Republic of the Philippines
Department of the Education PUBLIC TECHNICAL-VOCATIONAL HIGH SCHOOLS
Unit of Competency: Process Fish by Salting, Curing and Smoking Module No.: 1
Module Title: Processing Fish by Salting, Curing and Smoking
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MODULE 1 QUALIFICATION TITLE :
FOOD PROCESSING/FISH PROCESSING NC II
UNIT OF COMPETENCY:
PROCESS FISH BY SALTING, CURING AND SMOKING
MODULE TITLE
:
PROCESSING FISH BY SALTING, CURING AND SMOKING
NOMINAL DURATION
:
426 hrs
WHAT IS THIS MODULE ABOUT? This module deals with the skills, knowledge and attitudes required to process fish by salting, curing and smoking. It also involves preparing the needed equipment, tools and materials, preparing ingredients and materials, preparing salting and curing solutions, curing the fish, finishing the cured products and preparing production reports. WHAT WILL YOU LEARN? After completing this module, you should be able to: 1. 2. 3. 4. 5. 6.
prepare equipment, tools, materials and utensils; prepare raw materials; prepare salting and curing solutions and mixture; cure the fish; finish the cured fish; and prepare production report.
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LESSON 1. PREPARE EQUIPMENT, TOOLS AND UTENSILS WHAT IS THIS LESSON ABOUT? This lesson deals on how to prepare equipment, tools, materials and utensils needed in salting, curing and smoking. This includes lessons on checking, sanitizing and calibrating the tools used in acquiring the said competencies. WHAT WILL YOU LEARN? At the end of the lesson, you should be able to : 1. prepare equipment and tools for salting, curing and smoking fish and other fishery products in accordance with manufacturer‘s specification; 2. check, sanitize and calibrate equipment for fish processing methods in accordance with manufacturer‘s specifications; 3. make ready and sanitize kitchen utensils for fish curing methods in accordance with manufacturer‘s specifications; 4. prepare materials/supplies needed in fish curing in accordance with approved specifications by the Bureau of Fisheries and Aquatic Resources (BFAR); and 5. observe accuracy, cleanliness, sanitation and proper care of tools and equipment. WHAT DO YOU ALREADY KNOW? Let‘s find out how much you already know about preparing the equipment, tools and materials for salting, curing and smoking. Pre-Test A. Multiple Choice Directions: Read and analyze the questions below. Select the correct answer from the letter of your choice on your answer sheet. Do not write anything on the module. 1. Which of the following equipment is used to measure brine strength? a. Salinometer c. Thermometer b. Refractometer d. all of the above
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2. What is the purpose of sanitizing the tools/utensils before they are used? a. To kill bacteria b. To get rid of dirt c. To improve the quality of the product d. To avoid accident 3. Your teacher instructed you to prepare the measuring device you will use in measuring salt and water you will prepare into a brine solution, which of these measuring devices will you prepare? a. weighing scale b. measuring cup for liquid and solid ingredients c. table spoon d. Erlen Meyer flask 4. The following are the steps in preparing equipment ready for processing except ONE. a. checking b. sanitizing c. calibrating d. storing 5. Your teacher instructed you to make ready and sanitize kitchen utensils you will use in curing fish, which of the options below will serve as your guide or basis in doing the assigned task? a. manufacturer‘s specifications b. product requirements c. industry requirements d. approved specifications by BFAR B. Checklist Direction: Given below is a five item checklist. On your answer sheet, put a check (√) before item that you can do competently and an (X) for before item that you can‘t. Can you… __________ 1. __________ 2. __________ 3. __________ 4. __________ 5.
Assemble equipment & tools for salting & curing? Assemble equipment & tools for smoking fish? Calibrate a weighing scale? prepare a sanitizing solution for kitchen utensils? prepare materials needed in curing fish?
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LET US STUDY Let us define Calibrate - to indicate a scale on a measuring instrument. Fish curing - a method of preserving fish by salting, drying and smoking. Preservatives - substances added to food to inhibit spoilage organisms Raw materials - include fish and other ingredients like spices etc. Salting - the application of salt to the fish. Smoking - the application of smoke to the fish. Equipment, tools, materials and utensils are important aspects to consider in the processing of fish by salting, curing and smoking. Without them, difficulty in the preparation may arise. Hence, proper usage is necessary. Equipment and Tools for Salting, Curing and Smoking to Be Assembled According to Manufacturer’s Specifications For Salting and Curing Chiller/freezer/refrigerator freshness of fish.
-
Freezer
necessary
in
maintaining
the
Refrigerator
Gas range/oven- source of heat.
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Salinometer - an instrument used to measure brine strength.
-------------------------- the salinometer is inside the graduated cylinder
Weighing scales of varying capacities – devices used to measure the weight of fish/raw materials and ingredients needed in fish/food processing.
Beaker- a device used to measure liquid ingredients.
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Measuring cup - used to measure dry ingredients.
Measuring spoon - used to measure small amount of solid and liquid.
Cutting board - used to protect the table when slicing or cutting food.
Cutting implements/knives - used for cutting fish and other raw materials.
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Basin – use in the preparation of brine or curing mixture.
Kitchen scissor – used in trimming-off the fins of a fish.
Food tong - used to turn or lift food
For Smoking Fish salting/curing fish) 1. 2. 3. 4. 5. 6.
(Refer
to
the
Chiller/freezer/refrigerator Salinometer Cutting implements Measuring spoon and cups Beaker/graduated cylinder Smokehouse—an airtight introduced
function
container
as
described
where
smoke
in
is
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Cabinet type smokehouse
oil drum type
Smoking tray – where fish to be smoked is placed Soaking/container- used for the preparation of brine or where fish are soaked for a required time
Checking, Sanitizing and Calibrating of Tools for Fish Processing Methods Procedure in checking, sanitizing and calibrating of equipment and tools for fish processing methods are necessary in the preparation of tools needed in processing.
Checking salinometer
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Checking of Tools Have all the equipment checked for any defects. Discard those that are defective. Repair if necessary. Continuous maintenance on the use of equipment must be practiced and checked every after each use based on the maintenance schedule for every equipment. Sanitizing Sanitizing rids or reduces the number of microorganisms on the surface where food comes in contact with. It cannot be accomplished until the surface, where foods are processed, are cleaned.
Sanitizing tools/utensils
Preparing sanitizing solution
The Recommended Use Levels for Sanitizers to Consider when Sanitizing In preparing a sanitizing agent from 5.25% sodium hypochloride diluted with water, consider the following: Area to be sanitized with recommended chlorine concentration Hand dip (30 ppm) ( 350 ppm) Floor ( 350 ppm) Equipment (150 ppm) (200 ppm)
volume of desired solution 1 liter (1000ml) 1 gallon 5 gallons volume of sodium hypochloride
6.67 ml
water for food processing (75 ppm) for washing vegetables dressed chicken, etc.)
0.57 ml 25 ml 6.67 ml
216 ml 108 ml 125 ml 25 ml 125 ml
2.86 ml 3.81 ml
10.8 ml 14.4 ml
54 ml 72 ml
1.43 ml
5.40 ml
27 ml
Remarks Dilute the amount of sodium hypochloride required up to the
volume of desired Footbath solution as indicated in each corresponding column to obtain the needed concentrated on of chlorinated water
To sanitize the equipment, prepare a solution as prescribed on the recommended dosage. Wash the equipment with soap and water. Scrub or brush if necessary. Rinse with water then sanitize and allow draining or rinsing with 5ppm chlorinated water.
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Calibrating Equipment Calibrating equipment is necessary to test for the accuracy of certain device or to indicate the scale. An example of equipment to be calibrated is the weighing scale. To calibrate, have the reading of the weighing scale pointed or set at 0. Refer to Fig. 1 below.
Fig.1 Calibrating a Weighing Scale
To calibrate a salinometer, have the brine solution poured into the graduated cylinder, and dip the salinometer to get the reading (Fig. 2) Allow the instrument to float in the brine solution and get the reading. _____________________ salinometer
Figure 2. Calibrating a Salinometer
Kitchen Utensils For Fish Curing To Be Made Ready And Sanitized According To Manufacturer’s Specification 1. 2. 3. 4. 5.
Cutting implements like knives Cutting board Kitchen scissors Tongs Basin/bowl
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Fig. 3 Washing/Sanitizing kitchen utensils
Sanitizing Kitchen Utensils Flush all surfaces with water. Scrub or brush to remove loosely adhering dirt if necessary. Dissolve adequate amount of detergent in water with the scrubbing pad or brush, clean also surfaces of each utensils with detergent. Give particular attention to corners, flaps, edges and cracks where dirt is likely to accumulate. Rinse thoroughly with tap water. Sanitize by soaking processing implements in 150-200 ppm chlorinated water or (refer to recommended use\age for sanitizing solution. After 2 minutes, rinse with 5 ppm chlorinated water or tap water. Ingredients and Raw Materials to be Prepared for Fish Curing For salting 1. Fresh Fish
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For Smoking 1. Fresh Fish 2. Salt 3. Fuels for smoking- smoke producing materials preferably saw dust or wood shavings from hard wood or sugar cane bagasse. Avoid using soft wood because it contains high quality of soot. Procedure in Preparing Supplies and Materials for Salting, Curing and Smoking 1. Have all the supplies and materials ready. 2. check for the freshness of materials like fish 3. Prepare all the ingredients needed in salting, curing and smoking. LET US REMEMBER 1. All equipment, tools and materials needed in fish curing must be properly checked, prepared and sanitized. 2. Calibrate tools for accuracy of measurements or weights. 3. Sanitize the equipment/utensils to get rid of dirt that may contaminate food leading to food spoilage. 4. Always observe care, cleanliness and sanitary practices in using equipment and utensils in processing fish. 5. Observe accuracy in doing work and in using tools and equipment. HOW MUCH HAVE YOU LEARNED? Post Test A. Multiple Choice Directions: Read and understand the questions below. Select the correct answer by writing the letter of your choice on your answer sheet. 1. Which of the following equipment is used to measure brine strength? a. Salinometer c. Thermometer b. Refractometer d. all of the above 2. What is the purpose of sanitizing the tools and utensils before they are used? a. To kill bacteria b. To get rid of dirt c. To improve the quality of the product d. To avoid accident
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3. Your teacher instructed you to prepare the measuring device you will use in measuring salt and water you will prepare into a brine solution, which of these measuring devices will you prepare? a. weighing scale b. measuring cup for liquid and solid ingredients c. table spoon d. Erlen Meyer flask 4. The following are the steps in preparing equipment ready for processing except one. Which one is not? a. checking b. sanitizing c. calibrating d. storing 5. Your teacher instructed you to make ready and sanitize kitchen utensils you will use in curing fish, which of these will serve as your guide or basis in doing the assigned task? a. manufacturer‘s specifications b. product requirements c. industry requirements d. approved specifications by - (Bureau of Fisheries and Aquatic Resources) B. Checklist Directions: Given below is a five-item checklist. On your answer sheet, put a check (√) mark for each item that you can do competently and an (X) for each item that you cannot. Can you… __________ 1 __________ 2. __________ 3. __________ 4. __________ 5.
Assemble equipment and tools for salting and curing? Assemble equipment and tools for smoking fish? Calibrate a weighing scale? Prepare a sanitizing solution for kitchen utensils? Prepare materials needed in fish curing?
C. Observation and Oral Questioning 1. Correctly identify the tools and equipment needed in fish curing placed in each station. 2. Answer these questions: a. What are the uses of each tool and equipment you identified?
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LET US APPLY WHAT HAVE YOU LEARNED Demonstration Method 1. Prepare a sanitizing solution and apply the steps in sanitizing equipment and utensils. 2. Calibrate a weighing scale and a Salinometer. Be sure to do it correctly. Test for Valuing Explain why you must always observe accuracy and cleanliness in using different equipment, tools and utensils for salting and curing fish? RESOURCES The following resources are needed: 1. Equipment, Tools, Utensils and Materials a. b. c. d. e. f. g. h. i. j. k.
Smokehouse Polysealer Soaking vats Chiller/refrigerator/freezer Oven Bottles Salinometer Weighing scales of varying capacities and sensitivities Cutting implements like knives, slicers, peelers Measuring tools like measuring cups and spoons Fuel for smoking like wood, wood shavings, saw dust, halfdried leaves, coconut husks and shells, rice hulls, corn cobs
2. Learning guides a. b. c. d.
Module CD Rom Activity sheets Manual on Occupational Health and Safety Requirements in Preparing Supplies and Materials
1. Personal computer (PC) 2. LCD screen and projector
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REFERENCES Books Avery, Arthur. Fish Processing Handbook of the Philippines Bardey, Catherine, Secrets of the Spas, Blac Bauer, W.W.MD, Health for All, 1967 Calmorin, Laurentina P., Calmorin, Melchor A., Tinaypan, Alfredo S.. (1990). Introduction to Fishery Technology, Manila, Philippines. National Bookstore Inc. Calmorin, Laurentina P., Post Harvest Fisheries. Philippines: national Bookstore, Inc. 2000.
Manila,
Cortez, Lourdes A., Processing and Preservation of Freshwater Fish., Manila, Philippines ., National Bookstore Inc.,1990 Dagoon, Jesse D. Exploratory Fishery Arts. Manila, Philippines: Rex Bookstore, 1985. Espejo, Jasmin. Fish Processing Handbook of the Philippines Hermes-Espejo, Jasmin. Fish Processing Technology in the Tropics, Quezon City, Philippines, Tawid Publications, 1998. Hand- outs and Pamphlets on Fish Processing. Lagna, Rosalinda T. Food Preservation for Filipinos, 1977 Maharajh, Christina “20 Amazing Ways to Use Salt” Mendoza, Leonarda. Fishery Exploratory, 1987
Arts
for
Secondary
Schools
Photo Researchers, Inc./Dr. Jeremy Burgess/Science Source Microsoft ® Encarta ® 2006. © 1993-2005 Microsoft Corporation. Training Regulation for Food Processing NC II, TESDA, Metro Manila
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Food Safety and Sanitation, A paper presented at Foresight on Food Safety, International Food Safety Seminar at Seoul, Korea on April 24, 2006 Other Sources http://www.saltinstitute.org/ http://www.salttraders.com/StoreFront.bok http://www.slate.com/id/2117243 http://www.gourmetsleuth.com/saltguide.htm http://www.flickr.com http://www.initial-impressions.net http://www.msn.com
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LESSON 2. PREPARE INGREDIENTS AND RAW MATERIALS WHAT IS THIS LESSON ABOUT? This lesson deals on sorting and grading raw materials, cleaning and washing fish, eviscerating, descaling, deboning, filleting and weighing cleaned raw materials. WHAT WILL YOU LEARN? At the end of the lesson, you should be able to: 1. sort and grade raw materials in accordance with Bureau of Fisheries and Aquatic Resources (BFAR) specifications; 2. clean and wash fish in accordance with approved BFAR standard procedures; 3. eviscerate and wash fish in accordance with the product requirements; 4. descale and eviscerate fish and other marine products fully without damage to the meat; 5. debone fish in accordance with the product requirements without damage in the flesh; 6. fillet fish in accordance with product specifications; 7. weigh cleaned raw materials in accordance with BFAR approved specifications; and 8. observe accuracy in preparing raw materials in accordance with BFAR and product specifications. WHAT DO YOU ALREADY KNOW? Pre-Test A. Multiple Choice Directions: In your Test Booklet, write the letter that corresponds to your answer in the following items: 1. Fish has bulging eyes, red gills and a firm body. What can you say about the fish? a. The fish is fresh b. The fish is stale c. The fish is partially fresh d. The fish is undergoing rigor mortis
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2. The fishes you graded have slightly sunken eyes with grayish pupil; the flesh and backbone are slightly soft and with a slightly sour odor. To what grade will you assign them? a. Grade I c. Grade III b. Grade II d. Off-grade 3. Why must raw materials like fishes be eviscerated before salting, curing or smoking them? a. To remove the internal organs which contain spoilage organisms b. To improve the odor of the fish c. To thoroughly clean the fish d. To prevent spoilage of the fish 4. When descaling a fish like tilapia or bangus, why should you use a blunt knife? a. To prevent injuring the fish flesh b. To hasten the removal of scales c. To maintain firmness of the fish flesh d. To prevent damaging the scales 5. When washing fish with clean water, why must you soak it first in a 10% brine? a. To improve the appearance of the fish b. To hasten protein coagulation c. To leach-out the blood and improve texture of the fish flesh d. To improve the odor and taste of the fish 6. If you are assigned to debone a fish like bangus, which of the steps below will you do first? a. Remove the backbone b. Split fish along its dorsal side c. Make superficial cuts along the dorsal side of the fish d. Remove the rib bones 7. Your teacher instructed you to remove the Y-shaped spines embedded in the flesh of the fish, which of these will you do? a. Remove the spines near the caudal fin b. Remove the spines along the dorsal side c. Remove the spines along the lateral line d. Remove the rib bones 8. The product specifications require removing the meaty section of the fish from the backbone and ribs of the fish. Which of these will you do? a. Cut the fish into steaks b. Dress the fish c. Debone the fish d. Fillet the fish 18
9. If you are going to fillet a fish, which of these will you do first? a. Split fish along the dorsal side from the head to the tail b. Lay the fish on its side. Cut from just behind base of pectoral fin round the back of the head c. Cut fish across its body with a thickness of 1-2 cm. d. Eviscerate the fish 10. To have an accurate data on the weight of the fish, which of these will you do? a. Weigh the fish using standard weighing devices b. Weigh the fish using improvised weighing devices c. Weigh the fish before and after cleaning d. Estimate the weight of the fish then record B. Test for Valuing Explain why there is a need to observe accuracy in preparing raw materials in accordance with BFAR and product specifications. LET US STUDY Let us define Scales - the protective covering on the body of a fish attached to the skin Operculum - a plate-like shape that covers the gills Belly walls - the underside skin of the fish body Flabby - the texture of fish flesh when it lacks stiffness or vitality Caudal peduncle - part of the fish connecting the body and the caudal fin Guts - the viscera or internal organs of a fish Fillets - the meaty section of a fish removed from the backbone and ribs Mosquito forcep - a nickel plated or stainless steel tool, measuring 5-6‖ long with pointed ends for penetration in fish muscles Superficial cut - a shallow cut on the surface of the fish flesh Backbone - the biggest bone of the fish which is situated in the middlemost portion. Fresh fish - a newly caught fish from unpolluted waters exhibiting normal quality requirements and which has not undergone processing. Organdeptic characteristics –the characteristics of a fish evaluated using the sense of sight, smell, touch such as appearance, color and texture. Raw materials refer to fresh fishes newly caught, chilled or frozen that are not yet subjected to the treatment with preservatives like salt, vinegar and smoke. They are used during salting, curing and smoking. Prior to processing of fish, the raw materials must be efficiently prepared to achieve top quality processed products, maximum yield and highest possible profits. 19
The method of fish preparation depends on the size of the raw materials, market demands and product specifications. Very small species of fish like anchovies and wily slipmouth are simply washed. Medium-sized fishes like roundscad and common slipmouth are gutted to lessen bacterial load. Some are splitted to hasten drying process. Big sized fishes are splitted, skinned, filleted, etc. Bony and spiny fishes like milk fish (bangus) are deboned while scaly fishes are descaled. However, before all these are done, raw materials are first sorted and graded. Sorting Raw materials are classified/grouped according to: a. Quality – fresh, stale or spoiled, damaged b. Species – example : tuna, mackerel, milkfish c. Sizes – small, medium and big with sizes ranging from 6 cm. - 54 cm. Characteristics of a Fresh and Spoiled Fish Fresh Fish
Spoiled Fish
Odor
fresh fishy odor
stale sour or putrid
Eyes
bright and bulging, dull, wrinkled and pupil is velvet black, sunken pupil is dull cornea is transparent black cornea is opaque
Gills
bright red, covered with dull brown or gray with slime odor under gill cloudy slime, odor cover is fresh under gill cover is sour and offensive
Body color
bright
Flesh
firm stiff body, finger soft and flabby, finger impressions do not impressions remain remain
Belly walls
intact
often ruptured, viscera protruding
Muscle tissue
white
pinkish especially around the backbone
Vent
pink, not protruding
brown, protruding
faded
Sorting fish according to their quality is done with the organoleptic evaluatin of their condition based on the characteristics of a fresh and a stale fish.
