COMPETENCY BASED LEARNING MATERIAL

Sector Processed Foods and Beverages

Qualification Title FOOD PROCESSING NC II

Unit of Process Foods by Sugar Concentration

competency

Module Title Processing Foods by Sugar Concentration

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 UNIT OF COMPETENCY : Process food by sugar concentration

UNIT DESCRIPTOR : This unit deals with the knowledge, skills and attitudes required to
process foods by sugar concentration which include to prepare equipment, tools, materials
and utensils, prepare the raw materials, pack sugar concentrated products and perform
post- production activities.

Information Sheet 3.1

Manufacturer’s Specification on the Use of Equipment and Tools Food

processing equipment is provided with the manufacturer’s manual which serves as a guide
to workers of the proper use of the said equipment. This contains specifications on the
uses and other pertinent information that a user must know about the equipment or
device. It also provides necessary reminder in the form of a sticker or warning label that is
attached to the equipment. This indicates that the equipment, machine, or tool is in
excellent condition and has passed the quality control in its construction and fabrication.
Specifications to consider on the use of equipment and tools:

1. Preheat cooking equipment according to the manufacturer’s recommendations.

Failure to follow instructions can increase energy usage or sometimes may cause
damage to the equipment.
2. Use cooking equipment to full capacity. Fully loaded equipment utilizes energy more
efficiently.
3. Turn off ovens during low production periods to save gas and electricity.
4. Use the recommended capacity of food to be cooked in certain equipment according
to manufacturer’s recommended capacity. Overloading can increase cooking time
and energy consumption.
5. Do not open the refrigerator too often or when not needed. Frequent opening of
doors whether oven or refrigerator increases electricity consumption. Check for door
seals or gaskets to ensure tight fit to avoid leaks.
6. Clean equipment regularly as specified by the manufacturer to prolong their usage
and serviceability.
Cleanliness should be observed during and after the preparation of tools,
equipment, and utensils. Handle the equipment properly by following the recommended
manufacturer’s specification provided.

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Preparing Tools and Equipment for Sugar Concentrates

Same with the tools and equipment used in curing and fermentation, preparation of
sugar concentrates require different equipment and tools to be used.
Cleaning and sanitizing should be done after use to ensure prolonged serviceability.

1. Juice extractor. Used to extract juices of citrus fruits. It may be glass or plastic, and
may come in different sizes.
2. Slicer. Used to cut fruits and vegetables according to size. This may be stainless,
ordinary plated or plastic.
3. Osterizer or blender. Used to liquidize and blend foods particularly fruits for sugar
concentrates to improve the texture of mashed fruits.
4. Spatula. Used for leveling off dry ingredients like sugar, salt and flour.
5. Candy thermometer. Used to measure the setting state of jellies, jams, and candies if
the desired consistency of the product is attained.
6. Jelly Tester or thermometer. Used to test the sugar concentration in jams, jellies or
sugar concentrates.

Packaging Materials

Packaging materials for sugar concentrates can be the following:

• Thins cans
• Pouches
• Plastic jars
• Glass jars
Cleaning and Sanitizing of tools and equipment

Stove/Gas Range

1. Remove all burnt foods and dirt during cooking

2. Scrape grease from cracks, openings, and hinges and wash the plates with soap and
water.
3. Clean the top part of the stove when cooled.
4. Soak and scrub burners with a stiff brush to avoid clogging of holes that may
interrupt the flow of heat.
5. Wipe dry
6. Sanitize or disinfect

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 Refrigerator/freezer

1. Pack the food in separate container for easy cleaning

2. Wipe up spilled food immediately to avoid stubborn spilled foods that may impart
odor to the equipment.
3. Keep trays and shelves clean by washing as often as possible. If preferred, apply
baking soda or charcoal to keep out bad odor. Rinse and dry the shelves thoroughly.
4. Flush drains and defrost weekly if possible to maintain the cleanliness of the
equipment.
Cooking Utensils

1. Clean the utensils thoroughly by removing dirt that adheres and wash with soap
and detergents and rinse.
2. Immerse in sanitizing solution, then dry using cloth
3. Stow the utensils clean
Cutting Implements and other tools and equipment

1. Clean immediately after using. Remove all remaining food particles and wash with
water and detergent
2. Rinse and dip in sanitizing solution
3. Wipe with damp cloth and stow away properly

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Selection and Preparation of raw Materials for Sugar Concentrates

Primarily, the right choices of raw materials contribute to the success of any preserved
sugar concentrates. Raw materials refer to fruits and vegetables that have high pectin
content in order to produce good jellies, jams and marmalade. The variety of fruits,
freshness, size and maturity of fruits should always be considered.

