Food processing

From Wikipedia, the free encyclopedia

Jump to navigationJump to search

Not to be confused with Food processor.

See also: Convenience food

Industrial cheese production

Food processing is the transformation of agricultural products into food, or of one form of food into
other forms. Food processing includes many forms of processing foods, from grinding grain to make raw
flour to home cooking to complex industrial methods used to make convenience foods. Some food
processing methods play important roles in reducing food waste and improving food preservation, thus
reducing the total environmental impact of agriculture and improving food security.

Primary food processing is necessary to make most foods edible, and secondary food processing turns
the ingredients into familiar foods, such as bread. Tertiary food processing has been criticized for
promoting overnutrition and obesity, containing too much sugar and salt, too little fiber, and otherwise
being unhealthful in respect to dietary needs of humans and farm animals.

Contents

1 Process

1.1 Primary food processing

1.2 Secondary food processing

1.3 Tertiary food processing

2 History

3 Benefits and drawbacks

3.1 Benefits

3.2 Drawbacks

4 Added sodium

5 Added sugars

6 Nutrient losses
7 Trans fats

8 Other potential disadvantages

9 Performance parameters for food processing

10 Industries

11 See also

12 Notes and references

13 Bibliography

14 External links

Process

Primary food processing

These whole, dried bananas in Thailand are an example of primary food processing.

Primary food processing turns agricultural products, such as raw wheat kernels or livestock, into
something that can eventually be eaten. This category includes ingredients that are produced by ancient
processes such as drying, threshing, winnowing and milling grain, shelling nuts, and butchering animals
for meat.[1][2] It also includes deboning and cutting meat, freezing and smoking fish and meat,
extracting and filtering oils, canning food, preserving food through food irradiation, and candling eggs,
as well as homogenizing and pasteurizing milk.[2][3][4]

Contamination and spoilage problems in primary food processing can lead to significant public health
threats, as the resulting foods are used so widely.[2] However, many forms of processing contribute to
improved food safety and longer shelf life before the food spoils.[3] Commercial food processing uses
control systems such as hazard analysis and critical control points (HACCP) and failure mode and effects
analysis (FMEA) to reduce the risk of harm.[2]

Secondary food processing

A man using a bread peel to slide a round disk of raw flatbread dough into a brick oven

Baking bread is an example of secondary food processing.

Secondary food processing is the everyday process of creating food from ingredients that are ready to
use. Baking bread, regardless of whether it is made at home, in a small bakery, or in a large factory, is an
example of secondary food processing.[2] Fermenting fish and making wine, beer, and other alcoholic
products are traditional forms of secondary food processing.[4] Sausages are a common form of
secondary processed meat, formed by comminution (grinding) of meat that has already undergone
primary processing.[5] Most of the secondary food processing methods known to human kind are
commonly described as cooking methods.

Tertiary food processing

Tertiary food processing is the commercial production of what is commonly called processed food.[2]
These are ready-to-eat or heat-and-serve foods, such as TV dinners and re-heated airline meals.

History

Food processing dates back to the prehistoric ages when crude processing incorporated fermenting, sun
drying, preserving with salt, and various types of cooking (such as roasting, smoking, steaming, and oven
baking), Such basic food processing involved chemical enzymatic changes to the basic structure of food
in its natural form, as well served to build a barrier against surface microbial activity that caused rapid
decay. Salt-preservation was especially common for foods that constituted warrior and sailors' diets
until the introduction of canning methods. Evidence for the existence of these methods can be found in
the writings of the ancient Greek, Chaldean, Egyptian and Roman civilizations as well as archaeological
evidence from Europe, North and South America and Asia. These tried and tested processing techniques
remained essentially the same until the advent of the industrial revolution. Examples of ready-meals
also date back to before the preindustrial revolution, and include dishes such as Cornish pasty and
Haggis. Both during ancient times and today in modern society these are considered processed foods.

Michael Foods egg-processing plant in Wakefield, Nebraska

Modern food processing technology developed in the 19th and 20th centuries was developed in a large
part to serve military needs. In 1809, Nicolas Appert invented a hermetic bottling technique that would
preserve food for French troops which ultimately contributed to the development of tinning, and
subsequently canning by Peter Durand in 1810. Although initially expensive and somewhat hazardous
due to the lead used in cans, canned goods would later become a staple around the world.[6]
Pasteurization, discovered by Louis Pasteur in 1864, improved the quality and safety of preserved foods
and introduced the wine, beer, and milk preservation.