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Below are the descriptions of the specific characteristics of a fresh fish: 1. A fish with clear bright eyes have eyes with a convex shiny black pupil and translucent cornea. 2. A fish with bright colored gills have gills which are shiny red or pink, not dull brown or gray. 3. The odor of a fresh fish is similar to that of a newly gathered seaweeds. 4. A fresh fish has a firm flesh characterized by a stiff body and texture elastic to slight pressure. 5. A fresh fish with intact belly walls have no protruding viscera and the walls are not soft or ruptured but firm and springy. 6. The fish with a bright body color has a glossy appearance, with body color typical of the species. 7. The slime present in a fresh fish must be clear, colorless and transparent in normal quantities at the gills and body. A stale fish has the following specific characteristics: 1. Discoloration which is a discernible abnormal color changes in some parts characterized by varying degrees of spoilage. 2. Damage is a defect in the fish which materially detracts from the appearance or edible or shipping quality of the fish. It includes loose scales, bruises and abrasions due to mishandling affecting more than 5% of the body of the fish, cuts and punctures made by tools used in catching or transporting fish that expose the flesh with a length of one-tenth of the length of the fish or excessively deep. 3. The stale fish is considered to have loose scales when the scales have been removed from the skin over more than 5% of the surface area of the fish or when scales are easily rubbed off because of bacterial decomposition. 4. The eyes are considered slightly sunken if the eyes are not bulging, or are slightly depressed. 5. The milky slime in stale fish appears cloudy white and is slightly transparent. 6. Slightly discolored gills have abnormal color change from bright red or pink to dull gray or brown. 7. A fish with a slightly soft flesh has a texture which is not elastic and leaves a dent or mark to slight pressure.
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Another aspect involved in grading fish is to sort them according to their species as shown below: Classification of Fish According to Species a. Roundscad or galunggong
b. Mackerels such as hasa-hasa and alumahan
short-bodied mackerel- Hasa-has Kastrelliger brachyosomus (Blecker) Average length 20 centimeters.
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c. Sardines and herrings such as tamban and tunsoy
d. Slipmouth such as sapsap and dalupani
Sapsap
Dalupami
e. Long-tailed Nemipterids or bisugo
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f. Anchovies such as dilis and tuakang
Fishes are also classified according to their weight as shown below: Classification of Fish According to Weight Fish
Small
Medium
Large
Milkfish
less than 250 gr
250-500 gr.
more than 500 gr.
Mackerels
less than 4.5 gr.
4.5-6 gr.
more than 6 gr.
Nemipterids
less than 4.5 gr.
4.5-6 gr.
more than 6 gr.
Roundscad
less than 4.5 gr.
4.5-6 gr.
more than 6 gr.
Sardines/herrings less than 4.5 gr.
4.5-6 gr.
more than 6 gr.
Slipmouths
less than 1.5 gr.
1.5-2.5 gr.
more than 2.5 gr.
Anchovies
less than 1.5 gr.
1.5-2.5 gr.
More than 2.5 gr.
How to Get the Estimated Size of a Fish Measurement which is done by ocular estimation is calculated from the tip of the snout to the tip of the caudal fin. It can be measured using a measuring device like a foot ruler. The size of a fish is also obtained by getting its total length. Total length refers to the length from the tip of the snout to the tip of the tail of a fish.
Snout
Caudal Fin
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Guide for Determining the Size of a Fish (Based on Total Length in Centimeters) Source: Philippine Fish Classification (Food Terminal Inc.) Extra Large 1. Alumahan 2. Apahap 50 or more 3. Asohos 4. Ayungin 5. Bagaong 6. Bangos 50 or more 7. Baracuda 8. Biya 50 or more 9. Bisugo 10. Dalag 50 or more 11. Dalagang Bukid 12. Dilis 13. Galong- gong 14. Hasa-hasa 15. Hito 45 or more 16. Kabasi 17. Kanduli 50 or more 18. Kalaso 19. Kitang 20. Labahita 21. Lapad 22. Lapu-lapu 50 or more 23. Martiniko 24. Matang Baka 25. Maya- maya 26. Mayang 27. Salay- salay 28. Samaral 29. Sapsap 30. Talakitok 50 or more 31. Talilong 32. Talimosak 33. Tamban 34. Tanigi 75 or more 35. Tuna 75 or more 36. Tunsoy Species
Large
Medium
Small
40 40 30 40 -
25 30 20 10 20 30 25 25 20 30 30
- 29 – 39 or more or more or more – 39 or more – 29 or more – 39 or more
20 - 24 20 – 24 20 – 29 15 – 19 6–9 15 – 19 20 – 29 20 – 24 20 – 24 15 – 19 25 – 29
Average Length 25 – 35 20 – 50 20 10 20 30 – 100 25 30 – 40 20 30 – 40 30
15 or more
6 – 10 10 – 14
8 20
20 24 20 30 20 20 30 20 30 20 25
15 20 15 20 15 15
– – – – – –
19 24 19 29 19 19
15 25 10 18
– – – –
19 29 19 24
20 20 15 50 20 20 30 15 40 10 20
– 49
– 49 – 39 – 49
35 40 35 40 35
– 44 – 49 or more – 49 or more
or more – 34 or more – 39 or more or more – 34 or more – 39 or more – 34
– 45 – 20 – 75
– 18 – 20 – 30
-
25 or more
15 – 24
20
35 or more
30 or more 25 – 34
20 – 29 20 – 24
20 – 30 25 – 35
40 – 49 65 – 74 65 – 74 -
30 or more 25 or more 30 – 39 20 or more 10 or more 20 or more 55 – 64 5 – 64 20 or more
25 – 29 15 – 24 25 – 29 15 – 19 6–9 15 – 19 45 – 54 45 – 54 13 – 19
30 30 40 – 60 20 10 20 50 – 100 100 15 – 18
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Grading Evaluating the raw materials based on their organoleptic characteristics such as appearance, color, odor and texture.
Grading of Fishery Products The grading of fishery products is based on the organoleptic characteristics as shown in the grading of tuna. Organoleptic characteristics refer to the characteristics of a fish obtained through the use of the sense organs like the color, odor, texture, etc. Grading of Tuna The prescribed standards for tuna: Grade I. This consists of strictly fresh fish possessing the following characteristics: a. b. c. d. e. f.
Eyes, clear, and bright Gills, bright red-colored Fresh odor Firm flesh and intact belly walls Color of the body must be bright Absence of discoloration, loose scales, bruises, abrasions, cuts, punctures or other injuries
Grade II. This consists of chilled or frozen (quick or sharp) fish which failed to meet the requirements for Grade I. a. b. c. d. e. f.
Eyes, clear, and bright Gills, bright red-colored Fresh odor Firm flesh and intact belly walls Normal body color characteristics of the species Absence of discoloration, loose scales, bruises, abrasions, cuts, punctures or other injuries
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Grade III. This consists of fish which failed to meet the requirements of Grades I and II, but which has the following characteristics: a. b. c. d. e. f.
Eyes, slightly sunken; pupil, grayish Gills, slightly discolored and shiny Body, covered with somewhat milky slime Abdomen and belly walls, slightly soft Flesh and backbone, slightly soft Odor, slightly sour and somewhat like bread or weak acetic acid.
Off – Grade. This consists of fish which failed to meet the requirements of Grade III and therefore must be rejected. Scaling Removal of the scales from a fish using a blunt knife. knife is not used because it might injure the fish. The scales 1. 2. 3.
A sharp
of a fish can be removed using the following: Knife Metal Scaler Electric Scaler
Prepare the fish for scaling in the following way: a. Hold the fish firmly with one hand in the caudal peduncle. Hold the knife almost vertical to the fish. b. Remove the scales by scraping motion.
NOTE: Use blunt knife in scaling the fish. Sharp knife might injure fish skin.
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c. Wash off the scales with clean water.
Eviscerating/Gutting Removal of the internal organs, viscera or guts through the operculum Gut scaled or unscaled fish:
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Washing Cleaning the scaled and eviscerated fish is done by: a. Soaking or tank washing Wash fish by soaking them in a basin or cemented tank with a 10% brine solution to leach out blood before finally washing them in clean tap water.
b. Washing by agitation Fish are washed with a 10% brine in a tank with agitator before finally washed with fresh clean water. c. Spray washing Fish are washed using running water from a faucet or with strong jets of water from a water sprayer.
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Deboning Some fishes like bangus and gizzard shad are turned down by some consumers even if they have a nice flavor due to their numerous numbers of spines. Their inter-muscular spines are annoying and cause difficulty when lodged in the throat while eating. A process, called deboning, has been devised to avoid such annoyance and danger of eating spiny fishes. The spines from the different portions of a fish like bangus can be removed with the use of a mosquito forcep. Deboning improves the acceptability of the product. The bangus is deboned using the following procedure: 1. WASHING – wash fish upon arrival from the market. Scales may or may not be removed. 2. SPLITTING – split fish on the dorsal side starting from the tail to the head by running the edge of the knife along the backbone.
3. REMOVAL OF INTERNAL ORGANS – lay fish open like butterfly fillet. Remove gills and internal organs. Wash fish to remove blood and dirt. The black membrane covering the belly cavity may or may not be removed depending upon the consumers choice. Wash fish in running water. 4. REMOVAL OF BACKBONE and DORSAL FIN – remove backbone by laying fish flat on the cutting board with the skin down. Hold the knife in a horizontal/slanting position and cut in with the tip of the blade along the backbone from head to tail. Trim off the dorsal fin.
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5. DEBONING It is important to know the exact location of the spines most especially the intermuscular spines.
The Spine Location in a Milkfish Place fish in a shallow tray. removing the spines.
With the aid of mosquito forceps, start
A. RIB BONES – the rib bones are located in the belly cavity. They are visible and are superficially embedded thus easy to pull out.
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B. DORSAL INTERMUSCULAR SPINES – make a superficial slit from head to tail along the dent of dorsal muscle. Pull out the embedded intermuscular spines one at a time.
The spines on the head portion are branched spines while the rest are unbranched. The spines on the tail portion are very much attached to the muscle tendon, making it difficult to remove. It is necessary to make a horizontal slit on this portion for easier removal of these spines. C. LATERAL INTERMUSCULAR SPINES – are located in-between the dorsal and ventral muscles. Pull out first the large arch-shaped spines at the base of the opeculum. Proceed pulling out the Y-shaped spines up to the mid-portion of the body ending with 3 single delicate spines.
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D. VENTRAL INTERMUSCULAR SPINES – make a shallow slit along the dent between the muscle segments of the ventral side from the midportion of the body to the tip of the muscle in the tail. Pull out the first 2 very fine and delicate spines found in the mid-body which is the start of the spines located in this portion. Proceed to the tail region.
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Filleting A process of preparing fish into fillets with the use of a sharp thin knife. The kinds of fillets are: a. Block fillets (butterfly fillet, cutlet, double fillet). These are the flesh from both sides of a single fish, usually joined along the back. b. Cross-cut fillets. These are fillets from flat fish, i.e. sole fish, the flesh from each side is removed as a single piece. c. Quarter-cut fillets. These are fillets from flat fish, the flesh from each side is taken off in two pieces. d. Single fillet. This is the flesh from one side of the fish. The Kinds of Fillets
Butterfly fillet
Single fillet Block fillets
Procedure in Filleting Fish 1. Lay fish on side. Cut from just behind base of pectoral fin round the back of the head.
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2. Cut towards tail along the line of the dorsal fin. The cut should only penetrate as far as the backbone.
3. Cut forward to clear fillet from the ribs. The knife should be held parallel to the rib bones, cut through the ―pin‖ (small rib) bones.
4. Cut over the edge of the ribs towards the tail, flatten knife on to the backbone after finishing cutting over the ribs and remove fillet. The fillet should be trimmed to remove any belly flap or fin. 5. Turn fish over. Cut just behind base of pectoral fin and round the back of the head.
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6. Cut from tail as close to backbone as possible into the corner at the back of the neck. Note the angle at which the head is held. This keeps the backbone flat on the board. 7. Cut forward parallel to angle of the rib bones cutting through the ―pin‖ bones and open cut fillets. 8. Cut from behind head over the ends of ribs towards tail, knife should be held at an angle to remove flesh from the center of fish without cutting off fins. On large fish, two cuts may be required if a shortbladed knife is used. Trim fillet to remove any belly flap or fin. Below are trimmed single fillets:
Weighing To get the exact mass of the prepared raw materials for future references especially in the preparation of the production report, the weight must be taken with the use of standard weighing devices like the beam balance or any other weighing device. The weights are properly recorded. Procedure in weighing 1. Place the material to be weighed on the weighing scale. 2. Weigh the material accurately. 3. Record the obtained weight.
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LET US REMEMBER Raw materials refer to fresh fishes newly caught or frozen that are not yet subjected to the treatment with preservatives like salt, vinegar and smoke. They are used during salting, curing and smoking. Raw materials must be prepared in accordance with product specifications and approved BFAR specifications. In preparing raw materials for salting, curing and smoking accuracy and correct performance of given procedures must be strictly followed in order to produced cured products with excellent quality. HOW MUCH HAVE YOU LEARNED? Post Test Oral interview 1. If you are assigned to grade the raw materials, how will you sort or classify them? Explain. 2. Given the following situation, describe how to grade fish from the highest to the lowest grade. 5 kilograms of bangus for deboning with varying sizes and degree of freshness were given to you to grade. Computer/Paper-based Written Test Directions: In your Test Booklet, write the letter that corresponds to your answer in the following items: 1. What refers to a fish with bulging eyes, red gills and a firm body is ____________. a. fresh b. stale c. partially fresh d. undergoing rigor mortis 2. The fishes you graded have slightly sunken eyes with grayish pupil; the flesh and backbone are slightly soft and with a slightly sour odor. To what grade will you assign them? a. Grade I b. Grade II c. Grade III d. Off-grade
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3. Why must raw materials like fishes be eviscerated before salting, curing or smoking them? a. To remove the internal organs which contain spoilage organisms b. To improve the odor of the fish c. To thoroughly clean the fish d. To prevent spoilage of the fish 4. When descaling a fish like tilapia or bangus, why should you use a blunt knife? a. To prevent injuring the fish flesh b. To hasten the removal of scales c. To maintain firmness of the fish flesh d. To prevent damaging the scales 5. When washing fish with clean water, why must you soak it first in a 10% brine? a. To improve the appearance of the fish b. To hasten protein coagulation c. To leach-out the blood and improve texture of the fish flesh d. To improve the odor and taste of the fish 6. If you are assigned to debone a fish like bangus, which of the steps below will you do first? a. Remove the backbone b. Split fish along its dorsal side c. Make superficial cuts along the dorsal side of the fish d. Remove the rib bones 7. Your teacher instructed you to remove the Y-shaped spines embedded in the flesh of the fish, which of these will you do? a. Remove the spines near the caudal fin b. Remove the spines along the dorsal side c. Remove the spines along the lateral line d. Remove the rib bones 8. The product specifications require removing the meaty section of the fish from the backbone and ribs of the fish. Which of these will you do? a. Cut the fish into steaks b. Dress the fish c. Debone the fish d. Fillet the fish 9. If you are going to fillet a fish, which of these will you do first? a. Split fish along the dorsal side from the head to the tail b. Lay the fish on its side. Cut from just behind base of pectoral fin round the back of the head c. Cut fish across its body with a thickness of 1-2 cm. d. Eviscerate the fish
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10. To have an accurate data on the weight of the fish, which of these will you do? a. Weigh the fish using standard weighing devices b. Weigh the fish using improvised weighing devices c. Weigh the fish before and after cleaning d. Estimate the weight of the fish then record Practical Demonstration Directions: Perform the task of deboning bangus. Sub-tasks
Completed YES NO
Removed the indicated number of spines (95%) from the different portions of the bangus with the use of a mosquito forcep a. rib bones (all) b. epaxial/intermuscular spines (at least 77) c. hypaxial intermuscular spines (at least 40) d. Y-shaped spines (at least 36) Rating
Pass Failed
Note: You must be able to perform all the tasks to pass. If not, you have to repeat the lesson.
LET US APPLY WHAT YOU HAVE LEARNED Prepare the different kinds of fillets using the correct procedure. Be sure to properly wash, scale and weigh the prepared fillets. Test for Valuing: How can you show that you value accuracy in doing your assigned tasks? Why is accuracy in doing your work important? Explain. RESOURCES The following resources are needed: 1. Tools and equipment a. b. c. d. e. f. g.