Guide to the selection of some common Philippine fruits

NAME
Quality Characteristics Undesirable characteristics

Shiny green, firm ripe Soft, decayed tip

Abokado (avocado)

Anonas (anonas) Not too soft, sweet smelling, Presence of insects, too soft,
plump, whole broken

Balimbing(carambola) Bright green,firm, crisp Shriveled, bruised, dull green,

decayed spots

Yellowish green rind, plump Decayed spots, dry rind

Dalanghita (native orange) juicy

Green rind Decayed spots, dry rind

Dayap (lime)

Yellowish green rind Decayed spots, dry rind

Durian (durian)

Guayabano (soursop) Bruised, overripe, brown,

Whole, firm yet soft, juicy decayed spots

Istoberi (strawberry) Firm, bright red Bruised, overripe, decayed

spots

Langka (jack fruit) Pulp-bright yellow, firm, sweet Strong pungent odor, overripe,
smelling, young fibrous

Bright red, juicy, plump Shriveled, dull, decayed

Makopa (curacao apple)

Mangga (Mango) Bright yellow, smooth skin, Shriveled, overripe, decayed

plump, juicy spots

Mangostan (mangosteen) Not too soft, sweet smelling, Shriveled, overripe, decayed
plump, whole spots

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Milon (melon) Color characteristic of variety, Broken, bruised, overripe,
firm, juice, whole decayed spots

Pakwan (watermelon) hard green rind, pulp juice,

firm Broken, bruised, pulp limp

Pinya (pineapple) Whole, greenish, yellow rind, Bruised, underripe, overripe,

sweet smelling decayed spots

Rambutan (rambutan) Firm, bright red Bruised, overripe, decayed

spots

Saging na saba Color characteristics of variety,

firm, juicy, whole Broken, bruised, underripe

whole broken
Sampalok (tamarind)

Santol (santol) Golden yellow, firm

Shriveled, soft, decayed spots

Glossy green violet, firm, Bruised, underripe, overripe,

Siniguelas (Spanish plim) plump, juicy decayed spots

Suha (pomelo) Light green, plump

Shriveled, bruised, underripe,

overripe, decayed spot

Guide to the selection of common Philippine vegetables

Name Good Quality Characteristics

Kalabasa (squash) skin, free from bruises, pulp-bright yellow, firm
Kamote (sweet potato) Free from ulalo
Karot (carrot) Crisp, good orange color, free form green tap
Gabi (taro) Free from decayed spots, firm
Luya (ginger) Firm, free from decayed spots
Mani (peanut) Firm, free from decayed spots

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 Niyog (coconut) Tender, young, juicy
Papaya (papaya) Color characteristics of variety, firm, juicy, whole

Steps in Making Jelly

1. Choose the ripe ones that are free from any blemishes. Slightly ripe fruits can also
be selected but not the overripe nor underripe ones
2. Two or more fruits of the same kind can be combined when boiling.
3. Wash the fruit thoroughly with water before crushing, grinding or chopping it into
pieces. Peels of the fruits contain a large amount of pectin so these are not removed
when crushing, grinding or chopping
4. Place the fruits in a large casserole or kettle. Add about ½ cup per one kilogram of
fruit. Crushed, mashed or chopped fruit should be immersed in water.
5. If the fruit has low acid content, add calamansi to aid conversion of protopectin to
pectin. But if it has high acid content, add sugar to lower down acidity.
6. Boil the mixture of mashed fruits and water on a low heat fire until the flesh
becomes soft. This is necessary to get the maximum extraction of juice and pectin. If
the fruit is soft, boiling it for three minutes is enough.
If firm, prolong the boiling time until it softens but do not overcook.

7. Cool the mixture and strain using a jelly bag or a clean piece of cheesecloth. Twist
and press the cheesecloth hard enough to squeeze out the juice. After the first
extraction, return the pulp to the casserole or kettle, add enough water and let it
boil again.
8. Extract the mixture for the second time. Mix the first and second strained juice.