A form of pre-made split-pea soup that has become traditional

In the 20th century, World War II, the space race and the rising consumer society in developed countries
contributed to the growth of food processing with such advances as spray drying, evaporation, juice
concentrates, freeze drying and the introduction of artificial sweeteners, colouring agents, and such
preservatives as sodium benzoate. In the late 20th century, products such as dried instant soups,
reconstituted fruits and juices, and self cooking meals such as MRE food ration were developed. By the
20th century, automatic appliances like microwave oven, blender, and rotimatic paved way for
convenience cooking.

In western Europe and North America, the second half of the 20th century witnessed a rise in the
pursuit of convenience. Food processing companies marketed their products especially towards middle-
class working wives and mothers. Frozen foods (often credited to Clarence Birdseye) found their success
in sales of juice concentrates and "TV dinners".[7] Processors utilised the perceived value of time to
appeal to the postwar population, and this same appeal contributes to the success of convenience foods
today.

Benefits and drawbacks

Benefits

Processed seafood – fish, squid, prawn balls and simulated crab sticks (surimi)

Benefits of food processing include toxin removal, preservation, easing marketing and distribution tasks,
and increasing food consistency. In addition, it increases yearly availability of many foods, enables
transportation of delicate perishable foods across long distances and makes many kinds of foods safe to
eat by de-activating spoilage and pathogenic micro-organisms. Modern supermarkets would not exist
without modern food processing techniques, and long voyages would not be possible.

Processed foods are usually less susceptible to early spoilage than fresh foods and are better suited for
long-distance transportation from the source to the consumer.[3] When they were first introduced,
some processed foods helped to alleviate food shortages and improved the overall nutrition of
populations as it made many new foods available to the masses.[8]

Processing can also reduce the incidence of food-borne disease. Fresh materials, such as fresh produce
and raw meats, are more likely to harbour pathogenic micro-organisms (e.g. Salmonella) capable of
causing serious illnesses.

The extremely varied modern diet is only truly possible on a wide scale because of food processing.
Transportation of more exotic foods, as well as the elimination of much hard labor gives the modern
eater easy access to a wide variety of food unimaginable to their ancestors.[9]

The act of processing can often improve the taste of food significantly.[10]
Mass production of food is much cheaper overall than individual production of meals from raw
ingredients. Therefore, a large profit potential exists for the manufacturers and suppliers of processed
food products. Individuals may see a benefit in convenience, but rarely see any direct financial cost
benefit in using processed food as compared to home preparation.

Processed food freed people from the large amount of time involved in preparing and cooking "natural"
unprocessed foods.[11] The increase in free time allows people much more choice in life style than
previously allowed. In many families the adults are working away from home and therefore there is little
time for the preparation of food based on fresh ingredients. The food industry offers products that fulfill
many different needs: e.g. fully prepared ready meals that can be heated up in the microwave oven
within a few minutes.

Modern food processing also improves the quality of life for people with allergies, diabetics, and other
people who cannot consume some common food elements. Food processing can also add extra
nutrients such as vitamins.

Drawbacks

Meat packages in a Roman supermarket

Processing of food can decrease its nutritional density. The amount of nutrients lost depends on the
food and processing method. For example, heat destroys vitamin C. Therefore, canned fruits possess
less vitamin C than their fresh alternatives. The USDA conducted a study of nutrient retention in 2004,
creating a table of foods, levels of preparation, and nutrition.[12]

New research highlighting the importance to human health of a rich microbial environment in the
intestine indicates that abundant food processing (not fermentation of foods) endangers that
environment.[13]