Descaling knife Cutting board Filleting knife Mosquito forceps Kitchen knife Weighing scale Aluminum trays and basins
2. Materials 39
a. Potable water b. Fresh fish with scales like tilapia and bangus c. Fresh fish for deboning like bangus 3. Personal protective equipment a. Rubberized hand gloves b. Apron c. Headband 4. Learning guides a. Module b. CD - Rom c. Manual for grading, scaling, deboning and filleting fish 5. PC with LCD projector and screen REFERENCES 1. Philippine Handbook on Fish Processing Technology by Jasmin M. Espejo 2. Fish Processing Handbook for the Philippines 3. Fish Cookery by Jasmin Espejo and Alberta Tumonde 4. Learning Element for Preparing Raw Materials by CDC, BTVE 5. Learning Element for Grading and Classifying of Fish by CDC, BTVE 6. Learning Element for Bangus Deboning by CDC, BTVE 7. Hand-outs on Deboning Fish produced by BFAR Region I Other Sources: http://www.saltinstitute.org/ http://www.salttraders.com/StoreFront.bok http://www.slate.com/id/2117243
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LESSON 3. PREPARE SALTING AND CURING SOLUTIONS AND MIXTURING WHAT IS THIS LESSON ABOUT? This lesson deals on preparing salting and curing solutions and mixtures. It includes a study of the kinds of salt, properties and composition of salt and the ingredients in curing fish. It also covers the procedure in preparing brine and curing solutions and Occupational Health and Safety (OHS) specifications for salt and curing ingredients. WHAT WILL YOU LEARN? At the end of the lesson you should be able to: 1. measure and weigh required salt and other ingredients for salting and curing in line with approved specifications and Occupational Health and Safety (OHS) requirements; 2. measure and weigh required ingredients for salting and curing in line with approved Bureau of Fisheries and Aquatic Resources (BFAR) and Bureau of Food and Drugs Administration (BFAD) specifications; and 3. practice accuracy in measuring and weighing ingredients of salting and curing solutions and mixtures. WHAT DO YOU ALREADY KNOW? Pre-Test A. Multiple Choice Directions: Read and analyze the questions below. Select the correct answer from the options given. Write the letter of your choice on your answer sheet. 1. Which of the following mixtures would you use if you are instructed to prepare 10% brine solution. How will you measure it? a. 1 part salt, 8 parts water b. 1 part salt, 7 parts water
c. 1 part salt, 9 parts water d. 1 part salt, 5 parts water
2. How many grams of salt is applied to 700 grams of fish in Kench salting using the ratio 1:7 by weight? a. 100 grams of salt c. 200 grams of salt b. 150 grams of salt d. 250 grams of salt 3. In preparing curing solution, the following are measured EXCEPT ONE a. vinegar c. sugar b. salt d. oil
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4. How many cups of salt is added to 27 cups of fish for curing using 1:3 ratio? a. 10 cups c. 8 cups b. 9 cups d. 7 cups 5. If you are asked to prepare a brine with a concentration of 20%, what is its equivalent in terms of ratio? a. 1:4 c. 1:5 b. 1:7 d. 1:9 6. Which of the following consist the preparation of a 25% brine solution, with a 1:5 ratio meaning it consists of: a. 1 part salt, 5parts water c. 1 part water, 5 parts fish b. 1 part salt, 5 parts fish d. 1 part fish, 5 parts salt 7. How many volumes of water is added to salt to make a solution of 1:4 if the salt weighs 250 grams/cup? a. 1,000 ml of water c. 500 ml of water b. 800 ml of water d. 900 ml of water 8. Which among the concentration of salt given below is required to kill most species of unwanted bacteria? a. 10% c. 20% b. 25% d. !5% 9. If the ratio of preparing brine is 1:9, what is the volume of water to dissolve 250 grams of salt? a. 2250 ml of water c. 1500 ml of water b. 2500 ml of water d. 2000 ml of water 10. In using a salinometer to test for brine strength, at what concentration is 20º S brine? a. 250 grams of salt, 800 ml of water b. 200 grams of salt, 800 ml of water c. 250 grams of salt, 750 ml of water d. 200 grams of salt, 750 ml of water Test for Valuing Explain briefly the importance of accurate weights and measurement of ingredients for salting and curing solutions and mixtures.
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LET US STUDY Let us define Agitation - refers to constant stirring of the brine. Brine solution - the mixture of salt and water. Curing - refers to the method of preservation and flavoring processes in meat and fish by the combination of salt, sugar and nitrate or nitrite. Iodized salt - a kind of table salt that contains small amount of potassium iodide and dextrose as a dietary supplement to prevent thyroid disease. Osmosis - the flow of a substance from a region of lesser to a greater concentration through a semi-permeable membrane. Preservatives - substances added to food to prevent or inhibit the growth of spoilage organisms. Salinity - refers to the degree of saltiness Salinometer - an instrument used in measuring salinity Salt - a white crystalline combination of acid and base Saturated solution - a solution where there is an equal amount of salt dissolved in small amount of water Sea salt - made from ocean or sea water that contains trace minerals not found in the mined salt. Solute - a substance dissolved in another substance. Table salt - a mined salt usually dissolved in water to create brine. Unrefined salt are commonly used as ingredients in bathing additives Salt and Other Ingredients for Salting and Curing to be Measured and Weighed in Line with Approved Specifications and Occupational Health and Safety (OHS) Requirements Curing fish includes the application of dry salt, brine or pickle or smoke, which in a wider sense, applies to any saline or acid preservative solution with some modifications.
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Salting involves the application of salt to the fish whereby the moisture content in the fish is lowered to the point where bacterial and enzymatic activities are retarded. Functions of Salting and Curing Ingredients 1. Salt. The essential ingredient in salting is salt. It draws moisture from the muscle cells and at the same time enters the cells by osmosis. Salt-Too high salt content reduces protein solubility and results to a firm product, while too low concentration yields otherwise. (Loterte,1978) Curing salt- consists of 94% refined salt and 6% nitrite 2. This is needed in the preparation of a brine solution. The water must be potable, clean and fresh.
3. Vinegar gives flavor, makes the product firm and also acts as a preservative.
4. Sugar acts as a preservative mainly by increasing the thickness of the cured pickling solution which lowers the water activity. It also adds sweetness to the product. (Lagua et al,1977
5. Spices The most common spices are black pepper onions, garlic etc. The spices used may also have some preservative action but it is more probable that they mask the color and odor rather than inhibit spoilage.
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Preservatives like nitrate or nitrite will not only help kill bacteria, but also produce a characteristic flavor and give meat a pink or red color. Nitrite in the form of either sodium nitrate or potassium nitrate is used as a source for nitrite. The nitrite further breaks down the meat into nitric oxide which then binds o the iron atom in the center of myoglobin‘s heme group, preventing oxidation.
Measuring and Weighing Required Salt for Salting and Curing Approved by the Bureau of Foods and Drugs (BFAD) A. For Salting Measuring and weighing the required salt for salting varies on the methods of salting to be applied to the fish namely: 1. Kench Salting or Dry Salting produces a product locally called Binuro. Fish are heavily salted in a ratio 1:7 ( one part fish to seven parts water). The weight of salt depends on the volume or weight of fish to be salted. Example: If the volume of fish to be salted is 700 grams, applying the Ratio 1:7, the amount of salt to be used is 100 grams. 2. Dry Salting to Make Brine produces a product locally known as Tinabal to the Cebuanos. Fish are salted and the liquid is allowed to cover the fish. The ratio of salt to fish is 1: 4 ( 1 part salt to 4 parts fish or 20% by weight. 3. Brine Salting involves the immersion of fish in brine. The amount of salt depends on the volume of water. Mix salt with the fish in a proportion of 20% to 25% by weight. To prepare a brine of certain concentration, a known weight of salt is dissolved in a known volume of water.
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Brine Preparation To prepare brine or salt solution, consider using the different concentrations: a. 10% b. 20% c. 25 %
(1:9 ratio) (1:4 ratio) (1:3 ratio)
Fig. Measuring the amount of salt needed in preparing brine solution
Examples: 1. 10% brine consists of 1 part salt and 9 parts water. If 1 cup of salt is 250 grams, then for 9 cups of water is 2,250 grams or millimeters of water. To weigh the solution dissolve 250 grams of salt in 2250 g/ml of water, therefore the weight of solution is 2,500 ml. 2. To measure 20% (1:4 ratio) 1 part salt to 4 parts water. If 1 cup of salt is 250 grams, then 4 cups of water is 1000 ml 3. To measure 25% ( 1 part salt to 3 parts water) 1 cup of salt=250 grams added to 750 ml of water would give 1000 ml solution. 4. To weigh the solution, dissolve 250 grams salt to 1000 ml of water, therefore the weight of the solution is 1,250 ml.
Fig. Weighing the solution using A weighing scale or simply a Beaker
Note* A concentration of salt up to 20% unwanted bacteria.
is required to kill most of
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Salt concentration is measured with a salinometer and expressed in terms of degree salinity. This instrument is allowed to float in a brine solution with a temperature ranging from 0º to 35º. The highest ream is at the weighted end of the salinometer spindle. Maximum degree salinometer is based on the saturation of water with 25% sodium chloride at room temperature. This point is referred to as 10º salinity. Plain water will read 0º salinity. (Refer to Fig. Lesson 1 in calibrating a salinometer) Preparation (measuring and weighing) of salt depends on composition, characteristics, impurities and kind of salt. The purer the salt, the faster the salt penetration; the more impurities, the slower the salt penetration The Properties and Characteristics of Salt 1. It is a colorless or white crystalline compound known chemically as Sodium chloride (NaCl). 2. Sources: sea water, salt wells, salt spring, lakes and underground deposits. 3. Composition: it is composed of 39.39% sodium chloride, constitutes about 2.6% water. 4. It has antiseptic properties. 5. It melts at 14.21 º F or 77.2 º C and vaporizes rapidly in heat. 6. Pure sodium chloride is slightly hydroscopic/hygroscopic. 7. Pure salt is a white, lustrous solid material which generally crystallizes into cubes. 8. It has a bitter brackish taste. Impurities in Salt The quality of finished salted or cured products depends on the application of salt and its action. Salt penetration into the fish is faster when relatively pure sodium chloride is used than when impurities are present. A pure salt contains 100 % Sodium Chloride (NaCl). An impure salt contains impurities like: 1. Physical –insoluble materials that go with the solar salt such as sand, silt, bits of shells or tiny pieces of woods. 2. Microbial - like the halophilic bacteria which thrives very well in salt concentration. 3. Chemical- the main chemical impurities are calcium and magnesium chloride.
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Factors Affecting Salt Penetration 1. Types/kinds of salt
Table salt
refined salt
Sea salt
unrefined salt
pepper corn
sea salt
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2. Brine temperature The rate of salt penetration is affected by temperature. At 0 º C, salt penetration is slower, but is faster at 15 º C and fastest at 30 º C at identical periods of observation. 3. Salt concentration A difference in salt concentration between the fish and the brine results in gradual diffusion of salt into the fish. The higher the salt concentration, the rapid the salt penetration. Salt concentration may be: a. Saturated solution – there is an equal amount of salt dissolved in small amount of water b. Super saturated- great amount of salt dissolved in small amount of water c. Unsaturated- - less amount of salt dissolved in more amount of water 4. Brine volume A small volume of brine in proportion to the fish affects results in a small concentration of salt. 5. Agitation of the brine If the brine is occasionally stirred while it surrounds the fish, salt diffusion into the fish is hastened. For Curing Fish may either be dry-cured or pickle cured. The amount of salt in both methods is generally the same; ¼ of the total weight or 1/3 of the total volume of the fish. Dry salt curing is a process where each fish is rubbed thoroughly with salt and then stacked in rows in appropriate containers, scattering a little salt between the layer and around the pieces. Pickle cure method is a process where fish is packed in vats and barrels and other appropriate containers. In dry salt curing the average amount of salt is 1 to 4 parts by weight of the fish. In pickle cure method, a concentrated solution is poured ( 1 part to 3 parts water and the fish is completely immersed in brine.
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Measuring/Weighing the Ingredients of the Curing Solution To prepare a curing solution, the quantity depends on the type of cure, individual preferences and processing requirements stated in the procedure. Measure the amount of ingredient using the required measuring tools.
Measuring curing ingredient
Preparing curing mixture
Occupational Health and Safety Requirements on the Use of Salt and Other Curing Ingredients 1. Some advocate that sea salt or manufactured salt is healthier than refined salt. Sea salt is better due to its magnesium and calcium compounds. However, it doesn‘t contain iodine to prevent iodine deficiency. 2. Salt when combined with other ingredients are used for healing and therapeutic effects. 3. Iodized salt contains a minute amount of potassium iodide and sodium iodide to help reduce the chance of iodine deficiency in humans like thyroid gland problems or goiter. 4. Unrefined salt contains 4 electrolytes (sodium, potassium, magnesium and calcium). 5. Too much or too little salt in the diet can lead to muscle cramps, dizziness or even electrolytes disturbance which can cause severe, even fatal, neurological problems. 6. Drinking too much water with insufficient salt intake, puts a person at risk of water intoxication (hyponatremia). 7. Salt is even used sometimes as a health aid, such as in treatment of dysautonomia.
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8. Too much preservatives like sodium nitrate or nitrite is harmful to one‘s health because they are carcinogenic. The information cited above will guide a food processor in selecting the best kind of salt appropriate in curing the food like fish or meat which is not hazardous to ones‘ health. Bureau of Foods and Drugs (BFAD) Specification on the Use of Curing Ingredients 1. The Food Standard Agency (counterpart of BFAD) defines the level usage of salt in foods as follows: a. High is more than 1.5 g salt pe 100 g. ( or 0.6 g sodium) b. Low is 0.3 g salt or less per 100 g. ( 0.1 g sodium) If the amount of salt per 100 g is in between these figures, then that is the medium level of salt. 2. The Food and Drug Administration (FDA) Food Labeling Guide stipulates whether a food be labeled as ―free‖, ―low‖ or ―reduced/less‖ in respect of sodium. 3. Other health claims are made about a food (e.g low in fat, calories etc), a disclosure statement is required if the food exceeds 480 mg of sodium per serving. 4. Recommended usage to some is 6 g. of salt per day 5. Recommended level for iodized salt usage is 150 micrograms of iodine per day for both man and woman. 6. Recommended use level for curing salt—1/2 tsp/kg of meat, 0.2 % of weight of fish or 2 grams per kg of finished product, 125 ppm sodium nitrite. LET US REMEMBER 1. All ingredients in salting and curing must be properly measured and weighed in accordance with OHS and BFAD requirements 2. The quality of salted/cured products depends on the proper measurements/weights of salt and curing ingredients. Inaccurate measurements of ingredients will result to defective products. 3. Curing mixtures especially preservatives must be used in tolerable amounts. Using more than what is allowed is damaging to the health. 4. Amount of salt needed for fish depends on the type of cure or method of salting you are going to apply to the fish. 5. Observe accuracy on the measurement of ingredients in salting and curing. 6. Be cautious/careful in measuring ingredients for salting and curing, solutions and mixtures.
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HOW MUCH HAVE YOU LEARNED? Post Test A. Written Test Multiple Choice Directions: Read and analyze the questions below. Select the correct answer from the options given. Write the letter of your choice on your answer sheet. 1. Which of the following mixture would you use if you are instructed to prepare 10% brine solution. How will you measure it? a. 1 part salt, 8 parts water c. 1 part salt, 9 parts water b. 1 part salt, 7 parts water d. 1 part salt, 5 parts water 2. How many grams of salt is applied to 700 grams of fish in Kench salting using the the ratio 1:7 by weight? a. 100 grams of salt c. 200 grams of salt b. 150 grams of salt d. 250 grams of salt 3. In preparing curing solution, the following are measured EXCEPT ONE a. vinegar c. sugar b. salt d. oil 4. How many cups of salt is added to 27 cups of fish for curing using 1:3 ratio? a. 10 cups c. 8 cups b. 9 cups d. 7 cups 5. If you are asked to prepare a brine with a concentration of 20%, what is its equivalent in terms of ratio? a. 1:4 c. 1:5 b. 1:7 d. 1:9 6. Which of the following consist the preparation of a 25% brine solution, with a 1:5 ratio meaning it consists of: a. 1 part salt, 5parts water c. 1 part water, 5 parts fish b. 1 part salt, 5 parts fish d. 1 part fish, 5 parts salt 7. How many volumes of water is added to salt to make a solution of 1:4 if the salt weighs 250 grams/cup? a. 1,000 ml of water c. 500 ml of water b. 800 ml of water d. 900 ml of water 8. Which among the concentration of salt given below is required to kill most species of unwanted bacteria? a. 10% c. 20% b. 25% d. !5%
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9. In the ratio of preparing brine 1:9, what is the weight of the solution dissolved in 250 grams of salt? a. 2250 ml of water c. 1500 ml of water b. 2500 ml of water d. 2000 ml of water 10. In using a salinometer to test for brine strength, at what concentration is 20º S brine? a. 250 grams of salt, 800 ml of water b. 200 grams of salt, 800 ml of water c. 250 grams of salt, 750 ml of water d. 200 grams of salt, 750 ml of water B. Oral Questioning/Interview 1. Can you prepare a brine solution of different concentrations using a salinometer? How will you do it?. 2. Can you measure in terms of cups the amount of salt to be dissolved in a solution 1000ml of water? C. Problem Solving How many grams of water will you use to dissolve 250 grams of salt to produce a 10% brine? LET US APPLY WHAT YOU HAVE LEARNED Perform the following: a. Kench Curing 1. Compute for the weight of salt to be added/applied to fish in kench salting if the weight of fish is 700 grams using 3:7 ratio by weight. 2. Demonstrate how you will cure the fish with the salt you measured. b. Prepare a brine solution of different concentrations; 1. 10% 2. 20 % 3. 25 % Note: Points will be based on the accuracy of your computation for the given concentrations.
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Test on valuing Why do you have to observe accurate measurement ofingredients used for salting and curing? What would be its effect to health if it exceeds more than the required limit? Explain briefly. RESOURCES The following resources are needed: 1. Learning guides a. Module b. Manual for preparing brine and curing solutions c. Handouts on OHS indicators 2. Equipment, tools for preparing brine and curing solutions a. b. c. d. e.
Measuring cups and spoons Mixing bowls Wooden ladle Salinometer Basins
3. Materials a. Potable water b. Rock salt/table salt REFERENCES Avery, Arthur. Fish Processing Handbook of the Philippines Bardey, Catherine, Secrets of the Spas, Blac Bauer, W.W.MD, Health for All, 1967 Calmorin, Laurentina P., Calmorin, Melchor A., Tinaypan, Alfredo S.. (1990). Introduction to Fishery Technology, Manila, Philippines. National Bookstore Inc. Calmorin, Laurentina P., Post Harvest Fisheries. Manila, Philippines: national Bookstore, Inc. 2000. Cortez, Lourdes A., Processing and Preservation of Freshwater Fish., Manila, Philippines ., National Bookstore Inc.,1990 Dagoon, Jesse D. Exploratory Fishery Arts. Manila, Philippines: Rex Bookstore, 1985. 54
Espejo, Jasmin. Fish Processing Handbook of the Philippines Hermes-Espejo, Jasmin. Fish Processing Technology in the Tropics, Quezon City, Philippines, Tawid Publications, 1998. Hand- outs and Pamphlets on Fish Processing. Lagna, Rosalinda T. Food Preservation for Filipinos, 1977 Maharajh, Christina “20 Amazing Ways to Use Salt” Mendoza, Leonarda. Fishery Arts for Secondary Schools Exploratory, 1987 Photo Researchers, Inc./Dr. Jeremy Burgess/Science Source Microsoft ® Encarta ® 2006. © 1993-2005 Corporation.