Making Jam

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 Jam is a jelly-like product mad from fruit such as mangoes either crushed, cut, or
mashed cooked to moderate consistency. It contains not less than 45% of fruit by weight
and 55% of sugar.

Steps in making Jam

1. Select fresh, mature and well-ripened fruits.

2. Clean the fruits to remove adhering dirt, pesticide, etc. Wash thoroughly to remove
the chemicals present due to pesticide used or sprayed
3. Peel the fruits, soften or mashed. Fruits with seed may be left whole or seeded. In
some cases, fruits may simply be cut in smaller pieces.
4. Test the pectin and acid content of the fruit
5. Measure the amount of flesh produced when the sugar is added.
6. Add ¾ cup sugar for a cup of pulp. The amount of sugar varies depending on the
pectin content as tested.

Making Marmalade

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 Marmalades differ slightly from jams for it contains pieces preferable thin slices
of fruit suspended in a clear sparkling jelly. Unlike jams, they are cut in small pieces or
mashed. The best known marmalades contain citrus fruits such as calamansi, oranges,
lemons, limes and grape fruits. These have uneven texture and slightly has acidic taste.

Preparing the Fruits

Two ways of preparing marmalade:

a. Juice and peel prepared separately or combined

b. Whole fruit together with the peel chopped finely Procedure:

1. Wash the fruits well in detergent water (1/2 tsp. detergent in 4 cups water)
2. Scrub with a soft clean brush if the skins are all dirty
3. To peel fruit more easily, blanch them in boiling water for 1 to 2 minutes especially if
the fruits have tough skin or peel.
4. Cut the fruit. If citrus is used, slice the peel finely so that the pectin can easily be
dissolved. If marmalades with little pith are desired, cut the peel finely but do not
discard the pith. Instead, cut it up roughly, tie it loosely in a pieces of muslin cloth
and cook with the peel until just before the sugar is added.
5. Squeeze the bag and remove it. Add calamansi juice or citric or tartaric acid
6. Test for pectin. Apply the test for pectin when peels are soft. Use the same test as in
jellies.

Making Fruit Preserve

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 Fruit preserves are products made from small or large pieces of fruits cooked in
heavy thick syrup until crisp texture is attained. Fruits to be preserved should be of
high quality, free from blemishes, and possess uniform color.

1. Cut the fruits into halves and remove the seeds when necessary.
2. Prepare syrup using 1 cup sugar per cup of water and immerse the fruits.
3. Boil the syrup, add the fruits.
4. Let the fruits soak in the syrup overnight making sure all is covered with syrup.
5. The next day, remove the fruit from the syrup and drain. Repeat the process
depending on the fruits used.

The amount of sugar to add depends upon the texture and acidity of the fruit, though ¾
part sugar per part of fruit by weight is generally accepted. If fruits are soft and sour, more
sugar is needed. If the fruit is sweet or hard, less sugar is required.
6. Cook the fruit over a slow fire and stir making sure that cooking is done shortly for
successive days in syrup to ensure plumpness and better flavor. A 40% sugar may
be used as initial sugar concentration allowing the fruit to cook for few minutes to
make it tender and to allow the syrup to penetrate into the fruit. Let the fruit stand
in that syrup overnight. 7.
7. The following day, drain the syrup and increase the sugar concentration by 10%.
8. Boil the syrup.
9. Add the fruit and allow the mixture to simmer for 3 to 4 minutes again and set aside
overnight.
10. Repeat the process until a syrup of desired consistency is attained. Make sure
that the fruit is clear, plump, and thoroughly impregnated with the syrup. Prevent
the fruit from shriveling by cooking hard fruits
like kundol or papaya in water until tender before adding the sugar.
Fruits that are soft may be cooked in heavy syrup right away.

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 Task Sheet 3.1.1
Making Fruit Preserves

Be able to prepared kundol preserve given the following materials and ingredients:

Materials:
 Mature kundol
 Lime solution (apog)
 Suagr
 Water
 Glass jars
 PPEs
Procedure
1. Cut and peel the fruit according to desired size
2. Soak overnight in lime solution 1T in 4 qt. water
3. Blanch the fruit and drain
4. Simmer ion water for 15 to minutes until pieces become translucent
5. Prepare syrup using 1 cup sugar per cup water. Bring to a boil and add
the fruit. Simmer for 5 minutes.
6. Soak fruit in syrup overnight. Drain and add ½ amount of sugar
previously used and add ½ tsp. kalamansi juice per cup of syrup
7. Bring syrup to a boil. Add fruit and simmer again for 3 to 5 minutes and
soak overnight
8. On the third day, add sugar and acid again.
Repeat step 7