Using some food additives represents another safety concern. The health risks of any given additive vary
greatly from person to person; for example using sugar as an additive endangers diabetics. In the
European Union, only European Food Safety Authority (EFSA) approved food additives (e.g., sweeteners,
preservatives, stabilizers) are permitted at specified levels for use in food products. Approved additives
receive an E number (E for Europe), simplifying communication about food additives included in the
ingredients' list for all the different languages spoken in the EU. As effects of chemical additives are
learned, changes to laws and regulatory practices are made to make such processed foods more safe.
Food processing is typically a mechanical process that utilizes extrusion, large mixing, grinding, chopping
and emulsifying equipment in the production process. These processes introduce a number of
contamination risks. Such contaminants are left over material from a previous operation, animal or
human bodily fluids, microorganisms, nonmetallic and metallic fragments. Further processing of these
contaminants will result in downstream equipment failure and the risk of ingestion by the consumer.
Example: A mixing bowl or grinder is used over time, metal parts in contact with food will tend to fail
and fracture. This type of failure will introduce into the product stream small to large metal
contaminants.[citation needed] Further processing of these metal fragments will result in downstream
equipment failure and the risk of ingestion by the consumer. Food manufacturers utilize industrial metal
detectors to detect and reject automatically any metal fragment. Large food processors will utilize many
metal detectors within the processing stream to reduce both damage to processing machinery as well as
risk to consumer health.[citation needed]

Food processing does have some benefits, such as making food last longer and making products more
convenient. However, heavily processed foods also have drawbacks. Whole foods and those that are
only minimally processed, like frozen vegetables without any sauce, tend to be more healthy. An
unhealthy diet high in fat, added sugar and salt, such as one containing much highly processed food, can
increase the risk for cancer, type 2 diabetes and heart disease, according to the World Health
Organization.[citation needed]

Added sodium

One of the main sources for sodium in the diet is processed foods. Sodium, mostly in the form of sodium
chloride, i.e. salt, is added to prevent spoilage, add flavor and improve the texture of these foods. Some
processed food may contain over 2% salt.[14] Americans consume an average of 3436 milligrams of
sodium per day, which is higher than the recommended limit of 2300 milligrams per day for healthy
people, and more than twice the limit of 1500 milligrams per day for those at increased risk for heart
disease.

Added sugars

While it is not necessary to limit the sugars found naturally in whole, unprocessed foods like fresh fruit,
eating too much added sugar found in many processed foods increases the risk of heart disease, obesity,
cavities and Type 2 diabetes. The American Heart Association recommends women limit added sugars to
no more than 420 kilojoules (100 kilocalories), or 25 grams, and men limit added sugars to no more than
650 kJ (155 kcal), or about 38.75 grams, per day. Currently, Americans consume an average of 1,490 kJ
(355 kcal) from added sugars each day.

Nutrient losses
Processing foods often involves nutrient losses, which can make it harder to meet the body's needs if
these nutrients aren't added back through fortification or enrichment. For example, using high heat
during processing can cause vitamin C losses. Another example is refined grains, which have less fiber,
vitamins and minerals than whole grains. Eating refined grains, such as those found in many processed
foods, instead of whole grains may increase the risk for high cholesterol, diabetes and obesity, according
to a study published in "The American Journal of Clinical Nutrition" in December 2007.[citation needed]

Trans fats

Foods that have undergone processing, including some commercial baked goods, desserts, margarine,
frozen pizza, microwave popcorn and coffee creamers, sometimes contain trans fats. This is the most
unhealthy type of fat, and may increase risk for high cholesterol, heart disease and stroke. The 2010
Dietary Guidelines for Americans recommends keeping trans fat intake as low as possible.

Other potential disadvantages

Processed foods may actually take less energy to digest than whole foods, according to a study
published in "Food & Nutrition Research" in 2010, meaning more of their food energy content is
retained within the body. Processed foods also tend to be more allergenic than whole foods, according
to a June 2004 "Current Opinion in Allergy and Clinical Immunology" article. Although the preservatives
and other food additives used in many processed foods are generally recognized as safe, a few may
cause problems for some individuals, including sulfites, artificial sweeteners, artificial colors and flavors,
sodium nitrate, BHA and BHT, olestra, caffeine and monosodium glutamate — a flavor enhancer. [15]

Performance parameters for food processing

Factory automation - robotics palettizing bread

When designing processes for the food industry the following performance parameters may be taken
into account:

Hygiene, e.g. measured by number of micro-organisms per mL of finished product.

Energy efficiency measured e.g. by “ton of steam per ton of sugar produced”.

Minimization of waste, measured e.g. by “percentage of peeling loss during the peeling of potatoes”.

Labour used, measured e.g. by “number of working hours per ton of finished product”.

Minimization of cleaning stops measured e.g. by “number of hours between cleaning stops”.
Women working in a cannery

Industries

Food processing industries and practices include the following:

Cannery

Fish processing

Food packaging plant

Industrial rendering

Meat packing plant

Slaughterhouse

Sugar industry