Microsoft
Training Regulation for Food Processing NC II, TESDA, Metro Manila Food Safety and Sanitation, A paper presented at Foresight on Food Safety, International Food Safety Seminar at Seoul, Korea on April 24, 2006 Other Sources http://www.saltinstitute.org/ http://www.salttraders.com/StoreFront.bok http://www.slate.com/id/2117243 http://www.gourmetsleuth.com/saltguide.htm http://www.flickr.com http://www.initial-impressions.net http://www.msn.com
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LESSON 4. CURE THE FISH WHAT IS THIS LESSON ABOUT? The lesson deals on how to cure the fish by salting and smoking. This includes the procedure in curing fish, methods of storing fish while curing, ideal temperature for storing fish while curing and importance of submerging fish in the curing solution. WHAT WILL YOU LEARN? At the end of the lesson, you should be able to: 1. mix the prepared materials for curing solution in accordance with approved Bureau of Fisheries and Aquatic Resources (BFAR) specifications and enterprise requirements; 2. store cured fish at room or refrigerating temperature for appropriate number of days in accordance with approved BFAR specifications; and 3. keep or submerge the fish to be cured in the curing solution to obtain even distribution/penetration of solution in line with approved BFAR and Bureau of Foods and Drugs (BFAD) specifications; and 4. appreciate the importance of properly practicing the curing the fish for salting and smoking. WHAT DO YOU ALREADY KNOW? Pre-Test Multiple Choice: Directions: Choose the correct answer from the options given. Write only the letter of your choice in your test booklet. Do not write anything on the module. 1. You are curing fish by salting them through the Kench or dry salting method. Why do you need to remove the internal organs before curing with salt? a. To remove the enzymes and microorganisms present in the viscera b. To improve the appearance of the fish c. To lengthen the storage life of the fish d. To improve the texture of the fish 2. What method of curing fish with the use of salt starts with rubbing the fish with dry salt granules before packing them to allow the formation of brine? a. dry salting b. brine salting c. dry salting to make brine d. fermentation 56
3. When smoking fish, why do you need to treat the fish with salt prior to smoking? a. to reduce moisture content through osmosis b. to improve texture and taste of fish c. to destroy microorganisms through plasmolysis of microbial cells d. all of these 4. One of the steps involved in smoking fish is drying the pre-cooked fish for 1 – 3 hours. Why is it done? a. to slightly dry the fish b. to slightly harden the fish c. to facilitate formation of pellicle d. to kill the microorganisms 5. Why are drying and dehydration considered as a curing method of preserving fish? a. because the fish is first treated with salt before drying naturally or artificially b. drying and dehydration involves the removal of moisture from the fish c. because the fish muscles harden and cannot be acted upon by enzymes and microorganisms d. none of these 6. While curing the fish with brine, why do you need to cover the curing container? a. to shorten curing time b. to prevent contamination with germs and microorganisms from the air and flies c. to hasten the curing process d. to prevent adulteration 7. Why is it important to keep the fish being cured at room temperature or at a low temperature? a. to slow down microbial activity b. to maintain the good condition of the fish being cured c. both a and b d. to harden the fish while curing 8. Fish being cured with the curing solution like brine be must be thoroughly submerged into the brine __________. a. to keep the flies from coming in contact with the fish b. in order for the fish to be thoroughly cured with the curing solution c. to prevent contamination of fish while curing d. to thoroughly preserve the fish
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9. What happens if the fish being cured are kept in a place with a poor ventilation or quite hot? a. the fish will not be thoroughly cured b. the quality of fish will deteriorate due to microbial action c. microbial activity increases resulting to spoilage d. both a and b 10. To keep the fish submerged in the curing solution, which of the following will you do? a. cover with a ‗panakip‘ b. cover with banana leaves c. cover with a metal basin d. cover with old newspapers Test for Valuing Complete the statement: If I am going to cure fish through salting and smoking, I will practice correct curing procedure because______________________________. LET US STUDY Let us define Autolysis - the self digestion of the fish due to enzymes naturally present in the digestive tract of the fish resulting to partial liquefaction and softening of the fish flesh. Contaminant - a substance that makes other substances like air, water, or food impure. They include germs and microorganisms that infect the food. Contamination - a state of being infected with germs or microorganisms or made impure with contaminants. Curing solution - a mixture of salt and water which is used to cure or treat fish. Drying - a method of curing in which moisture is removed through natural or artificial means. Drying involves exposure to natural air currents and humidity is regulated by climatic condition. Artificial drying or dehydration involves the use of a mechanical device which controls relative humidity as in the use of oven, kiln or dehydrator. Dry salted fish - a fishery product which is dried first before it is salted as in dry salting of alamang or small shrimp.
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Fermenting - a method suitable for small fishes with fish paste (bagoong) and fish sauce (patis) as end products. Fish Curing - a method of preserving fish and other fishery products by means of salting, drying and dehydration, smoking and pickling. Isthmus - the part that joins the lower jaw of the mouth of a fish and the breast which is located at the lower end of the operculum. Kench salted fish - refers to a heavily salted fish locally known as binuro. Osmosis - the process whereby moisture from the fish is removed while salt enters it through the skin as semi – permeable membrane. Pellicle - a glossy film substance imparted to the fish that aids in giving the fish desirable smoke color. Plasmolysis - the shrinking of the protoplasm of a living cell like a bacterial cell due to the loss of water by osmosis. Salting - a curing fish which is integrated in almost all methods of preserving fish with salt as the chief preservative. Smoking - a smoke – curing method of preserving fish by the application of smoke with the aid of salting, drying and heat treatment. Submerge - means to place under water or cover with water. In developing countries like the Philippines, fish curing is still the principal method of processing fish and other fishery products. Many fish processors prefer to engage in producing cured fishery products like salted fish (binuro, tinabal, guinamos and bagoong), smoked fish (tinapa) and dried fish in whole form like the dried small fishes (dilis and slipmouth) and the dried splitted fish (daeng) because most Filipinos prefer to eat these products rather than the canned, iced or frozen ones. In preparing cured fishery products, the methods used are salting, smoking, drying and dehydration. Procedure in Curing Fish A. Salting Salting is one of the fish curing methods wherein salt is the chief preservative. It preserves fish by lowering its moisture content through the process of osmosis. During osmosis, the bacterial cells undergo plasmolysis as a result of osmotic pressure thus destroying the bacteria.
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Salt – The Chief Preservative in Curing Fish through Salting and Smoking There are five methods of salting fish as follows: 1. Kench or Dry salting involves heavily salting the fish with dried salt granules with a ratio of 1:7 ( 1 part fish to 7 parts salt). The salted product prepared through this method is referred to as binuro. The species of fish commonly kench-salted are: 1. 2. 3. 4. 5.
Indian sardine (tamban tuloy) Fimbriated herring (tunsoy) Short – bodied mackerel (hasa – hasa) Striped mackerel (alumahan) Yellow – striped crevalle (salay – salay)
Procedure: a. Weigh the fish
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b. Eviscerate and wash them with fresh water. The scales may or may not be removed.
c. Soak in a 10% brine, (1 part salt to 9 parts water), for 30 minutes to leach out the blood.
d. Half dry the fish for two hours.
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e. Salt them with the ratio of 1:7 (1 part fish to 7 parts salt) by weight.
Concrete Tank for Brine - Salting of Fish f. Pack the fish in newspaper for home consumption and pack in wooden boxes for commercial purposes.
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Wooden Boxes for Packing Cured Fish 2. Dry salting. In this method, the fishery product is dried first before it is salted as in dry salting of alamang (small shrimps) or anchovies. Also, fresh small herrings are dried first before they are salted. The steps in preparing salted alamang are as follows: a. Remove the adhering foreign materials from small shrimps. b. Wash then dry the small shrimps under the sun for one day. c. Pound the dried small shrimps with the use of mortar and pestle. d. Add salt to pounded shrimps. The ratio is 1:5 (1 part salt to 5 parts pound shrimps). e. Add little washed sugar to salted pounded shrimps. The ratio is 1:32 (1 part washed sugar to 32 parts salted pounded shrimps). Blend them thoroughly. f. After mixing, form them into paste ready for sale. 3. Dry salting to make brine. It involves curing the fish with dry salt granules before they are packed in containers so that brine will be allowed to form. The product prepared through this method is known locally by the Cebuanos as tinabal. The species of fish commonly cured through dry salting to make brine are short-bodied mackerel, striped mackerel, yellow striped crevalle and yellow tuna or albacora.
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The steps in salting fish through dry salting to make brine are as follows: a. Weigh the fish b. Eviscerate them and if their flesh are thick, make a gash on them. c. Wash them with freshwater and pack in 10% brine for 30 minutes to leach out the blood. d. Drain the fish for one hour. e. Rub thoroughly each fish with salt so that all surfaces will be coated. f. Pack the fish in layers in big plastic or glass containers with salt sprinkled between layers so that brine formed will cover the fish. The ratio of salt to fish is 1:4 (1 part salt to 4 parts fish) or 20% by weight. Pack also the fish in 25% brine with the ratio of 1:3 (1part salt to 3 parts fish) by weight. 4. Brine salting is curing the fish with the brine formed after letting the mixture of salt and fish stand for 24 hours. The product produced through this method is locally known as ginamos by the Cebuanos. The brine salted fish are stored for one month or two months and usually eaten uncooked with calamansi juice or vinegar. The brine of this salted product is called una, which is used as seasoning for broth and vegetables. Fish commonly brine - salted are anchovy and herring. The steps in brining the fish are as follows: a. b. c. d. e.
Weigh the fish and wash them in fresh water. Mix salt with the fish in a proportion of 1:4 or 1:5 by weight. Let the mixture stand for 24 hours. Decant the brine formed. Boil the brine formed together with the saturated brine for 30 minutes and let it cool. f. Pack the salted fish in big plastic or glass container. g. Pour the boiled brine into the salted fish. h. Cover the container and store in a cool place. 5. Fermenting is a method of salting fish which is done by dry salting the fish and left to ferment so that protein hydrolyzes to produce paste and sauce. This method has two products, namely fish paste or bagoong and fish sauce or patis. Some fish processors apply papain to make the fermentation period shorter and faster. Anchovy, sardine, herring, shad, silverside and slipmouth are common species fermented.
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The steps in fermenting fish are as follows: a. b. c. d. e. f. g. h. i.
Weigh the fish. Cut into small pieces if fish are large. Wash the fish and drain for 30 minutes. Mix salt thoroughly with the fish in a ratio of 1:4 (1 part salt to 4 parts fish) by weight or 20%. If 25% is used, the ratio is 1:3 (1 part salt to 3 parts fish) by weight. Add papain to shorten the fermentation period (optional). Pack the fish in plastic or glass containers. Store the fermented fish for a month to a year for it to develop the aroma caused by the breakdown of fish proteins. Separate the fish sauce from the fish paste. Extract the fish sauce and pack in bottles. Containers for Fermenting Fish
B. Smoking Smoking or smoke-curing is a method of preserving fish by the application of smoke with the aid of salting, drying and heat treatment. Smoked fish is locally known as tinapa. The two types of smoking are hot smoking and cold smoking. Hot smoking is a slow type of broiling wherein fish is placed near the fire at smoke temperatures ranging from 66˚C to 88˚C. Smoking lasts for one hour to 3 hours depending upon the size of the fish. The fish are cooked in addition to being saturated with smoke. This is also referred to as barbecue smoking. There are two hot smoking methods namely: 1. boiling 2. pressure cooking
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Below are some types of not smoke house for not smoking:
Native Pot Type
Drum Type
Cold smoking is done by placing the fish far away from the fish at a distance of almost two meters away from the source of smoke with a temperature ranging from 32˚C to 43˚C. Below are examples of Smokehouse used in cold smoking:
Cabinet Type Smokehouse Differences Between Hot Smoking and Cold Smoking Differences 1. Distance of fish from source of heat 2. Temperature 3. Length of smoking 4. Finished product 5. Shelf - life
Hot Smoking Close proximity to the fire 66˚C to 88˚C 1 – 3 hours Little bit moist and heavier in weight 3 days to a week
Cold Smoking 2 meters away from the source of fire 32˚C to 43˚C 1 to 2 weeks Dry and lighter in weight More than a month 66
Procedure in Hot Smoking Fish Boiling Method of Hot Smoking a. Weigh the fish and wash them with freshwater. b. Remove the internal organs by ripping out the gills, making sure the isthmus is not destroyed. The removal of viscera eradicates the enzymes that cause autolysis and reduces the microorganisms present. c. Rewash the fish with freshwater. d. Soak the fish in saturated brine for two hours. e. Boil the fish in 10% brine solution for 10 minutes till the eyes of fish become white. f. Dry the boiled fish in a cool, shady and breezy place for 1 to 3 hours or until a thin slimy skin or pellicle is formed on the surface. g. Hot-smoke the fish at temperatures ranging from 66OC to 88OC for 1 to 3 hours depending upon the size of the fish. Pressure-Cooking of Hot Smoking a. Weigh the fish and wash with freshwater. b. Remove the viscera by ripping out gills through the operculum. The removal of viscera leads to the destruction of enzymes and reduction of microorganisms present in the fish. Be sure the isthmus is not destroyed. c. Rewash the fish with freshwater. d. Soak the fish in saturated brine solution for two hours. e. Pressure- cook the fish at temperature of 240OF or 10 pounds, pressure per square inch gauge for 90 minutes for milkfish; 70 minutes for short-bodied and striped mackerel; and 60 minutes for herring and sardines. f. The pressure-cooked fish are dried in a cool, shady and breezy place for 20 to 30 minutes or until a thin slimy skin or pellicle is formed on the surface. g. The fish are hot-smoked at temperature ranging from 66OC to 88OC for 1 to 3 hours depending upon the size of the fish. h. The smoked products are weighed and packed in waxed paper ready for the market. Procedure in Cold Smoking Fish a. Weigh the fish and wash with freshwater. b. Remove the viscera by ripping out the gills through the operculum. Be sure the isthmus is not destroyed. c. Rewash the fish with freshwater. d. Soak the fish in saturated brine solution for two hours. e. Pressure-cook or brine-cook the fish following the instructions in letter e procedure of hot smoking.
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f. The pre-cooked fish are laid on bamboo racks and dried in a shady place for 1 to 3 hours or until the pellicle forms on the surface. g. Cold-smoke the fish at temperatures ranging from 32OC to 43OC for 7 to 14 days. Thin smoke is applied during the first two days and thick smoke for the remaining days. h. Weigh and pack the smoked products in waxed paper ready for the market. Methods of Storing Fish While Curing When curing fish with salt prior to drying or salting it is important that the fish being cured must be properly stored in order to prevent deterioration of the fish as a result of contamination due to careless handling during storage and improper storage practices. While curing, the fish must be protected from possible contamination so the salting trough, curing tank or wooden vessel with fish and curing solution must be covered to prevent contaminated air, flies and other carriers of germs and microbes from coming in contact with the fish. The processor must see to it that the fish being cured are stored in a cool place. Below are some methods of storing fish while curing: 1. Dry storage method involves storing the fish being cured in an area with a moderate room temperature of 10˚C (50˚F) to 21˚C (70˚F) and a relative humidity of 50% to 60% to maintain the freshness or good condition of the fish. Sunlight must be prevented from getting into the room because it generates heat resulting to an increase in the temperature which is conducive for microbial growth and activity.
Dry Storage Medium for Cured Smoked Fish 2. Refrigerated storage method is done when storing the fish being cured in storage areas with refrigerators. This method slows down microbial growth and preserves the good quality of the fish while curing it. With a refrigerator, a temperature of 3˚C (38˚F) is maintained. The processor must make sure that the fish being cured are kept at an ambient temperature if this method is done.
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A Refrigerator for the Refrigerated Storage of Fish while Curing Temperatures Ideal for Storing Fish While Curing Temperature is a vital factor to consider when storing fish while curing because it greatly affects the maintenance of the good quality of the fish. Spoilage organisms like the bacteria become more active at higher temperatures hence the need to keep the fish in a low temperature. Low temperatures slow down microbial activity thus delaying or preventing the onset of spoilage. Fishes being cured with salt can be kept at a normal room temperature of about 35˚C. Below are other ideal temperatures for keeping fish while curing: 1. moderate room temperature of 10˚C (50˚F) to 21˚C (70˚F) 2. a refrigerated temperature of 3˚C (38˚F)
A Fish Cooling Device It must be noted that all bacteria do not have the same temperature requirements for growth. A knowledge on this will help a processor determine the ideal temperature most appropriate for storing a particular kind of cured fishery product.
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Below are the classification of bacteria and their temperature growth range: 1. Psychrophilic bacteria grow within a temperature range of 0˚C (32˚F) to 21˚C (70˚F). These the troublesome microorganisms because they are capable of multiplying at both refrigerated and room temperatures. Most are spoilage organisms. 2. Mesophilic (middle range) bacteria grow at temperatures between 21˚C (70˚F) to 43C (110F), with most rapid growth at a temperature of 37˚C (98.6˚F). 3. Thermophilic organisms are heat – loving and grow best at temperatures above 43˚C (110˚F). All thermophiles are spoilage organisms. Importance of Submerging the Fish in the Curing Solution while Curing The salt used in curing the fish to be salted, dried or smoked preserves the fish by lowering the moisture content through the process of osmosis, whereby the moisture in the body of fish is removed while salt enters it through the skin as semi - permeable membrane. The flow of water is from a lesser to greater concentration. Thus, when fish is soaked in a concentrated brine solution, the water inside flows out rapidly through the skin. Eventually, when the concentration of the solution inside the cell walls into the protoplasm equals that of the brine, the salting process is completed and the fish is said to be thoroughly struck. Submerging the fish in the curing solution will facilitate a thorough exposure of the fish muscles to the curing solution thereby hastening the removal of moisture from the fish and the penetration of salt into the cells of the fish. If the fish are kept submerged all through out the curing period, the fish will be completely salted. To make sure that the fish are completely submerged in the curing solution, they must be covered with a woven bamboo cover known as panakip. LET US REMEMBER Fish curing is still the principal method of processing fish and other fishery products commonly used by Filipinos. This can be done through salting, drying, smoking and pickling. It is popular among Filipinos because its application is simple, easy and economical. It involves the use of salt as the chief preservative. When preserving fish through drying or smoking, they are first cured with a brine solution to lower the moisture content, improve the texture, and impart a desirable salty taste.