PERFORMANCE CRITERIA CHECKLIST 3.1.2

Criteria Yes No

Did the candidate…

1. Cut and peel the fruit according to desired size

2. Soak overnight in lime solution 1T in 4 qt. water

3. Blanch the fruit and drain
4. Simmer ion water for 15 to minutes until pieces become
translucent
5. Prepare syrup using 1 cup sugar per cup water. Bring to a boil
and add the fruit. Simmer for 5 minutes.

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 6. Soak fruit in syrup overnight. Drain and add ½ amount of
sugar previously used and add ½ tsp. kalama
nsi juice
cup of syrup

7. Bring syrup to a boil. Add fruit and simmer again for 3 to 5

minutes and soak overnight
8. On the third day, add sugar and acid again. Repeat step 7

Information Sheet 4.1

Preparing Production Report

Sugar concentrates should have a format on the preparation, computation,
recording and documentation.
Actual spoilage or rejects depends on the product to be made. For example, in
mango jam, excess refers to the peel and seeds of mango and spoilage pertains to those
flesh or mixture of mangoes in excess or that are not included or left during packing.

Product Name : MANGO JAM

Production Date : May 2016
Description of Materials:
Ripe Mango 1000g Refined Sugar
500 g Other Ingredients:
Weight of Calamansi 10g
Total Weight of materials (input) 1560g
Output
Total Weight of leftover material 30g
Spoiled/reject 1530g

Percentage Yield = 1530 x 100%

1560
Approximate number of finished products= 2 bottles at 190 grams/bottle

Computing for the Percentage Yield

Yield refers to the number of finished product produced after computing the production
input and output.
Formula in getting the percentage yield:
% Yield= Production input x 100%
Production Output x 100%

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Recording Calculated Data
All records and reports made from the gathered and computed production input,
output, rejects, spoiled, weight of peel, actual yields, or recoveries are kept and recorded for
documentation purposes. This will serve as reference for future use and will determine the
progress of succeeding products to be made.

Self Check 4.1.1

Make your own production Report based on the following data provided.
Compute the input, output, and percentage yield.

1000g. ripe guava Manufacturing date: May 20,2012

500g sugar
10 ml. calamansi juice
Weight of excess material—50 grams

Answer Key 4.1.2

Product Name : GUAVA JAM

Production Date : May 2012
Description of Materials:
Ripe Guava 1000g Refined Sugar
500 g Other Ingredients:
Weight of Calamansi 10g
Total Weight of materials (input) 1510g

Output
Total Weight of leftover material 50g
Spoiled/reject 1550g

Percentage Yield = 1530 x 100%

1510
Approximate number of finished products= 2 bottles at 190 grams/bottle

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 COMPETENCY BASED LEARNING MATERIAL

Sector Processed Foods and Beverages

Qualification Title FOOD PROCESSING NC II

Unit of Process food by drying and dehydration

competency

Module Title Processing food by drying and dehydration

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 UNIT OF COMPETENCY : Process food by drying and dehydration

Unit descriptor : This unit deals with the knowledge, skills and attitudes required
to process foods by sun drying, dehydrator, and solar drying. It includes drying and
dehydration of fruits, vegetables, herbs and spices, root crops, fish and meat.
Information Sheet # 4.1

Dehydration, in food processing, means by which many types of food can be

preserved for indefinite periods by extracting the moisture, thereby inhibiting the growth of
microorganisms. Dehydration is one of the oldest methods of food preservation and was
used by prehistoric peoples in sun-drying seeds. The North American Indians preserved
meat by sun-drying slices, the Chinese dried eggs, and the Japanese dried fish and rice.

Dehydration equipment varies in form with different food products and includes
tunnel driers, kiln driers, cabinet driers, vacuum driers, and other forms. Compact
equipment suitable for home use is also available. A basic aim of design is to shorten the
drying time, which helps retain the basic character of the food product. Drying under
vacuum is especially beneficial to fruits and vegetables. Freeze-drying benefits heat-
sensitive products by dehydrating in the frozen state without intermediate thaw. Freeze-
drying of meat yields a product of excellent stability, which on rehydration closely resembles
fresh meat.

