92-90 = A-, 89-87 = B+, 86-83 = B, 82-80 = B-, 79-77 = C+, etc. It is acceptable (and desirable) for the entire class to receive As, if you earn them. Homework: Every Monday except the first one, there is a homework assignment due. The class will begin with students pairing up to discuss answers, followed by asking Dr. Barringer any questions that your partner can’t answer. After this, the homework will either be turned in to be graded, or there will be a quiz that contains one or more of the questions from the homework assignment. Due Dates: Lab reports: Homework: Exams Every Thursday (a week after the lab) Every Monday see schedule Possibly useful texts and websites. Many of the books are on reserve in the library. Fellows, P. 1996. Food Processing Technology, Principles and Practice. Woodhead Publishing Lmt, England. ISBN 1855732718 Fennema’s Food Chemistry is on reserve under FST 601 and is available electronically through the library. Wills, R.B.H., W.B. McGlasson, D. Graham, T.H. Lee and E.G. Hall. 1989. Postharvest. BSP Professional Books. Carlton, Australia ISBN 0442439432. Somogyi, L.P., Ramaswamy, H. S. and Hui, Y.H., eds. 1996. Processing Fruits: Science and Technology. Vol. 1. Biology, Principles and Applications. Technomic Publishing Co., Lancaster PA. ISBN 1566763622 Gould, W.A. Tomato Production, Processing and Technology, AVI Publishing Co., 1993. Lopez, A. A Complete course in canning. The Canning Trade. Luh and Woodroof. Commercial Vegetable Processing. AVI Publishing Tressler, D.K. and Joslyn, M.A. (Editors). Fruit and Vegetable Juice Processing Technology. 2nd Ed, AVI Publishing Co., Westport, Conn. 1971. Woodruf and Luh. Commercial Fruit Processing. AVI Publishing Ashurst, P.R., ed. 1995. Production and Packaging of non-carbonated fruit juices and fruit beverages. 2nd ed. Blackie Academic & Professional. TP562 Arthey and Ashurst, Fruit processing Dauthy. Fruit and vegetable processing http://www.fao.org/docrep/V5030E/V5030E00.htm Salunkhe, Kadam. Handbook of fruit science and technology The Almanac of the canning, freezing and preserving industry. TX599. Contains part of the CFR CFR 21 (Code of Federal Regulations) Available in the reference section of the main library, or on the FST-files, f&s, Barringer or on the web at http://www.access.gpo.gov/nara/cfr/cfr-table-search.html#page1 then title 21, current year USDA grading standards: http://www.ams.usda.gov/standards/standpfv.htm Food composition: http://www.nal.usda.gov/fnic/foodcomp/ then “search” Agricultural production: Agricultural Statistics (HD1751 in the reference section of the Agricultural library) or http://www.usda.gov/nass/pubs/agstats.htm or http://www.census.gov/statab/www/ Worldwide agricultural production: http://apps.fao.org/page/collections?subset=agriculture Chemical structures and characteristic aroma: http://www.nysaes.cornell.edu/fst/faculty/acree/flavornet/chemsens.html and http://chemfinder.cambridgesoft.com/ then enter the name. Francis, F. J. 1999. Colorants. EHS Reference TP456.C65 F73 for pigment structures http://www.lib.ohio-state.edu/find/titles.php#F then to Food Science and Technology Abstracts (FSTA) for flavors and pigments Academic Misconduct: See University rule #3335-31-02. Plagiarism and cheating are grounds for dismissal from the University. Students are allowed to work on their lab reports together, but each student must write their own report in their own words. Topic Sept W 21 Syllabus, Lab introduction to Fennema 984 Changes in tomato tomatoes R 22 F 23 Due, including readings quality Tomato lab Typical tomato line. Critical control points (for lab) M 26 F vs V. Pigments Fennema 659-703 pigments; 966–969 structure W 28 R 29 Oct Fennema 492 – 501 enzymes Enzymes. Peeling methods Peeling lab Tomato lab due F 30 Juice, chip and almond videos M3 Pigment activity Homework 1. W5 Composition Fennema 944-966 Composition; 532-533 vitamins R6 F7 Enzymes & Pigments Steps in processing Peeling lab Fellows 83-96 raw materials; 233-235 blanching M 10 Steps in processing Homework 2 W 12 Steps in processing Fellows 40-43 microbial death; 250-254 retort theory R 13 Canning green beans Enzyme lab F 14 EXAM M 17 Steps in processing Homework 3 W 19 Retorts Fellows 261-264 retorts R 20 Tour Lynd Fruit Farm Green bean lab F 21 Drying Fellows 44-48 water activity M 24 Drying Homework 4. Fellows 311-317 drying theory W 26 Drying R 27 F 28 Fellows 321-339 drying equip Potato Chip Lab/Drying Drying Freezing Homework 5. Fellows 418-423; 425-439 Freezing M 31 Nov W2 Fennema 984 – 987 potatoes QA of potato chip processing R3 Drying/Freezing Potato chip lab F4 Freezing M7 Freezing W9 Freezing/ Juice R 10 Homework 6 Freezing/ Cider F 11 HOLIDAY M 14 Postharvest physiology Drying lab Homework 7. Fennema 974 – 982 Respiration W 16 EXAM R 17 Jelly F 18 CAP/MAP M 21 Refrigeration/humidity/Jam Freezing lab Homework 8. Fellows 406-411 CA; 388-390 chilling and respiration. Fennema 998 – 1003 Temp, CA, RH; 216-217 pectin gels Dec W 23 VACATION DAY M 28 Waste and water/Irradiation W 30 Grades and standards R1 F2 None Review Final exam: R8 Cider lab. Homework 9. 7:30 - 9:18 AM Jelly lab, Review questions