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HOW MUCH HAVE YOU LEARNED? Post Test Multiple Choice: Directions: Choose the correct answer from the options given. Write only the letter of your choice in your test booklet. 1. You are curing fish by salting them through the Kench or dry salting method. Why do you need to remove the internal organs before curing with salt? a. To remove the enzymes and microorganisms present in the viscera b. To improve the appearance of the fish c. To lengthen the storage life of the fish d. To improve the texture of the fish 2. What method of curing fish with salt starts with rubbing the fish with dry salt granules before packing them to allow the formation of brine? a. dry salting b. brine salting c. dry salting to make brine d. fermentation 3. When smoking fish, why do you need to treat the fish with salt prior to smoking? a. to reduce moisture content through osmosis b. to improve texture and taste of fish c. to destroy microorganisms through plasmolysis of microbial cells d. all of these 4. One of the steps involved in smoking fish is drying the pre-cooked fish for 1 – 3 hours. Why is it done? a. to slightly dry the fish b. to slightly harden the fish c. to facilitate formation of pellicle d. to kill the microorganisms 5. Why are drying and dehydration considered as a curing method of preserving fish? a. because the fish is first treated with salt before drying naturally or artificially b. drying and dehydration involves the removal of moisture from the fish c. because the fish muscles harden and cannot be acted upon by enzymes and microorganisms d. none of these
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6. While curing the fish with brine, why do you need to cover the curing container? a. to shorten curing time b. to prevent contamination with germs and microorganisms from the air and flies c. to hasten the curing process d. to prevent adulteration 7. Why is it important to keep the fish being cured at room temperature or at a low temperature? a. to slow down microbial activity b. to maintain the good condition of the fish being cured c. both a and b d. to harden the fish while curing 8. Fish being cured with the curing solution like brine must be thoroughly submerged into the brine __________. a. to keep the flies from coming in contact with the fish b. in order for the fish to be thoroughly cured with the curing solution c. to prevent contamination of fish while curing d. to thoroughly preserve the fish 9. What happens if the fish being cured are kept in a place with a poor ventilation or quite hot? a. the fish will not be thoroughly cured b. the quality of fish will deteriorate due to microbial action c. microbial activity increases resulting to spoilage d. both a and b 10. To keep the fish submerged in the curing solution, which of the following will you do? a. cover with a ‗panakip‘ b. cover with banana leaves c. cover with a metal basin d. cover with old newspapers Practical Demonstration with Oral Interview: Demonstrate these tasks: 1. Hot smoking of fish 2. Dry storage method of storing fish while curing
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LET US APPLY WHAT YOU HAVE LEARNED Performance Test Perform the actual curing of fish by kench salting. You will be rated using the following criteria: Accuracy
Speed
10%
10%
Workmanship Quality of Work Habits Products 40% 30% 10%
Test for Valuing Explain briefly why it is important to observe accuracy in curing fish to be salted, dried or smoked. RESOURCES The following resources are needed: 1. Learning guides a. Module b. Computer based activity guides c. Activity sheets 2. Equipment, tools and utensils a. b. c. d. e. f.
Mixing bowls Salting/curing vats Wooden ladle/stirrer Freezer Food tongs Salinometer
3. Materials a. Rock salt/table salt b. Potable water 4. Personal protective equipment a. Apron b. Rubberized hand gloves c. Headband
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REFERENCES Essentials of Food Safety and Sanitation, Third Edition by David McSwane, H.S.S., Nancy Rue, Ph. D. and Richard Linton, Ph. D. Post Harvest Fisheries by : Laurentina –Paler Calmorin, 2006 http://www.saltinstitute.org/ http://www.salttraders.com/StoreFront.bok http://www.slate.com/id/2117243 http://www.gourmetsleuth.com/saltguide.htm http://www. image.google.com
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LESSON 5. FINISH THE CURED FISH WHAT IS THIS LESSON ABOUT? The lesson deals on finishing the cured fish like draining the brinecured fish. This also includes drying cured fish in appropriate equipment and medium; packing cured fish using appropriate medium; cooking fish in brine using appropriate cooking equipment and medium; smoking the cooked fish; cooling the smoked fish and packing the smoked fish. WHAT WILL YOU LEARN? At the end of the lesson, you should be able to: 1. 2. 3. 4. 5. 6. 7. 8.
drain brine cured fish; dry cured fish using appropriate equipment and medium; pack cured fish using appropriate packing medium; store packed cured fish in appropriate storage medium; cook fish in brine using appropriate cooking equipment; smoke cooked fish; pack smoked fish; and appreciate the importance of properly finishing the cured fish.
WHAT DO YOU ALREADY KNOW? Pre-Test Multiple Choice – Directions: Let‘s find out how much you already know about finishing the cured fish. Read and understand the questions below. Select the best answer and write the letter in your test booklet. 1. Why do you need to drain the brine cured fish? a. to remove excess moisture b. to let the fish oil drip away from the fish c. to harden the fish d. to facilitate pellicle formation 2. What method of drying the salted fish will you do if the product specification requires you to naturally dry it? a. artificial drying b. drying with a dehydrator c. sun drying d. dry inside an oven
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3. You are going to dry salted splitted fish. Which one will you do? a. split the fish before salting b. clean and wash the fish c. cure fish with salt d. spread fish on drying trays and dry 4. Your teacher assigned you to prepare the tools you will use in drying salted fish, which of these will you prepare? a. salting vat, wooden stirrer and aluminum trays b. knife, forcep and wooden vat c. bamboo trays d. basin and mixing bowl 5. How will you properly package a smoked fish? a. Pack them in metal containers. b. Pack them in glass jars. c. Pack the fish in polyethylene bags. d. Wrap the fish with banana leaves. 6. Why do you need to drain the fish after washing? a. to remove excess water b. to let the oil drip c. to improve texture of the fish d. to dry the fish 7. Which of the following will you do if you are instructed to brine the fish? a. Prepare a brine. b. Soak the fish in the brine. c. both a and b d. none of these 8. If you are going to pre-cook a fish before smoking, which of the following will you do? a. prepare a saturated brine b. dip fish into the boiling saturated brine c. drain the brined fish d. boil the fish in plain water 9. How will you properly cool the fish after smoking? a. place inside a freezer b. aerate with an electric fan c. place inside the setting cabinet for cooling d. expose to natural air 10. a. b. c. d.
Why do you need to properly package smoked fish? to prevent contamination of the product to improve the salability of the product to improve product appearance to improve texture of the smoked fish 76
LET US STUDY Let us define Brine - a mixture of salt and water. Dehydrator - a mechanical device used to lower the moisture content of the fish under controlled conditions. Preservative - refers to a substance added to food to prevent its spoilage and maintain its freshness. Example: Salt, vinegar and smoke. Salted fish - a product prepared from whole, eviscerated or splitted fish treated with salt. Saturated - loaded to capacity. Smoked fish - a product prepared from whole, eviscerated or splitted fish treated with salt and subjected to smoke produced by combustion of wood or other smoking materials. Enzymes - endogenic bio – proteins which are naturally present in the digestive tract of living organisms that hasten digestion. Microorganisms - minute living organisms like bacteria, yeasts and molds which cause spoilage of the fish. Moisture - refers to the water content of a fish. Packing - filling the cured fish into a packaging material. Osmosis - the flow of substances from a lower concentration to a higher concentration through a semi – permeable membrane until a state of equilibrium is established. Salt - a colorless or white crystalline compound known chemically as Sodium chloride (NaCl) occurring abundantly in nature, both in solid or liquid form. A cured fish has been treated with preservatives like salt and smoke. This is to prevent spoilage and thereby lengthen the storage life of the product. Curing a fish is done through drying, smoking or salting. Drying as a preservation method which is integrated in salting and smoking is based on the following principles: a. Microorganisms cannot live without water. b. The action of microbial enzymes on food requires water. 77
Smoking involves the treatment of fish with smoke. The production of smoke implies fire and generation of heat. When fish is smoked, it is also dried and is also slightly cooked. Cooking destroys the action of enzymes and kills many microorganisms because of the high temperature. Chemicals in the smoke also destroy microorganisms. Smoke contains a substance called creosote which acts as a preservative agent. Salting, on the other hand, preserves the fish through treatment with salt. It reduces the moisture content of the fish through osmosis. Common salt (Sodium Chloride), if present in the fish flesh in sufficient quantities, will slow down or prevent microbial action. Salting fish is done through dry salting or Kench curing, dry salting to make brine, brine salting and fermentation. When salt is added to the fish before it is dried, less water needs to be removed from the cured product to achieve preservation. A product with a water content of 34% - 35% depending on the amount of salt present, is often dry enough to inhibit the action of microbes. When drying salted fish, these methods are used: 1. Sun drying – natural dehydration of fish through exposure to sunlight until the moisture content of the fish is lowered to a point unfavorable for microbial growth.
2. Artificial dehydration – the use of mechanical devices to provide artificial heat for the purpose of lowering the moisture content of the fish to inactivate microorganisms and other spoilage agents.
Dehydrators are used in the artificial removal of moisture from the fish 78
Procedures in Drying Fish Sun Drying of Fish The following are the general steps in sun drying: 1. Wash fish thoroughly in running water
2. Soak fish in a 10% brine for half an hour to leach out the blood.
3. Remove the viscera by opening and squeezing the belly cavity.
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4. Soak the fish in a concentrated brine solution for 3 to 6 hours to partially extract the moisture content of fish.
Salting Troughs for Brining Fish 5. Arrange the salted fish on coarsely woven bamboo trays/racks and dry under the sun for a few days depending on the size of the fish.
6. When thoroughly dried, place the fish in clean baskets or boxes, ready for market distribution.
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Artificial Dehydration of Fish Follow these steps when using the artificial dehydration method of preserving fish: 1. 2. 3. 4.
Wash fish thoroughly in running water. Soak fish in a 10% brine for half an hour to leach out the blood. Remove the viscera by opening and squeezing the belly cavity. Soak the fish in a concentrated brine solution for 3 to 6 hours to partially extract the water content of the fish. 5. Precook the fish for a short period of time depending upon its size. 6. Arrange the precooked fish on trays and racks. Place the fish in an oven or artificial dehydrator to dry under a controlled temperature.
7. When thoroughly dried, remove and collect the fish from the tray and pack them in boxes, ready for market distribution.
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Equipment and Materials Used in Drying The following equipment and materials are important in drying salted fish: 1. Anemometer - an instrument used in determining the velocity of the wind in sun drying.
2. Bamboo trays - woven bamboo slats used for holding fish for drying. Drying trays out of fine – meshed wire screen can also be used for drying fish.
Bamboo tray
3. Drying platforms - surfaces used to hold trays and racks when drying fish.
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4. Interval timer - a gadget used to note the exact interval of time in the drying process.
5. Oven or Dehydrator - a device that is used for artificial drying.
Dehydrator 6. Psychrometer - an instrument used to measure the relative humidity of the air when sun drying. The psychrometer is a hygrometer that utilizes two thermometers—one wet-bulb and one dry-bulb—to determine humidity through evaporation.
Digital Sling Psychrometer 83
7. Thermoguide - an instrument used for recording the daily temperature in order to establish a drying pattern. 8. Salinometer – used to determine the salinity of the brine to be used in curing the fish before drying.
9. Drying sheds – night covers commonly used to protect dried fish from the rain.
Packaging Materials Packaging is a container. It is a system or means of protecting goods for transport, distribution, storage, retailing and end-use. It also serves as an important marketing tool for enhancing product market appeal
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Below are the illustrations of some packaging materials:
Polyethylene Packaging Materials Kinds of Packaging Materials for Dried and Smoked Fish 1. Polyester – polyethylene (PET/PE) for local and foreign distribution of dried fish at ambient and refrigerated conditions, and of smoked fish at refrigerated condition. 2. Polyethylene (0.002 inch thick) for local and foreign distribution at refrigerated conditions 3. Traditional packaging materials like wooden boxes, baskets, used cartons, jute sacks, etc. These need to be improved to ensure product hygiene and safety. Packing Cured Fish The packing procedure depends on whether the cured fish are to be delivered at once to fish traders or will be kept in cold storage for future distribution. If they are to be delivered at once to fish traders, they are packed in boxes containing approximately 50 kg of dried fish.
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Procedure in Packing Cured Fish in a Wooden Box 1. Line fish box with old newspaper followed by wax paper. Provide an extra flap of newspaper for covering the fish. 2. Pack the cured fish in the box, cover with extra wax paper, flap top with several newspapers. 3. Nail the cover of the box. The dried fish are ready for delivery to fish traders or to public market. Retail Packaging The use of polyethylene films 0.001-0.002 inch thickness is recommended for retail packaging of smoked product. Other packaging materials such as laminator or combination of two or more flexible packaging materials may also be used but these are rather more expensive. Procedure for Retail Packaging of Cured Fish: 1. Sort cured fish according to size. 2. Pack cured fish in plastic bags at retail weight of 250g, 500g or 1000g per pack. 3. Seal filled packs by using a portable or fast sealer. 4. Transfer the packed products in bulk packaging material, seal and store preferably at refrigeration temperature to maintain the quality of the smoked fish. Storing Cured Fish Cured fish remain in sound and edible condition only over a short period of time. Smoked fish contain a high percentage of moisture making them highly susceptible to spoilage. Hence, they should be distributed or sold as soon as possible, while being kept chilled or refrigerated if possible. Smoked fish remain good for 3 days at room temperature and up to 2 weeks when refrigerated. During the dry season and peak season for fish, cured fish are produced in bulk and stored in cold storage for future distribution. They are packed and stored as follows: 1. Line an improvised basket made from coarsely woven bamboo slats with several layers of thick wax papers. 2. Pack the fish inside the baskets, cover with wax papers, and tie with straw cords. Each fish basket weighs 40-50 kilograms. 3. Keep the fish inside the cold storage with a temperature of 40OF – 50OF until final distribution.
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Cured fish are stored at ambient and refrigerated conditions.
The new Fish model keeps contents at -1°/+1°C and has a cooling system which is specially designed to prevent the surface of the fish from drying. It holds seven fish boxes, with a maximum load of 198kg.
Storage medium for smoked fish Draining Draining facilitates removal of excess moisture from a fish previously washed or soaked in a brine or curing solution. Steps in Draining Fish 1. Arrange fish inside a colander or on bamboo trays. 2. Let the excess water drip-off from the fish. Draining takes 30 minutes to one (1) hour depending upon the size of the fish.
The colander is an important device in draining fish.
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Brining Brining or brine salting involves curing fish by soaking it in a mixture of salt and water for 30 minutes to 1 hour depending upon the size of the fish. Brining is integrated in drying and smoking of fish. This is also one of the four methods of curing fish through salting using a salt concentration of 20% to 25%. Brining fish prior to drying or smoking is done to leach out the blood and slime, to improve the texture of the, to remove some of the moisture content of the fish through osmosis, and to impart a desirable salty taste.
Below are some materials and devices used in brining:
Salt spreader
Table salt
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Procedure in Brining a Fresh Fish 1. 2. 3. 4. 5.
Weigh fish and wash with fresh clean water. Mix salt with the fish in a proportion of 20% or 25% by weight. Let the mixture stand for 24 hours. Decant the brine formed. Pack the salted fish in oil cans. Seal.
Procedure in Brining Fish for Drying and Smoking 1. Weigh the fish. Record the obtained weight.
2. Clean and wash fish. 3. Let it stand for 30 minutes to drain. 4. Soak in a 20% brine (1 part salt to 4 parts fish) or 25% (one part salt to 3 parts fish by weight). 5. Drain for one hour. Pre-Cooking Fish The fish to be cured with smoke is pre - cooked in a 20% brine for 10 minutes or more depending upon the size of the fish. In pre-cooking fish, follow these steps: 1. Arrange the fish on small bamboo trays. 2. Dip the bamboo trays with fish into the boiling brine for 10 minutes or more depending upon the size of the fish or until the eyes turn white and opaque. 3. Remove pre-cooked fish from the brine.
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Packaging of Smoked Fish
Smoked fish is packed either in bulk or in retail packaging materials. Bulk packaging refers to those intended for wholesale or institutional distribution. Retail packs contain the product until it reaches the ultimate end-user or consumer. Procedure for Bulk Packaging 1. Sort cooled smoked fish according to size. 2. Pack or transfer smoked fish in bulk packaging materials by arranging the fish in a manner that heads and tails are in uniform position. 3. When the packaging material is nearly full, weigh the whole pack (container and smoked fish) to check product weight attained. Total weight minus weight of container will give the weight of the smoked fish. 4. Close or seal the pack and store at refrigeration temperature (3OC to 5OC) or in a cold storage. Procedure for Retail Packaging 1. Sort smoked fish according to size. 2. Pack smoked fish in plastic bags at retail weights of 250g., 500g, or 1,000g per pack. 3. Seal the filled packs by using a portable or fast sealer. 4. Transfer the packed products in bulk packaging materials; seal and store preferably at refrigeration temperature to maintain the quality of the smoked fish.
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LET US REMEMBER A cured fish is treated with preservatives and subjected to physical factors that lower the moisture content of a fish to a point where the growth and multiplication of organisms are inhibited. The preservatives usually used in treating cured fish are salt, smoke and vinegar. Salt is used in curing fish during salting and drying while smoke is used to cure a smoked fish. When curing fish or meat through pickling, salt and vinegar are used. The activities involved in finishing the cured fish depend on the kind of product produced and the method of curing done. However, all cured products need to be properly packed either whole sale or retail packaging. HOW MUCH HAVE YOU LEARNED? Post-Test Multiple Choice Directions: Read and understand the questions below. Select the best answer and write the letter only in your test booklet. 1. Why do you need to drain the brine cured fish? a. to remove excess moisture b. to let the fish oil drip away from the fish c. to harden the fish d. to facilitate pellicle formation 2. What method of drying the salted fish will you do if the product specification requires you to naturally dry it? a. artificial drying b. drying with a dehydrator c. sun drying d. dry inside an oven 3. You are going to dry salted splitted fish. Which one will you do? a. split the fish before salting b. clean and wash the fish c. cure fish with salt d. spread fish on drying trays and dry 4. Your teacher assigned you to prepare the tools you will use in drying salted fish, which of these will you prepare? a. salting vat, wooden stirrer and aluminum trays b. knife, forcep and wooden vat c. bamboo trays d. basin and mixing bowl
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5. How will you properly package a smoked fish? a. Pack them in metal containers. b. Pack them in glass jars. c. Pack the fish in polyethylene bags. d. Wrap the fish with banana leaves.
6. Why do you need to drain the fish after washing? a. to remove excess water b. to let the oil drip c. to improve texture of the fish d. to dry the fish 7. Which of these will you do if you are instructed to brine the fish? a. Prepare a brine. b. Soak the fish in the brine. c. both a and b d. none of these 8. If you are going to pre-cook a fish before smoking, which of the following will you do? a. prepare a saturated brine b. dip fish into the boiling saturated brine c. drain the brined fish d. boil the fish in plain water 9. How will you properly cool the fish after smoking? a. place inside a freezer b. aerate with an electric fan c. place inside the setting cabinet for cooling d. expose to natural air 10. a. b. c. d.
Why do you need to properly package smoked fish? to prevent contamination of the product to improve the salability of the product to improve product appearance to improve texture of the smoked fish
Practical Demonstration with Oral Interview Demonstrate the proper way of brining and draining fish to be cured. Valuing You brined and drained fish to be cured, why is it important to do it properly and accurately? 92
LET US APPLY WHAT YOU HAVE LEARNED Performance Test A. Perform Salting, Drying, Packing and Storing of Cured Fish Task: Salting, Drying, Packing and Storing of Cured Fish Sub-tasks
COMPLETED YES NO
1. Brine the fish 2. Drain the fish 3. Dry fish using appropriate equipment and medium 4. Wash fish for smoking 5. Pre-cook fish 6. Smoke the fish 7. Cool the smoked fish 8. Pack the smoked and salted fish 9. Store the packed cured fish Result : Pass Fail Note : You have to complete all nine sub-tasks in order to pass this lesson, or else you have to go over this once more. B. Prepare the different kinds of fillets using the correct procedure. Be sure to properly wash, scale and weigh the prepared fillets. Valuing: How do you show that you value accuracy in doing your assigned tasks? Why is accuracy in doing your work important? Explain.