The dairy industry is one of the largest processors of dehydrated food, producing
quantities of whole milk, skim milk, buttermilk, and eggs. Many dairy products are spray
dried—that is, atomized into a fine mist that is brought into contact with hot air, causing an
almost instant removal of moisture content.

Benefits

Molds, yeast and bacteria need water to grow. When foods are sufficiently dehydrated,
microorganisms cannot grow and foods will not spoil. Dried fruits and fruit leathers may be
used as snack foods; dried vegetables may be added to soups, stews or casseroles. Campers
and hikers value dried foods for their light weight, keeping qualities and ease of
preparation.

Nutritional value

The nutritive value of food is affected by the dehydration process. Vitamins A and C are
destroyed by heat and air. Using a sulfite treatment prevents the loss of some vitamins but
causes the destruction of thiamin. Blanching vegetables before drying (to destroy enzymes)
results in some loss of vitamin C and Bcomplex vitamins as well as the loss of some
minerals, because these are all water soluble. Yet blanching reduces the loss of thiamin and
vitamins A and C during dehydration and storage.

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Drying methods

Foods can be dehydrated by various means: the sun, a conventional oven, an electric
dehydrator or, for herbs only, a microwave oven. Dehydration, like other preservation
methods, requires energy. Unless sun drying is possible, the energy cost of dehydrating
foods at home is higher than for canning and, in some cases, more expensive than freezing.

1. Solar drying is a modification of sun drying in which the sun's rays are collected
inside a specially designed unit with adequate ventilation for removal of moist air.
The temperature in the unit is usually 20 to 30 degrees F higher than in open
sunlight, which results in a shorter drying time. While solar drying has many
advantages over sun drying, lack of control over the weather is the main problem
with both methods.
2. Oven drying is the most practical way to experiment with dehydration. It requires
little initial investment, protects foods from insects and dust and does not depend
on the weather. Continual use of an oven for drying is not recommended because
ovens are less energy-efficient than dehydrators, and energy costs tend to be high. It
is difficult to maintain a low drying temperature in an oven, and foods are more
susceptible to scorching at the end of the drying period. Oven-dried foods are
usually darker, more brittle and less flavorful than foods dried by a dehydrator.
3. Electric deyhdrator produces a better-quality dried product than any other method
of drying. Electric dehydrators are self-contained units with a heat source, a
ventilation system, and trays to place the food on. They are used to dry foods
indoors. Therefore, as with oven drying, they don't depend on the weather. Such
dryers can be purchased or made at home and vary in sophistication and efficiency.
Although an electric dehydrator requires a fairly high initial investment, it maintains
low temperatures and uses less energy than an oven.

Caution
It is not recommended that microwave ovens be used for drying foods, because the food will
partially cook before it dries, imparting an overcooked flavor. Microwave ovens can be used
to dry some herbs quickly—but watch them carefully to prevent them from catching on fire.
Check the owner's manual for drying recommendations.

Drying times in conventional ovens or dehydrators vary considerably depending on the

amount of food dried, its moisture content and room temperature and humidity—and in the
case of oven drying, the use of fans.
Some foods require several hours, and others may take more than a day. Interrupting
drying time, or prolonging it by using lower temperatures, may result in spoilage.

Air temperature and circulation must be controlled during the drying process. If the
temperature is too low or the humidity too high (resulting in poor circulation of moist air),
the food will dry more slowly than it should and microbial growth can occur. Watch
temperatures closely at the beginning and end of the drying period. If the temperature is too
high at first, a hard shell may develop on the outside, trapping moisture on the inside. This
condition is known as case hardening.

Temperatures that are too high at the end of the drying period may cause food to scorch.
Temperatures between 120 and 140 degrees F are recommended for drying fruits and

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vegetables. Temperatures up to 150 degrees F may be used at the beginning, but should be
lowered as food begins to dry. For at least the last hour of the drying period, the
temperature should not exceed 130 degrees F.

Selecting a dehydrator

Try drying several foods in your oven before buying a dehydrator. You will become familiar
with the process and pinpoint features to look for in the appliance. Also, experiment with a
variety of commercial dehydrated foods to test your family's acceptance of dried foods.
Remember, the equipment available for commercial drying will probably produce a product
superior to that you can achieve at home.