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RESOURCES The following resources are needed: 1. Learning guides a. Module b. Laboratory Manual/Activity sheet 2. Equipment and tools a. b. c. d. e. f. g. h. i. j. k.
Drying trays Polysealer Cooking vat Metal ladle Plastic bags Bamboo baskets Draining trays Freezer Wooden ladle Gas stove Food tongs
3. Personal protective equipment a. Pot holders b. Headband c. Apron REFERENCES THE III. Agriculture and Fishery Technology, SEDP Series, Department of Education Processing and Preservation of Freshwater Fish by Lourdes A. Cortez Learning Element for Drying, Packing and Storing of Fish, CDD, BTVE Fish Smoking prepared by : Technology Development Institute of DOST Learning Element for Distinguishing Salting, Drying and Smoking, BTVE Philippine Handbook on Fish Processing by Jasmin M. Espejo
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Other Sources http://www.saltinstitute.org/ http://www.salttraders.com/StoreFront.bok http://www.slate.com/id/2117243 http://www.gourmetsleuth.com/saltguide.htm http://www. image.google.com
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LESSON 6. PREPARE PRODUCTION REPORT WHAT IS THIS LESSON ABOUT? This lesson deals on how to prepare production report. This includes the importance of recording and documenting production input, procedure in recording and documenting production input and format of a production report. WHAT WILL YOU LEARN? At the end of the lesson, you should be able to: 1. note and document daily production input in accordance with basic accounting procedures; 2. record and present all production data in accordance with basic accounting procedures; and 3. practice accuracy in preparing production report. WHAT DO YOU ALREADY KNOW? Pre–Test Multiple Choice - Directions: Choose the correct answer among the options a, b, c and d. Write the letter only on the answer sheet provide for you. 1. Something that enters a process from the outside and is acted upon. a. input c. yield b. output d. none of the above 2. Which of the following will you prepare to have systematic procedure of keeping a record for reference? a. presentation c. documentation b. input d. none of the above 3. Input output relationship is important in the production. Which of the following would you prepare to show this? a. documentation c. production report b. input d. none of the above 4. A word meaning amount produced is: a. input c. emulsion b. output d. all of the above
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5. How many grams is four kilos of mangoes? a. one thousand grams c. three thousand grams b. four thousand grams d. all of the above Test for Valuing Briefly explain the importance of accuracy in preparing a production report. LET US STUDY Let us define Documentation - a systematic procedure of keeping a record for reference. Emulsion - a suspension of liquid with another liquid. Input - means something that enters a process from the outside and is acted upon. Output - the amount produce and yielded from a process. Production report - refers to a written record showing the input/output relationship in determining the yield from a certain procedure.
Importance of Recording and Documenting Production Input 1. To have a reference data on the materials used and their cost. 2. To determine the economic viability of the product. Procedure in Recording and Documenting Production Report 1. Have a complete list of the materials used for a certain product. 2. Determine the weight and cost of each material. 3. Determine and record the total yield per production.
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Format of a Production Report Production Data Sheet Product Name: ______________________ Product Date: _______________________ Description of Materials: ______________________ ______________________ Other Ingredients: Weight of _____________ Weight of _____________ Weight of _____________ Production Input _________________________ Weight of Spoiled Materials ________________ Production Output ________________________ Percentage of Yield _______________________ Number of Yield _________________________ Problem Encountered _____________________ Example of Production Report Production Name : Smoked Fish Production Date : May 31, 2007 Materials/ Ingredients: Bangus = 220 grams Salt = 500 grams Production Input = 720 grams Weight of Spoiled Materials = - 50 grams Production Output = 670 grams Percentage of yield = Production Output x 100% Production Input Percentage of yield = 670 grams x 100% 720 grams Percentage of yield = .93 x 100% Percentage of yield = 93% Number of yield = Production Output Weight of the product Number of yield = 4 pieces LET US REMEMBER Production report needs proper and correct noting, documenting, recording and presenting of data based on the basic accounting procedure. Accuracy in report preparation must always be observed in order to have ready record for future use or reference. 98
HOW MUCH HAVE YOU LEARNED? Post Test Multiple Choice - Directions: Choose the correct answer among the options a, b, c and d. Write the letter only on the answer sheet provided for you. 1. Something that enters a process from the outside and is acted upon. a. input c. yield b. output d. none of the above 2. A systematic procedure of keeping a record for reference. a. presentation c. documentation b. input d. none of the above 3. A written record showing the input-output relationship. a. documentation c. production report b. input d. none of the above 4. A word meaning amount produced is: a. input c. emulsion b. output d. all of the above 5. How many grams is four kilos of mangoes? a. one thousand grams b. four thousand grams c. three thousand grams d. all of the above LET US APPLY WHAT YOU HAVE LEARNED Demonstration 1. Make production report based on the given data: Smoked Milkfish Given: Milkfish Salt Water Internal organs Output
= = = =
200 grams 500 grams 1,600 ml. 50 grams = 150 grams
Test for Valuing: 1. Why is it important to observe accuracy in preparing production report? 2. What happens if the production report you prepared is inaccurate?
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RESOURCES The following resources are needed:
Learning guides o Module o Computer based activity instructions o Sample production report
Materials o o o o o o
Ledgers Bond papers Rulers Pencil Ball pen Calculator
REFERENCE Handouts from TESDA Centrex (CVS)
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Republic of the Philippines
Department of the Education PUBLIC TECHNICAL-VOCATIONAL HIGH SCHOOLS
Unit of Competency: Use of Processing Tools, Equipment and Utensils Module No.: 2
Module Title: Using of Processing Tools, Equipment and Utensils
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MODULE 2 QUALIFICATION TITLE
:
FISH PROCESSING NC II
UNIT OF COMPETENCY
:
The Use of Processing Tools, Equipment and Utensils
MODULE TITLE
:
Using Processing Tools, Equipment and and Utensils
NOMINAL DURATION
:
20 hours
CERTIFICATE LEVER
:
NC II
WHAT IS THIS MODULE ABOUT? This module covers the knowledge, skills and attitudes required to operate food processing tools, equipment and utensils such as performing pre – operation activities, operating food processing equipment and performing post operation activities. WHAT WILL YOU LEARN? After completing this module, you should be able to: 1. 2. 3. 4.
perform pre-operation activities; operate food processing equipment; perform post operation activities; and use processing tools, equipment and utensils accurately and carefully.
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LESSON 1. PERFORM PRE–OPERATION ACTIVITIES WHAT IS THIS LESSON ABOUT? The lesson deals on the study of the uses of specifications for equipment, tools and utensils; the study of the parts and functions of equipment, tools and utensils; the uses and specification of sanitizing agents and the proper stowing of tools, equipment and instruments. It also covers inspecting and checking the condition of equipment/ machines before operation and performing minor prevention maintenance. WHAT WILL YOU LEARN? At the end of the lesson, you should be able to: 1. prepare for use appropriate tools and equipment or utensils according to food processing methods; 2. inspect and check food processing tools and equipment or utensils according to manufacturer’s specifications; 3. set up, adjust and made ready food processing equipment according to job requirements; and 4. appreciate the importance of performing pre – operation activities. WHAT DO YOU ALREADY KNOW? Let’s find out how much you already know about using food processing tools, equipment and utensils. Select the best answer from the options given and write only the letter or your answer in your test booklet. Pre Test Multiple Choice Directions: Carefully read the questions and choose the best answer from the options given. Write only the letter of your answer in your test booklet. 1. Which of the following tool/equipment specifications are used by manufacturers? a. dimension as to size, height, capacity, etc. b. handling and operating requirements c. proper care and maintenance d. all of these
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2. Why are specifications for food processing tool, equipment and utensils necessary? a. they provide information to the user on how to handle and operate the equipment properly. b. specifications give information concerning the proper use, care and maintenance of the tools, equipment and utensils c. it provides information about the tools, equipment and utensils d. both a and b 3. If you are a food processor, why do you need to know the parts of the equipment, tool and utensil and their functions? a. to appreciate the usefulness of a particular device b. to be able to correctly operate/manipulate a tool, equipment or utensil c. to be able to do some simple repairs on them d. to easily determine if a part is missing 4. If you are going to pack processed foods in tin cans, why do you need to seal it with a can sealer? a. cans cannot be sealed manually b. tin cans are difficult to seal c. to properly seal them d. a can sealer is the appropriate equipment for attaching the cover to the body of a tin can with is first and second operation rolls 5. Which of the following will help you determine the kinds of tools, equipment and utensil you will assemble, sanitize, inspect or check? a. the kind of product to be produced b. the method of food processing to be done c. the raw materials to be processed d. the availability of tools, equipment and utensils 6. You have already removed the dirt from the tools, equipment or utensils have used in processing the food by washing them with soap and water. Why do you still need to sanitize or disinfect them? a. washing with soap and water only removes the adhering dirt b. washing alone cannot remove the microorganisms and germs c. to effectively kill or destroy all the germs and microorganisms which remained after washing d. all of these
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7. Which of these is a sanitizing agent you can use for killing the germs and microorganisms present in tools, equipment and utensils? a. sodium chloride b. sodium hypochloride c. magnesium sulfate d. calcium chloride 8. How will you properly store tools, equipment and utensils after using them? a. wipe dry all tools, equipment and utensils which were washed with water before keeping them b. stow them in a clean dry place with a good ventilation c. apply lubricant to parts of equipment that undergo friction to prevent wear and tear d. all of these 9. It is necessary to inspect and check the condition of equipment and machines before operating them in order to __________. a. to check if no parts are defective or missing b. to check if electrical plugs are in good condition c. to see if they are old or new ones d. both and b 10. Which of this preventive machine maintenance will you check before using equipment or a machine? a. machine temperature and hydraulic fluid b. wear and surface condition c. crack and leak detection and electric insulation d. all of these Test for Valuing Explain in five sentences why it is important to perform pre – operation activities especially when using food processing tools, equipment and utensils. LET US STUDY Let us define Tools - implements used by hand when doing an activity or work. These are devices for doing work or objects designed to do a particular kind of work, for example cutting or chopping, by directing manually applied force or by means of a motor. Equipment - the tools, supplies and other items needed for a particular task or activity. Utensil - an implement especially for use in the kitchen. 4
Sanitize - to clean something thoroughly by disinfecting or sterilizing to make it free from germs or microorganisms. Sanitation - the process of treating tools, equipment, and utensils with physical and chemical sanitizing agents to kill residual microorganisms present after cleaning. Disinfect - to rid of germs; to clean something so as to destroy disease – carrying microorganisms and prevent infection. Calibrate - to test and adjust the accuracy of a measuring instrument or process to ensure accuracy of obtained measurements or processes done. Check - to examine something in order to establish its state or condition. Assemble - to gather or collect things together in one place. Operate – to make equipment function or work correctly. Specification - the detailed description, dimensions, materials, etc of something, especially one detailed enough to provide somebody with the information needed to make that thing. Dimension - the measurement of the size of an object in terms of length, width, or height. Capacity - refers to the measurement of the amount which a device can hold or contain. Stow - to store or pack in an orderly way. When processing food, there are several tools, equipment and utensils which need to be properly inspected, checked, sanitized, assembled and operated based on specifications. The appropriate tools, equipment and utensils are assembled according to the food processing methods wherein they will be used. The food processing methods that will determine the kind of tools, equipment and utensils to be assembled are: 1. Salting 2. Curing 3. Smoking 4. Fermentation 5. Pickling 6. Canning 7. Bottling 8. Processing using sugar concentration 9. Drying 10. Dehydration or artificial drying When salting, the tools, equipment and utensils to be assembled, inspected, checked and sanitized are those for salting purposes like salinometer, earthen pots, wooden salting vat, etc. If the fish or meat is to be cured there is a need to prepare slicers, grinders, food processors, wooden or stainless steel basins, etc. In smoking fish, a smoke house, cooking vat, bakol, bistay, bamboo tray, etc. are to be assembled. In the fermentation of food fermenting jars, bottles, strainers, measuring spoons, measuring cups, etc. need to be prepared. In pickling, 5
preserving bottles and jars, aluminum utility trays, basins, etc must be assembled and prepared. The can sealer, pressure cooker, thermometers, stove, etc must be prepared when canning. If the food like fish and meat are to be dried, there is a need for dehydrators, drying trays, knives, weighing scales, etc. When processing food using different tools, equipment and utensils, it is also important to inspect and check them based on manufacturer’s specifications which include: 1. 2. 3. 4. 5. 6. 7.
Handling requirements Operating requirements Discharge label Reporting Testing Positioning Refilling
Equipment, Tools and Utensils: Uses and Specifications Every equipment, tool and utensil that are purchased are accompanied with a manual containing specifications as to how they are used, manipulated or operated, cared for and stored to lengthen their service ability. Specifications usually include the following: 1. 2. 3. 4. 5.
Important safeguards or basic safety precautions to follow when using the device like a pressure cooker for instance. Warning labels which serve as a reminder to the user to read and follow instructions on the proper use and operation of a certain device equipment or tool. Dimensions, weights and capacities as in the case of cookers, boilers and steamers. Instructions on caring for the equipment, tool or utensil. Instructions on the correct usage of the device.
When using any equipment, tool or device it is important to read and understand the manufacturer’s specifications in order to properly or accurately use or manipulate them and prevent any accident that may occur due to ignorance or lack of information pertaining to their correct usage. Being familiar with all information pertaining to food processing equipment results to systematic, orderly and accurate accomplishment of tasks.
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Parts and Functions of Equipment, Tools and Utensils Knowing the parts and functions of equipment, tools and utensils used in processing food ensures accurate or proper use, operation and care for them. It is very easy for a food processor to manipulate a particular device if he knows all its parts and their respective functions. Proper maintenance for the parts of any tool, equipment and utensil can also be done if a processor is familiar with them. The Can Sealer
The can sealer is equipment used to seal tin cans with its first and second operation rolls. Some processed food products are usually packed in tin cans which are mechanically sealed with a can sealer. Below are the functions of some parts of an automatic can sealer: 1. Clamp. This fastens the sealer on the table or arm chair and holds it tightly in place, especially during operation. 2. Base plate or plunger plate. Its function is to hold the base of the can. It has grooves to fit the can base wherein these grooves coincide the can size. 3. Can lifter handle. It is used to raise the base plate so that the can cover will reach up to the chuck and lower the base plate so that the can cover will reach up to the chuck and lower the base plate when sealing is through. 4. Crank. This part is turned during the sealing of can seams both first and second operation rolls. 5. First operation roll. It is used to clinch, partially or half – seal the seams of a can cover. 6. Second operation roll. It is used to complete – seal the seams of a can cover. 7. Seaming roller pin – first. It is placed on the hole of the first operation roll to fasten on it. 8. Seaming roller pin – second. It is placed on the hole of the second operation roll to fasten on it. 7
9. Rivet. This part is placed in the hole of the adjusting lever which coincides the can cover size. If can cover size is No. 2, for instance, one – half pound tuna can rivet is placed in No. 2 hole of the adjusting lever. Rivet is also called adjusting pin. 10. Chuck. It is used to hold the cover of the can while sealing is going on. Chuck has many sizes, namely Number 1, 2, 2 ½, and 3, respectively. If No. 2 cover is used, hence, hence, chuck No. 2 is used. 11. Height washers. These washers are placed in base plate shaft to match the height of the can when lifted up to the chuck. 12. Adjusting levers. There are two adjusting levers, one for the first operation roll and the other, second operation roll. There are numbered holes on these levers wherein rivets are placed to coincide the can size. 13. Base compression spring. It acts as cushion while sealing is on the process. 14. Base plate shaft. This is the part where compression spring and height washers are inserted. The Pressure Cooker
A pressure cooker is an important canning equipment used to process fish packed in a hermetically sealed container at a high controlled temperature and pressure for a certain period of time. Some of its parts and their functions are as follows:
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1. 2.
3. 4. 5. 6. 7. 8. 9. 10. 11.
Geared seam gauge or pressure gauge. It indicates the pressure and temperature inside the cooker while processing. Pressure regulator weight. It is used to close the vent pipe and regulate the accumulated pressure inside the cooker while processing. It contains holes which correspond to the desired pressure directly over the vent pipe. For instance, if the desired pressure is 10 pounds, the pressure regulator weight hole of 10 is inserted over the vent pipe. Vent pipe for pressure regulator weight. It is where the pressure regulator weight is placed. It releases steam when opened. Bakelite wingnut or knob. It is used to securely fasten the cover of the cooker to its body. Arrowhead and arrowline. They indicate if the cover is properly seated on the body. Automatic pressure control. It consists of the vent pipe and pressure regulator weight. It automatically controls the pressure inside the cooker while processing. Overpressure plug. It automatically vent or release steam if the vent pipe becomes clogged. Cover. Seals the body of the cooker during processing. Body. It holds the water for processing and the metal rack where the canned products are placed during processing. Bakelite top handle. This is for holding the cover when lifting it away from the body or seating it properly on the body. Body or side handles. This is used for holding the body of the cooker when transferring it from one place to another.
The Smokehouse A smokehouse is a device used in treating the fish or meat with smoke. It can be a cold smoke house or a hot smokehouse. It is a hot smokehouse if the fish is in close proximity to the source of smoke and a temperature of 66C to 88C is produced. If the source of smoke is 2 meters away from the fish and the temperature of smoke is 32C – 43C, then it is a cold smokehouse. Some are simple like the barrel and drum types while others are mechanized and controlled like the Torry smokehouse which can also be used as a drier.
The Drier Smokehouse
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Parts of a Drier Smokehouse and their Functions 1. Removable slatted benches. They hold the fish to be smoked. 2. Removable hangers with hook. They are used for hanging fish to be dried or smoked. 3. Wooden hooks. They are nailed from the top of a the drier smokehouse where fish are also hanged when drying or smoking. 4. Vents. These are located below the roof at the front and back of the smokehouse to provide the necessary air circulation. 5. Tunnel or pipe. Conveys the smoke from the concrete furnace into the smokehouse. 6. Concrete furnace. It is where the smoke – producing materials are placed and burned. 7. Tight sheathing rafters. Serve as the top cover or roofing of a smokehouse. 8. Meshed screen. Serve as a closure to openings like the vents to keep flies and insects from entering the smokehouse. The Torry Smokehouse and Its Parts
Some Types of Smokehouse 1. Stainless Steel Smokehouse Mechanical Smokehouse
2. Electric Smokehouse
Smokehouse control and sensor of an Electric Smokehouse
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Barrel Type Cold Smokehouse
Brick Smokehouse
Freezer and Refrigerator The freezer and refrigerator are used in maintaining the freshness of raw materials and in providing an ideal low or ambient temperature for storing processed foods.
Freezer for Fish
Compression System of Refrigeration
A Two – Door Refrigerator
Absorption System of Refrigeration
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The Parts of the Compression System of Refrigeration and their Functions In a refrigerator, the heat evolved by the compression of a gas in the compressor is removed by condensing coils. Still under pressure, the gas cools and condenses into a liquid at the condenser which is released through a control valve into the evaporating coils of the freezing compartment. As the pressure is removed, the liquid refrigerant turns into a gas (vaporizes), causing a sharp lowering of temperature. The Parts of the Absorption System of Refrigeration and their Functions In this system, a small burner flame provides heat which drives out the gas from the ammonia – water mixture. It utilizes an insulated box to keep the cold in and an evaporating gas or refrigerant. A mixture of ammonia passes through the evaporating coils of the freezing compartment where it evaporates into ammonia gas. The evaporation of ammonia removes heat from the food. The ammonia gas then goes down to the absorber where it is absorbed by water. A small amount of heat from the burner flame drives out the gas from the ammonia – water mixture and condenses back into liquid ammonia as it passes through the condensing coils. Tools and Utensils Used in Food Processing and their Uses 1. Measuring Devices a. Weighing scales
The triple beam balance is used for measuring small quantities like spices, preservatives, etc., while the heavy duty scale is for measuring fish, salt, etc.
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Checkweigher scale is a digital weigher scale used to get the weight of food like meat, fish, vegetables, fruits, etc.
Clock Type weighing scale for food
b. Measuring spoons A measuring spoon is used to measure an amount of a substance, either liquid or dry, when cooking. Measuring spoons may be made of plastic, metal, etc.
c. Measuring Cups A measuring cup is a kitchen utensil used primarily to measure the volume of liquid or powder-form cooking ingredients such as water, milk, juice, flour, etc. Measuring cups can be in plastic, glass and stainless. From mini shot measure to measuring pitcher and batter bowl.
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Measuring cups for measuring liquid ingredients like milk, vinegar, fish sauce, etc.
Measuring cups for solid ingredients like flour, salt, minced garlic, etc
c. Thermometers Thermometers indicate the degree of hotness or coldness of a thing or body. It measures how high or how low the temperature is.
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Glass Tube Thermometers d. Salinometer It is used to measure the salinity of a brine.
Salinometer
f. Psychrometer It is used to measure the relative humidity of the air when sun drying.
Digital Sling Psychrometer
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e. Anemometer It is used to determine the velocity of the wind in sun drying.
2. Cutting Implements a. Knives For cutting or slicing fish or meat; for scaling fish
b. Filleting knives
For filleting fish
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c. Scissors
For trimming – off fins of fish
3. Descaler or scalers They are used in removing the scales of a fish.
Electric Fish Scalers 4. Salting Equipment
salted fish
Oil drum – used as a container to keep during the process
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Earthen pots are used in storing the salted products.
Wooden salting vat is a container used in the salting process.
Wooden shovel or spade is used for mixing or stirring the mixture of salt and small fish for salting
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5. Smoking Equipment
Baklad made of bamboo used in drying the fish prior to smoking
Bakol is a bamboo basket used to transport smoked fish
Bistay is a bamboo basket for collecting sun dried fish
Dinarayan is a smoking tray made of wood
Panakip is a bamboo cover used to keep fish submerged in the brine while boiling
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Panandok is a big metal ladle to scoop up the cooked fish from the boiling brine
Bamboo poles used to hold the baklad with brine cooked fish while drying.
Pugon is a concrete heat source used when pre-cooking fish in a brine
6. Others
For picking up or handling food
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It is where fish or meat are ingredients are sliced or minced.
cut;
Sanitizing Agents: Uses and Specification Sanitizing agents are substances used in cleaning the tools, equipment and utensils thoroughly by disinfecting or sterilizing them to make them free from germs or microorganisms which may contaminate the food to be processed. Disinfecting the tools, equipment and utensils involves the use of chemicals that destroy or inhibit the growth of microorganisms that cause spoilage of food. Sterilizing involves destroying germs or microorganisms with the use of heat and substances capable of killing all germs and microbes. The use of sanitizing agents leads to effective sanitation of tools, equipment and utensils. Sanitation with the use of physical and chemical sanitizing agents will kill residual microorganisms that remain after cleaning. Cleaning by washing with soap and water is very important as it ensures the removal of dirt or debris by physical and/or mechanical means. Clean water is to be used to finally wash and rinse all utensils, tools and equipment. Sanitizing or disinfecting, on the other hand, rids or reduces the number of micro-organisms on surfaces where food comes in contact with. It cannot be accomplished until surfaces where foods are processed are clean. Moreover, it cannot be effective without a good pest control program. Cleaning alone by washing does not totally eradicate microbes, germs and viruses, hence there is a need to use sanitizing agents. Some sanitizing agents are detergent solution for scrubbing surfaces of processing tables, 150 – 200 ppm chlorinated water for sanitizing. All tools and utensils are also cleaned and sanitized with the use of detergent solution rinsed with tap water before sanitizing with 150 – 200 ppm chlorinated water by soaking.
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In preparing a sanitizing agent from 5.25 % sodium hypochloride diluted with water, consider the following: Area to be sanitized with recommended chlorine concentration
volume of desired solution 1 liter (1000ml) 1 gallon 5 gallons volume of sodium hypochloride
Remarks Dilute the amount of sodium hypochloride required up to the
Hand dip (30 ppm) (350 ppm) Floor ( 350 ppm) Equipment (150 ppm) (200 ppm) water for food processing (75 ppm) for washing vegetables dressed chicken, etc.)
0.57 ml
216 ml
108 ml
volume of desired Footbath
6.67 ml
25 ml
125 ml
solution as indicated
6.67 ml
25 ml
2.86 ml 3.81 ml
10.8 ml 14.4 ml
1.43 ml
5.40 ml
125 ml 54 ml 72 ml
in each corresponding column to obtain the needed concentrated on of chlorinated water
27 ml
The Recommended Levels Used for Sanitizing Agents Specific Area/Condition Aluminum equipment and utensils Concrete floors Glass Materials Hand dip/hand sanitizer Plastic crates Stainless steel surfaces or equipment and utensils Wood crates
Recommended Sanitizer Iodophor Quat Active Chlorine Quat Active chlorine Iodophor Acid sanitizer Ethyl alcohol
Concentration 25 ppm 250 ppm 1000 – 2000 ppm 500 – 800 ppm 1000 ppm 25 ppm 130 ppm 70% - 75%
Iodophor Acid – anionic Active chlorine Iodophor Quat Active chlorine
25 ppm 130 ppm 200 ppm 25 ppm 200 ppm 1000 ppm
Proper Stowing of Tools, Equipment and Utensils Tools, equipment and utensils must be properly stowed in order to protect them from rusting, contamination, etc. and thus lengthen their serviceability. They must be kept in clean cabinets which are well – ventilated and not subjected to drafts or rain. Tools and utensils which were washed must be drained and wiped – dry before keeping them. They should be kept in an orderly way in order to assemble them easily or prepare them when needed. 22
The cabinets or racks where they are kept must be properly labeled for easier identification on the part of the user. Inspecting and Checking Condition of Equipment and Machines Before any equipment or machine is used, it must first be checked to make sure that it functions well and in good condition. Checking and inspecting equipment and machines will guarantee that all parts are in tact and that no part is missing or defective. This will also assure that electrical plugs and wirings are not defective and will not in anyway cause problems on short circuits, electrocution or any form of accident. Religiously checking and inspecting equipment and machines will facilitate Preventive Maintenance which include checking the following: 1. 2. 3. 4. 5. 6. 7. 8.
Machine temperature Hydraulic fluid Wear and surface condition Crack Leak detection Vibration Corrosion Electric insulation
LET US REMEMBER Performing pre–operation activities ensures that all the tools, equipment and utensils assembled, checked, inspected, sanitized, readied and stowed after use are the appropriate devices required in processing the food based on the method of processing that will be undertaken like salting, curing, smoking, fermentation, pickling, canning, bottling, processing using sugar, drying, and dehydration or artificial drying. Doing this will prevent the use of inappropriate devices as well as the occurrence of accidents due to the use of faulty or defective tools, equipment and utensils. Sanitizing and disinfecting the tools, equipment and utensils will destroy all germs and microorganisms which were not removed after washing with soap and water. Proper cleaning and disinfecting leads to: 1. minimizing product rejection, return and complaints due to defects resulting from the use of defective or inappropriate tools, equipment and utensils; 2. lengthening product shelf life due to the reduction of contamination resulting from the use of properly sanitized and disinfected tools, utensils and equipment; 3. reduction of the risk on food poisoning due to the use of unsanitized tools, equipment and utensils; and 4. facilitating preventive maintenance which include checking the machine temperature, hydraulic fluid, wear and surface condition, crack, leak detection, vibration, corrosion, and electric insulation.
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HOW MUCH HAVE YOU LEARNED? Post-Test Multiple Choice Directions: Carefully read the questions and choose the best answer from the options given. Write only the letter of your answer in your test booklet. 1. Which of the following tool/equipment specifications are used by manufacturers? a. dimension as to size, height, capacity, etc. b. handling and operating requirements c. proper care and maintenance d. all of these 2. Why are specifications for food processing tool, equipment and utensils necessary? a. they provide information to the user on how to handle and operate the equipment properly. b. specifications give information concerning the proper use, care and maintenance of the tools, equipment and utensils c. it provides information about the tools, equipment and utensils d. both a and b 3. If you are a food processor, why do you need to know the parts of the equipment, tool and utensil and their functions? a. to appreciate the usefulness of a particular device b. to be able to correctly operate/manipulate a tool, equipment or utensil c. to be able to do some simple repairs on them d. to easily determine if a part is missing 4. If you are going to pack processed foods in tin cans, why do you need to seal it with a can sealer? a. cans cannot be sealed manually b. tin cans are difficult to seal c. to properly seal them d. a can sealer is the appropriate equipment for attaching the cover to the body of a tin can with is first and second operation rolls 5. Which of the following will help you determine the kinds of tools, equipment and utensil you will assemble, sanitize, inspect or check? a. the kind of product to be produced b. the method of food processing to be done c. the raw materials to be processed d. the availability of tools, equipment and utensils 24
6. You have already removed the dirt from the tools, equipment or utensils you have used in processing the food by washing them with soap and water. Why do you still need to sanitize or disinfect them? a. washing with soap and water only removes the adhering dirt b. washing alone cannot remove the microorganisms and germs c. to effectively kill or destroy all the germs and microorganisms which remained after washing d. all of these 7. Which of these is a sanitizing agent you can use for killing the germs and microorganisms present in tools, equipment and utensils? a. sodium chloride b. sodium hypochloride c. magnesium sulfate d. calcium chloride 8. How will you properly store tools, equipment and utensils after using them? a. wipe dry all tools, equipment and utensils which were washed with water before keeping them b. stow them in a clean dry place with a good ventilation c. apply lubricant to parts of equipment that undergo friction to prevent wear and tear d. all of these 9. Why is it necessary to inspect and check the condition of equipment and machines before operating them in order to __________. a. in order to check if no parts are defective or missing b. in order to check if electrical plugs are in good condition c. in order to see if they are old or new ones d. both and b 10. Which of the following preventive machine maintenance will you check before using equipment or a machine? a. machine temperature and hydraulic fluid b. wear and surface condition c. crack and leak detection and electric insulation d. all of these
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LET US APPLY WHAT YOU HAVE LEARNED Demonstration with Direct Observation: Perform/Demonstrate the following pre – operation activities: 1. Assembling tools and utensils for drying fish 2. Checking and inspecting the parts of equipment like can sealer and pressure cooker 3. Sanitizing utensils for food processing Oral Interview for the Valuing Test: 1. If you are going to process food you need to assemble, check, inspect, and sanitize equipment, tools and utensils. Why do you need to do this? 2. Do you think it is important to perform pre-operation of equipment and machineries by checking and inspecting them? Why? RESOURCES: The following resources are needed:
Food processing tools, equipment and utensils Minor preventive machine maintenance (like hydraulic fluid) Sanitizing agents
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REFERENCES: Learning Element for Drying, Packing and Storing of Fish, CDD, BTVE Learning Element for Distinguishing Salting, Drying and Smoking, BTVE Fishery Arts for Secondary Schools Exploratory by Pepito Fernandez, Enrico Villoso and Leonarda Mendoza, copryright 1980 Fish Smoking prepared by Technology Development Institute of DOST Food Preservation for Filipinos by Rosalinda T. Lagua, Carmelita P. Cruel and Virginia S. Claudio, copyright 1977 Food Safety and Sanitation, A Paper Presented at Foresights on Food Safety, International Food Safety Seminar at Seoul, Korea on April 24, 2006 Philippine Handbook on Fish Processing by Jasmin M. Espejo Post Harvest Fisheries by Laurentina Paler – Calmorin, Copyright 2006 THE III. Agriculture and Fishery Technology, SEDP Series, Department of Education Training Regulations for Food Processing NC II, TESDA, Metro Manila http://www.saltinstitute.org/ http://www.salttraders.com/StoreFront.bok http://www.slate.com/id/2117243 http://www.gourmetsleuth.com/saltguide.htm http://www. image.google.com
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LESSON 2. OPERATE FOOD PROCESSING EQUIPMENT WHAT IS THIS LESSON ABOUT? The lesson deals with the study and interpretation of manufacturers specifications, the equipment or machine wear and tear process; dismantling and assembling the equipment or machine parts; performance of machine trouble shooting and reporting equipment or machine, tools and utensils breakdown. It also includes recording breakdown of equipment or machine, tools and utensils in standard form. WHAT WILL YOU LEARN? At the end of the lesson, you should be able to: 1. Switch on food processing equipment according to teacher’s instructions/manufacturer’s specifications; 2. Check the performance of food processing equipment to ensure conformity with specified output; and 3. Observe accuracy and safety precautions in operating food processing equipment. WHAT DO YOU ALREADY KNOW? Let’s find out how much you already know about operating foodprocessing equipment. Answer the given pre test below to find out what you still need to know. Good luck! Pre-Test: Multiple Choice Directions: Carefully read the questions and choose the best answer from the options given. Write only the letter of your answer in your test booklet. 1. It is important to interpret correctly the manufacturer’s specifications of equipment before operating them in order to ___________. a. to be able to determine the correct operation of the equipment b. to avoid accidents due to faulty operation of equipment c. to be familiar with their parts and their function d. all of these
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2. In choosing food processing equipment, why is it better to choose those with parts easy to assemble and disassemble? a. for easily taking the parts apart if it breakdown b. to easily put back the parts after dismantling them c. both a and b d. because they are cheaper 3. Why should you check equipment that is electrically operated before using them? a. to make sure plugs, outlets and electrical insulation are not defective b. to prevent accident c. to practice using the equipment d. to avoid errors and accidents in their operation 4. Your teacher instructed you to use a blender in preparing mango jam. It is your first time to use such equipment. Which of the following will you do? a. read the manual containing the manufacturer’s specification b. practice using the blender c. ask your classmate to demonstrate it to you d. you will not do anything 5. Your can sealer is not sealing properly. Which of the following will you do? a. do not use it any more b. request for a new sealer c. undertake simple troubleshooting d. borrow a can sealer from another class 6. Why should food contact surfaces of machine or equipment be regularly lubricated? a. to prevent wear and tear b. to prevent corrosion c. both and b d. none of these 7. You find difficulty in turning the knobs of the pressure cooker you are using, which of the following will you do? a. change the knobs b. apply lubricants like grease or oil at the screws c. remove the knobs d. don’t do anything
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8. Your teacher instructed you to check and inspect all the food processing equipment in your laboratory room. Which of the following will you do later? a. prepare a written report following the standard format b. make a checklist of the tools and equipment inspected c. make an oral report d. none of these 9. Why should you operate or use equipment in accordance with manufacturer’s specifications? a. to correctly operate them b. to be familiar with their parts and functions and to correctly operate, care and troubleshoot them c. to determine cost of equipment d. to be familiar with the necessary safety precautions to observe 10. Which of the following equipment materials are porous to bacteria, absorb moisture and impart odor and color to the food? a. plastic b. metal c. stainless steel d. wood Test for Valuing: Answer these questions briefly: 1. As a food processor, is it important that you must correctly operate food processing equipment? Why? 2. When operating food processing equipment why do you need to observe safety precautions? Explain. LET US STUDY Let us define Assembling – fitting or putting together the parts of a machine like an equipment. Breakdown – to go out of working order as in a machine. Calibrate – to fix, check, or correct the graduation of a measuring instrument as in a thermometer. Dismantling – disassembling; taking apart the parts of a machine. Equipment – tools, supplies and other items needed for a particular task or activity; the appliances: stoves, ovens, etc.; and storage containers, such as refrigerated units used in food establishments. 30
Specification – is the detailed description, dimensions, materials, etc. of something, especially one detailed enough to provide somebody with the information needed to make that thing. Trouble shooting – locating and repairing mechanical breakdowns Equipment are tools, supplies and other items needed for a particular task. When processing food, there are several equipment that are to be used. These include the following: 1. cooking equipment like ovens and steam – jacketed kettles; 2. refrigeration and low temperature – storage equipment like refrigerators and freezers; and 3. cutting implements like slicers, mixers, grinders and choppers, etc. A food processor, however, must know the essential information regarding the equipment in terms of how they must be operated or used in accordance with the manufacturer’s specifications. Before operating any equipment, it is important to be familiar with the manufacturer’s specifications, which include: 1. 2. 3. 4. 5. 6. 7.
handling requirements; operating requirements; discharge label; reporting; testing; positioning; and refilling
Interpreting Manufacturer’s Specifications Food processing equipment when sold are provided with a manual containing the manufacturer’s specifications and a necessary reminder to the processor in the form of a sticker or Warning Label is attached to the equipment itself as an assurance that the equipment/machine or tool is in excellent condition for it has passed quality control in its construction. The specification usually gives a detailed description about the equipment, dimensions, materials, and other relevant information regarding the equipment or machine. The dimension gives the measurement of the size of an object in terms of length, width, or height of the equipment/machine or tool.