Space requirements
Dehydrators vary in size and can be round, square or rectangular. You will need to find a
convenient space to operate it. Place the dehydrator near an electrical outlet so that
extension cords are not necessary. You should have room to open the door and easily load
and rotate the trays. When deciding where to put the dehydrator, keep these points in
mind:

• The food will give off humidity

• The fan will create noise
• The appliance will give off heat
Heat control
The dehydrator should allow you to select heat settings from 85–160 degrees F and should
have a thermostat to maintain the selected temperature. The heating element should be
enclosed so that it does not present a shock or burn hazard. Some models have timers and
automatic shutoffs. Controls should be located on the front of the dehydrator. Check the
instructions to see how often the trays need to be rotated. Requirements for frequent
rotation can mean uneven heat in the dehydrator.

Air flow
As much food surface as possible should be exposed to warm, dry, moving air. Good air flow
is extremely important in removing moisture from food. Some dryers use natural convection
only; others use a fan. The addition of a fan will make even air circulation more likely. A fan
with two speeds is desirable. High speed is used at the beginning of the drying period when
moisture is readily available at the surface. Low speed is then used to slowly remove the
remaining moisture.

The two basic kinds of air flow systems are horizontal and vertical. Horizontal flow moves
air across the top and bottom of food and is considered the best system. Vertical air flow is
more easily blocked by food shelves.

Trays
Tray edges should be a quarter- to a half-inch high to prevent food from spilling or falling off
and to allow air to circulate. Trays should slide easily in and out.

There should be four to 10 open-mesh trays of sturdy lightweight plastic for drying. The
mesh size of the screening material should be large enough to allow air to circulate yet
small enough to prevent food falling through.

Finally, the trays should be easy to clean and lightweight.

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Door
The door should be easy to open and close. Doors may swing up or down, right or left. Some
are removable. When open, the door should not interfere with traffic passing by the
dehydrator. You may need both hands to load and unload the food trays so the door should
stay in an open position by itself. It should seal well and have strong hinges and latches
that will withstand repeated use as well as heat and humidity.

Cabinet
The cabinet should be built of a material that does not warp or get hot when in use—
double-wall construction of metal or plastic. It should be nonflammable and easy to clean.

Safety
Look for the UL label and a grounded plug.

Service and warranty

Review the service and warranty information to find out who can service the appliance.
Check the length of the warranty and what it covers. A one-year warranty is recommended.
Also, verify that replacement parts are available.

Capacity
Use common sense. If the capacity of the dehydrator does not look large enough to
accommodate the size of the loads you will dry frequently, it will not be a good buy.

Procedures for oven drying

When using the oven drying method, it is important to know if your oven can maintain the
appropriate temperatures. Use an oven thermometer to test the temperature of the oven at
its lowest setting. Many ovens cannot maintain a temperature below 200 degrees F. If your
oven cannot, it is too hot for successfully drying food, so alternative drying equipment must
be used.

Tray placement
Trays upon which the food is placed must be at least 1½ inches narrower than the inside of
the oven to allow for air circulation. Allow at least 2½ inches between trays and 3 inches of
free space at the top of the oven for good air circulation.

Arranging food layers

About 4 to 6 pounds of food can be dried in an oven at one time. Place food on drying trays,
or on wire cooling racks covered with cheesecloth or nylon netting, to allow easy removal of
dried food. Pieces of food should be in a single layer. Do not place food directly on oven
racks. Cookie sheets are acceptable only for fruit leathers, which do not require good air
circulation.

Setting the temperature

Place an accurate, easy-to-read thermometer on the top rack toward the back. Preheat oven
to 150 degrees F. For gas ovens, if temperature cannot be maintained below 200 degrees F,
it may be possible to use only the pilot light. For electric ovens, use only the bottom
element, disconnecting the broiler element if necessary. Arrange trays in the oven to allow
for adequate air circulation. Prop oven door open at least 4 inches.

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Ventilation
Place a fan outside the oven door to aid air circulation. Move it from side to side
occasionally. The room also should be well ventilated. Oven drying, particularly if a fan is
used, should be done with caution if small children are around.

Maintaining the temperature

Maintain the temperature at 140 degrees F. Watch the temperature even more carefully
toward the end of the drying process. To prevent scorching, lower temperature to 120
degrees F if possible. Examine the food often and turn trays frequently, removing foods as
they dry.

Procedures for drying in a dehydrator

When using a dehydrator, load food on trays in single layers so that pieces do not overlap.
This arrangement allows air to circulate through the trays. A constant temperature of 140
degrees F is necessary for dehydrator drying. Large pieces, such as apricot halves, should
be turned halfway through the drying time. Pieces near the sides of the tray should be
moved to the center. Stir small pieces with your fingers (make sure they're clean) every one
to two hours, separating bits that stick together. It may be necessary to rotate the trays
within the dryer at least once during the drying period. Vegetables usually take six to 16
hours to dry. Fruits can require up to 48 hours.

Never dry sulfured fruits in an oven or dehydrator, because the sulfur dioxide fumes can be
irritating. Use sulfite dips or steam, water or syrup blanching in place of the sulfur
treatment.
Separating foods
Different foods requiring similar drying times and temperatures can be dried together.
Vegetables with strong odors or flavors (garlic, onion and pepper) should be dried
separately. Don't dry strong-smelling vegetables outside in an electric dehydrator, because
dehydrators are not screened and insects may invade the food.

Choosing a dehydrator
Because an electric dehydrator can be an expensive investment, choose a specific brand or
model carefully. Refer to the sidebar for features to look for and evaluate before making
your investment.

When is it dry?
Judging when food is dry requires experience. It is better to overdry than to underdry. When
in doubt, continue drying for an additional 15–30 minutes. Check for doneness. Allow the
product to cool before testing.

Vegetables are sufficiently dried when they are leathery or brittle. Leathery vegetables will
be pliable and spring back if folded. Edges will be sharp. Corn and peas will shatter when
hit with a hammer.

Fruits are adequately dried when moisture cannot be squeezed from them, and if they are
tough and pliable when cut. Fruit leathers may be slightly sticky to the touch but should
separate easily from the plastic wrap.

Meats should be extremely dry unless they are to be refrigerated or frozen for long-term
storage. Meat is sufficiently dried when it is dark-colored and fibrous and forms sharp
points when broken.

Herbs are dried when brittle. Their leaves shatter when rubbed together.

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After drying

Even when a food tests dry, it may not be uniformly dry. Also, there is a chance of
contamination of dried foods, especially if racks have been exposed to the open air for any
time. Therefore, conditioning and pasteurizing should be done before storing.

Conditioning is the process used to equalize, or evenly distribute, moisture left in the food
after drying. It is usually done to fruits, herbs and seeds to improve storage, because it
decreases the chance of spoilage, especially by molds. To condition a food, follow these
steps:

• Cool foods on trays.

• Pour into a large, nonporous container of food-grade material; fill to about two-
thirds full.
• Cover container and place in a convenient, warm, dry place. Shake container daily
or stir contents at least once a day for 10–14 days.
• Check for condensation on the lid and any signs of spoilage. If condensation occurs,
return food to the dryer to finish the product. Recondition after it is dry.
• Cool thoroughly before packaging.

Caution
If any sign of mold growth occurs, destroy the product.

Freshly dried fruit can be added to the conditioning batch within the first five days.
Conditioning time will need to be lengthened to accommodate the additional food.
Pasteurizing is recommended for foods that have been contaminated before or during
storage. It can be used as a second treatment for vegetables held in storage if the vegetables
do not have any mold on them. Keep in mind that this treatment can cause quality
changes. To pasteurize, use one of the two following methods:

• Freezer—Seal dried food in a heavy, plastic bag after drying (and conditioning, if
necessary). Place in a freezer at zero degrees F for a minimum of 48 hours.
• Oven—Place the food in a single layer on a tray or in a shallow pan. Place in an
oven, preheated to 160 degrees F, for 30 minutes. Cool and package for storage.

Packaging dried foods

Package dried foods in glass jars, food-grade plastic storage containers, or plastic food-
storage bags. Make sure the package has an airtight seal. It is a good idea to package dried
foods in small amounts, because after the package is opened, the food can absorb moisture
from the air and quality deteriorates.

Storing dried foods safely

Store containers of dried foods in a cool, dark, dry area, such as a basement or cellar.
Exposure to humidity, light or air decreases the shelf life of foods. The lower the
temperature, the better: Foods stored at temperatures under 60 degrees F will keep about
one year. At 80–90 degrees F, the food begins to deteriorate within several months. The
shelf life of fruits increases three to four times for every 18 degrees F drop in temperature.

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 COMPETENCY BASED LEARNING MATERIAL

Sector Processed Foods and Beverages

Qualification Title FOOD PROCESSING NC II

Unit of Process foods by thermal application

competency

Module Title Processing foods by thermal application

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UNIT OF COMPETENCY : Process foods by thermal application

UNIT DESCRIPTOR : This unit deals with the knowledge, skills and attitudes required to
process foods by thermal application thru pasteurization, canning and bottling.

Information Sheet # 5.1

High Pressure Thermal Application in Food Processing

Both heat and pressure have long been used independently as means of preserving food.
For example, high pressure processing (HPP) at low or ambient temperatures can prevent
the growth of bacterial spores, and is an effective means of preservation in moderate and
high acid foods. However, low acid foods (LAF) remain impervious to standard pressure
processing at these temperatures, which allow the Bacillus and Clostridium strains of
bacteria to flourish, and have traditionally been preserved through thermal processing. But
this technique requires relatively long periods of heating to ensure that all the food within
the target pack has been heated to the minimum temperature – and the longer the heating
period is, the greater the risk of degradation to the food quality attributes (flavor, texture,
nutrient content and color). How HPT works food products are put through a pre-heating,
holding and cooling process in order to achieve the desired result. The equipment used is
designed to enable maximum compression heating which is vital for bacterial spore
inactivation. It must be able to maintain temperatures of up to 90°C, at pressures of 600-
800 MPa or higher (up to 1,500 MPa).

Firstly, the food product is placed in a holding unit and heated to a set temperature.

The holding unit is then pressurised, and the temperature is increased. The extent of these
increases depends upon the composition of the food product and its reaction to heat.

Once the required temperature has been reached it is maintained for a period of time long
enough to inactivate bacterial spores.
Decompression then takes place which cools the food product quickly, avoiding degradation
in terms of colour, taste, texture and nutritional value.

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The advantage of HPT processing lies in the reduced thermal load applied to products due
to:

the accelerated heating/cooling times of food products during

(de)pressurization; and potentially reduced processing temperatures and/or times through
the synergistic effect of heat and pressure on bacterial spore inactivation.

c. How successful is HPT? The results show that HPT processing is effective at preventing
reactivation in most – but not all – types of pathogenic bacteria. Spore reaction Bacteria
spores show different responses to HPT processing – even between strains of the same
species. For example, proteolytic Clostridium botulinum strains were more HPT resistant
compared to the nonproteolytic strains. Curiously, those bacterial spores which are
heatresistant differ in their response to the combined application of heat and pressure.

The very heat-resistant Bacillus amyloliquifaciens strains are highly pressure HPT-sensitive.

The very heat-sensitive Bacillus coagulans strains are the most HPT-resistant under a
variety of conditions.

While Clostridium thermosaccharolyticum strains are generally more than 10fold more heat-
resistant than C. botulinum, with the introduction of pressure they become far less HPT-
resistant.

The intrinsic properties of the underlying food also play a part; research suggests that spore
inactivation may be affected by the food’s water content, or its pH levels. Impact of
packaging The effect of HPT processing on food products also varies according to the barrier
properties used. Ideally, food packaging needs to be able to withstand changes in volume,
(de)compression, and temperature without any degradation of its aesthetic appeal. However,
HPT processing causes degradation to a certain extent in all forms of food packaging

this is more visible in barrier materials such as vapor-deposited nylon and oxide film, but
aluminum foil and PVDC-MA film are the least affected.

Further work is needed The use of HPT processing to sterilize low acid, shelfstable foods
remains a long term research challenge, although a more realistic goal is that of prolonging
the shelf life of low acid chilled foods. Further work needs to be undertaken into bacterial
spore inactivation in these chilled LAFs, in particular into the non-proteolytic C. botulinum
strain, which can germinate and produce toxin at refrigeration temperatures. Other areas to
be addressed include:

• improving pressurisation equipment to ensure optimum temperature distribution,

• developing food packaging to better withstand HPT processing, and
• better understanding the kinetics and mechanisms of spore inactivation through
HPT.

Self Check 5.1

Write T if the statement is correct and F if incorrect.

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____1. Thermal application requires relatively long periods of heating to ensure that all the
food within the target pack has been heated to the minimum temperature – and the longer
the heating period is, the greater the risk of degradation to the food quality attributes

____2. The process of pre-heating, holding and cooling process are not necessary to for food
to achieve the desired

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