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The capacity specifies the measurement of the amount, which a device can hold or contain as in boilers, cooker, or steamers or a weighing scale. The manufacturer’s specifications are usually contained in the manual, which accompanies the equipment. The food processor must thoroughly read and understand all the information contained in the manual especially if the equipment is to be operated electrically. Aside from knowing the correct operation of the equipment or machine, it is also important to know this information: 1. Basic safety precautions to follow when using the equipment 2. Warning labels which specify how to properly operate an equipment 3. Instructions on the proper care of the equipment/machine 4. Instructions on the correct operation of the equipment The manufacturer’s specifications must be thoroughly read and understood by the food processor and sees to it that he interpreted them in such a way that a food processing equipment can be properly operated. Below are some examples of manufacturer’s specifications, which must be properly interpreted resulting to an accurate and safe operation/manipulation of an equipment/machine: Directions for Use of the Hydrometer 1. Clean the hydrometer thoroughly and dry it before using. Handle with clean dry hands or with clean cloth. 2. Use with fluid juices, otherwise if the liquid to be tested is thick or slimy, the resting point of the hydrometer will be uncertain. 3. Pour a small quantity of juice into a glass cylinder and drop the hydrometer carefully. 4. Make sure that the instrument is floating freely and touches neither the bottom nor the sides of the cylinder. 5. To read correctly, set eye level with the surface of the liquid. 6. Since the specific gravity of juices varies with temperature, bring the juice to the standard temperature for which the hydrometer is adjusted usually 16C or 60F or make the necessary corrections in the reading. Add 0.1% for every 3 above the standard and subtract 0.1% for every 3. Tips on the Proper Use and Care of a Refrigerator 1. Put only clean food in the refrigerator. 2. Put only clean containers in the refrigerator. refrigerating them. 3. Keep the refrigerator closed.
Wipe before
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4. Keep fatty substances and hands off the rubber seal or gasket of the refrigerator door. A gasket kept in good condition seals the cold air in the refrigerator. 5. Wash and clean the refrigerator once a week with warm water to which a little baking soda has been added. This is prepared by mixing one teaspoon of baking soda per quart of water. The exterior should be washed with soap and water and then rinsed and dried. Avoid the use of abrasives. 6. Remove ice cubes by letting cold water run over them in the ice – cube pan. Removing them with an ice pick is liable to puncture the pan. 7. Defrost the refrigerator as follows: a. Turn – off the freezing unit b. Refill the ice cube pan with warm water not hot water, and place it on the bottom of the shelf of the freezing unit c. Keep the drip tray in place to catch the melting ice that drops off d. Wash and refill the ice cube e. Wash the refrigerator and the drip pan. Never try to speed up defrosting by prying – off ice. f. When done, turn the freezing unit on. General Directions for Using Pressure Canners for Fruits and Vegetables 1. Assemble materials and equipment. Pressure should be thoroughly cleaned with soap and water. 2. Check jar rings and closures. Wash and rinse thoroughly. 3. Have plenty of boiling water available. 4. Sort food for size and degree of ripeness. 5. Pour hot water into washed jars until needed. 6. Follow specific directions for best results. 7. Preheat or precook food as per recipe. 8. Place 2 quartz of boiling water in cooker with basket in place. Set cooker on heat. 9. Place clean, sterile rubber rings on jar or cover as directed, when closure requires separate rings. Return jars to hot water until ready to fill. 10. Fill hot containers promptly with hot food according to given directions. 11. Fill jar to proper level with boiling liquid when recipe so requires. Don’t fill the container up to the top but allow space for any expansion. All equipment used should be clean. 12. Work out bubbles with a clean knife or spatula. Wipe sealing edge with clean wet cloth. 13. Adjust closures on jars according to directions for types of closures used. If bottles are used, close tightly and then turn back by ¼ inch. 33
14. Place each hot container inside the pressure canner. Do not have these containers in direct contact with pressure – canner bottom or sides. 15. Put cover on cooker and lock in closed position. Use maximum heat under it. 16. Watch for steam to come from the petcock. Petcock valve should be opened wide. Under no conditions should pressure be raised in the cooker until it is in exact position. 17. Allow steam to come out freely for 7 – 10 minutes to eliminate all air pockets. Close petcock. 18. Use maximum heat to raise pressure to required point and then lower heat to maintain the pressure desired. Start counting processing time the moment required pressure is reached. To eliminate fluctuations in pressure, pressure cooker should be kept at required point by raising or lowering the heat as needed. 19. Turn off heat at end of processing time or move cooker from heat at end of processing time when using electric stove or any other constant heat unit. 20. When canning in glass jars, allow pressure to return to zero of its own accord. When indicator reaches zero, let cooker cool for 2 – 3 minutes. 21. Open petcock. Remove cover from cooker. Under no circumstances should its cover be turned until dial on the steam gauge points to zero. Lift cover so steam is away from you. 22. Immediately toss dishtowel over cooker and containers. Let cooker stand for 3 – 4 minutes. 23. Remove basket of jars from cooker and place on board or towel free from draft. Be sure to follow the directions that come with pressure canner. Bear the alterations in mind. With regard to altitude processing, increase the pressure by 1 pound for every 508 meters or 2, 000 feet above sea level. How to Seal Tin Cans with Hand Automatic Can Sealer 1. Fasten sealer firmly to table or armchair using clamp. 2. Attach crank to worm shaft and tighten set screw. 3. Change the chuck, height washers, and levers to the size of can to be sealed. 4. Lower base plate by turning can lifter handle as far as possible to the left. 5. Place cover on can and set can on base plate. 6. Place the first operation roll and rivet in the first adjusting lever. 7. Raise can until it is clamped firmly between base plate and chuck.
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8. Turn crank clockwise (eleven turns) until the first operation roll is through half sealing. After half – sealing, the cans are placed in the pressure cooker for 15 minutes exhausting to form vacuum. 9. After exhausting the cans, remove first operation roll and put the second operation roll and rivet in the adjusting lever. 10. Turn crank clockwise (ten turns) until the second operation roll returns to its normal position away from the chuck. 11. Release sealed cans by turning can lifter handle as far as possible to the left. The machine is now ready to receive another can for sealing. Instructions for Changing the Automatic Can Sealer from One Size to Another 1. Pull down on chuck, which will slip out of place. While sealer is new it is sometimes necessary to force the chuck by placing a screwdriver against the chuck shaft, which is inside the chuck holder bushing. 2. Remove base plate, base plate shaft, and height washers. Put washers, marked with the size of can to be sealed on top of the compression spring. 3. Lift the rivet from the adjusting lever. Move the adjusting lever until the rivet is inserted into the hole marked with the size of can to be sealed. The rivet should be changed on both first and second operation side of sealer.
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How to Use the Pressure Cooker 1. Place one – and – a – half (1/2) inch water in the cooker 2. Put rack with stand in the bottom of the cooker. A rack can be old bottles or milk cans of the same height filled with water. 3. Place the packed glass jars on the rack in the cooker. 4. Put on the cover of the cooker. Be sure the cover arrow aligns with “line mark” on rim of the body of the cooker. 5. Tighten two opposite bakelite wing nuts or knobs at the same time evenly. Never tighten one wing nut or knobs at the same time evenly. Never tighten one wing nut or knob at a time. 6. Turn on the stove. The water in the cooker begins to boil at 212 F or 100C at sea level forming steam. The steam drives out the air through the vent pipe and heat begins to penetrate the glass jars. 7. Exhaust the air in the cooker for 8 to 10 minutes so that air cannot interfere with the passage of heat. 8. Close the vent pipe by putting the pressure regulator weight. The hole of the pressure regulator weight should correspond to the desired pressure directly over the vent pipe. For instance, if the desired pressure is 10 pounds so the pressure regulator weight hole of 10 be inserted over the vent pipe. 9. When vent pipe is closed, the steam can no longer escaped so the pressure rises up to the desired pressure. The pressure regulator weight jiggles or rocks when the pressure is reached. This is called coming up time (CUT). Water under pressure boils at temperatures above 212F. At 10 pounds pressure gauge pressure, water boils at 240 F. Then regulate the fire. 10. If desired pressure is reached, start counting the processing time. If processing time is 90 minutes, so maintain the pressure and temperature for 90 minutes. At this stage, heat penetrates the jar by conduction or heat passes from one vibrating molecule to another. It also penetrates by convection in which heated fluids expand, rise, and are replaced by cooker fluids. In other words, heat penetrates the jar by both conduction and convection. Likewise, headspace of one half (1/2) inch of the jar acts as a cushion. In jars, the pressure usually gets so great that most of the air is driven out under the cover. The pressure and temperature in the jar is finally the same with the pressure cooker. 11. At the end of the processing time, turn off the stove. Temperature and pressure begin to fall as the cooling off period starts. Wait until the gauge registers to zero (0) pressure and remove the pressure regulator weight. 12. Loosen two opposite bakelite wing nuts or knobs at the same time. When all wing nuts were loosened, open the cover of the cooker in slanting position away from the face. 13. Get immediately the glass jars one at a time from the cooker and close. Invert the glass jars to determine if bubbles continuous to flow as sign of good sealing. 36
14.
Cool the glass jars in room temperature as well as the cooker.
How to Care for the Pressure Cooker
1. Wash the pressure cooker if it is already cooled. 2. Store the cooker in a dry place. The cover is stored separately from the cooker body. 3. Be sure the cooker and cover are thoroughly dried to protect against pitting and corrosion. 4. Protect the metal – to – metal seal from being struck or dented. 5. Protect the metal - to – metal seal must be lubricated periodically with Vaseline oil to prevent the cover from scratching and sticking to the bottom. The metal – to – metal seal must not be permitted to become dry, as this could result on severe damage to the metal – to – metal seal and make it very difficult to remove the cover. 6. Wipe periodically the metal – to – metal seal with clean towel to remove any build – up of foreign material trapped in the lubricant. 7. Avoid hard scrubbing of the metal – to – metal seal to prevent damage. 8. The steam pressure gauge should be checked most often for its accuracy. 9. To prevent from pitting the cooker, wash, rinse and dry the cooker thoroughly every use. Do not wash the cooker while it is still hot. 10. Place lubricant on the threads of the bakelite wing nuts or knobs to help the knobs turn more easily and hold the cover securely to the cooker, preventing steam leaks. 11. Before using the cooker, hold the cover and bring against the light to see if vent pipe is clear. If you cannot see the light through the vent pipe, insert carefully a piece of wire in the vent pipe and run it gently in and out to be sure the tube is clear. Rinse the vent pipe with hot water. 12. Be sure there is always water in the cooker during canning. If cooker boils dry on the process of canning, never add cold water only hot water must be added. Do not subject cooker to sudden change of temperature, as this will cause expansion or contraction, which can crack a cast aluminum utensil. 37
13. Pressure cooker should never be made more than 2/3 full when cooking foods like arroz caldo with milkfish bone meal FPC. When coking foods which expand, fill cooker one – half full. Procedure for Calibrating Equipment Below is a sample of a manufacturer’s specification on calibrating a measuring device in order that the measurement that will be obtained is accurate: Calibrating a Loadtrac Consolidometer 1. Assemble the consolidometer with a hard steel disk of approximately the same height as the test specimen and 1millimeter smaller diameter than the ring. 2. Moisten the porous stones and filter papers. 3. Sufficient time, a minimum of 2 minutes, shall be allowed for the moisture to be squeezed from them during each increment of the calibration process. 4. Load and unload the consolidometer as in the test and measure the deformation for each load applied. 5. Plot corrections to be applied to the deformation of the test specimen. Equipment/Machine Wear and Tear One factor to consider in the selection/purchase of food processing equipment is the construction materials used in making the equipment/machine, tool or utensil. Food equipment and utensils have food contact and non – food contact surfaces. Food contact surfaces are the parts which normally come into contact with food or from which normally come into contact with food may drain, drip, splash, or spill into or onto a surface that is normally in contact with the food. Non – food contact surfaces are the remaining parts and the surrounding area that should not make contact with the food during the production. The food contact surfaces are usually the parts that undergo wear and tear due to rubbing surfaces, which undergo friction. The Food and Drugs Administration (FDA) and construction standards from Nation Sanitation Foundation (NSF) International and Underwriters Laboratories Inc. require food equipment and utensils to be: 1. 2. 3. 4. 5. 6.
Smooth Seamless Easily cleanable Easy to take apart, disassemble or dismantle Easy to put together or reassemble Equipped with rounded corners and edges
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Materials used in the construction of utensils and food – contact surfaces of equipment must be non – toxic and not impart color, odors, or tastes to foods. Stainless steel is a preferred material for food contact surfaces. Under normal use, the materials should be safe, durable, corrosion – resistant, and resistant to chipping, pitting, deterioration and wear and tear of parts. It must be noted that through constant use, equipment or machine parts suffer from wear and tear as a result of friction brought about by the rubbing surfaces or those that undergo corrosion due to a chemical reaction with substances present in the food. To be able to address problems on wear and tear of equipment/machine parts, they must be regularly inspected and checked to determine their condition. The right selection of equipment based on the construction materials will largely help in minimizing wear and tear that affects machine efficiency. Below are the kinds of construction materials for equipment: 1. Metals Chromium over steel gives an easily cleanable, high - luster finish. It is used in toasters, waffle irons, etc. Noncorrosive metals formed by the alloys of iron, nickel, and chromium are also used in the construction of food service equipment. Lead, brass, copper, cadmium, and galvanized metal must not be used as food – contact surfaces for equipment, utensils, and containers because they cause chemical poisoning if they come in contact with the food. 2. Stainless steel Stainless steel is the most popular materials for food operations. It is commonly used as food containers. It has a highly durable finish with a shiny surface which is easy to clean and maintain. 3. Plastic Plastics and fiberglass are frequently used in foodservice equipment because they are durable, inexpensive, and can be molded into different combinations.
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Some examples of plastics used in food establishments are: 1. 2. 3. 4. 5. 6.
Acrylics - used to make covers for food containers Melamines – used for a variety of dishes and glassware Fiberglass – used in boxes, bus trays, and trays Nylons – used in equipment with moving parts Polyethylene – used in storage containers and bowls Polypropylene – used for dishwashing racks
4. Wood Wood is light in weight and economical but it is porous to bacteria and moisture and it absorbs food odors and stains. Wood also wears easily under normal use, which requires frequent maintenance and repair. Wood is used for cutting boards, cutting blocks, etc. Equipment/Machine Parts Dismantling and Assembling Two of the FDA and construction standards from NSF International and Underwriters Laboratories Inc. for food processing equipment are easy to dismantle or disassemble and easy to assemble. To ensure that food processing equipment can be properly maintained in line with company or organization’s maintenance system. The condition of machine parts can be easily detected as to the presence of: a. wear and tear b. cracks c. leaks d. corrosion If the parts of equipment are easy to assemble and disassemble then the condition of machines or equipment can be easily reported as: a. serviceable b. repairable c. defective d. replaceable If the parts are easy to assemble and disassemble, it is easy to dismantle machine parts that breakdown so they can be repaired or replaced right away.
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Performing Minor Trouble Shooting One important skill required of anyone who uses or operates an equipment or machine is the ability to make minor repairs or trouble shooting with malfunctioning equipment or tools because of breakdown in their parts. Troubleshooting is done to locate and repair mechanical breakdowns. This is done by inspecting and checking machine parts to assess the condition of the machine/equipment and determine the appropriate measure to do as a way of addressing the problem. Equipment which are electrically operated are checked and inspected to find out if there are defective electrical insulations, plugs or outlets and thus prevent accidents on electrical circuits, etc. which may result to fire and other hazards in the work place. Machine parts, which undergo wear and tear due to friction and corrosion, must be regularly lubricated with appropriate lubricants like grease or oil for machine parts. Machine parts that easily undergo corrosion due to exposure to corrosive substances present in the food must be properly subjected to preventive maintenance. Machines/equipment with parts that have leaks and cracks must be checked to make sure the necessary repair or replacement if necessary. Reporting Breakdown of Equipment/Machine, Tools and Instruments Report preparation is important when using food processing equipment. The report will serve as a database for the company that serves as a ready source of information as to the condition of equipment and tools. This will help the company draft its contingency measures in relation with preventive maintenance measures that will prevent or minimize the breakdown of equipment or machines. Reports on breakdown of machine parts troubleshooting and procurement of parts needed replacement of parts that breakdown.
will facilitate for repair or
Below is a sample report on the breakdown of equipment/machine and tools: Equipment checked: Loadtrac Consolidometer Purpose: flexibility.
To
provide
instructions
for
checking
apparatus
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Inspection Equipment Required: Hard steel calibration disk. Tolerance: Tolerances are provided in the test methods shown above. Procedure: 1. Assemble the consolidometer with a hard steel disk of approximately the same height as the test specimen and 1millimeter smaller diameter than the ring. 2. Moisten the porous stones and filter papers. 3. Sufficient time, a minimum of 2 minutes, shall be allowed for the moisture to be squeezed from them during each increment of the calibration process. 4. Load and unload the consolidometer as in the test and measure the deformation for each load applied. 5. Plot corrections to be applied to the deformation of the test specimen. A Report on the Breakdown of Machine Parts Equipment
Type of Breakdown
Troubleshooting to be Undertaken
Parts to be Replaced
Remarks
Prepared by: ________________________ LET US REMEMBER All food processing equipment and tools must be properly operated in accordance with manufacturer’s specifications in order that they will properly function and serve their purpose. However, it is important that they must be regularly checked and inspected to determine the needed preventive maintenance to undertake. If machines breakdown, they must undergo troubleshooting right away in order to determine their condition as to: a. serviceability b. reparability c. defectiveness
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HOW MUCH HAVE YOU LEARNED? Post-Test Multiple Choice 1. It is important to interpret correctly the manufacturers specifications of equipment before operating them in order to ___________. a. to be able to determine the correct operation of the equipment b. to avoid accidents due to faulty operation of equipment c. to be familiar with their parts and their function d. all of these 2. In choosing food processing equipment, why is it better to choose those with parts easy to assemble and disassemble? a. for easily taking the parts apart if it breakdown b. to easily put back the parts after dismantling them c. both a and b d. because they are cheaper 3. Why should you check equipment that are electrically operated before using them? a. to make sure plugs, outlets and electrical insulation are not defective b. to prevent accident c. to practice using the equipment d. to avoid errors and accidents in their operation 4. Your teacher instructed you to use a blender in your activity of preparing mango jam. It is your first time to use such equipment. Which of the following will you do? a. read the manual containing the manufacturer’s specification b. practice using the blender c. ask your classmate to demonstrate it to you d. you will not do anything 5. Your can sealer is not sealing properly. Which of the following will you do? a. do not use it any more b. request for a new sealer c. undertake simple troubleshooting d. borrow a can sealer from another class 6. Why should food contact surfaces of machine or equipment be regularly lubricated? a. to prevent wear and tear b. to prevent corrosion c. both and b d. none of these 43
7. You find difficult in turning the knobs of the pressure cooker you are using, which of the following will you do? a. change the knobs b. apply lubricants like grease or oil at the screws c. remove the knobs d. don’t do anything 8. Your teacher instructed you to check and inspect all the food processing equipment in your laboratory room. Which of the following will you do later? a. prepare a written report following the standard format b. make a checklist of the tools and equipment inspected c. make an oral report d. none of these 9. Why should you operate or use equipment in accordance with manufacturers specifications? a. to correctly operate them b. to be familiar with their parts and functions and to correctly operate, care and troubleshoot them c. to determine cost of equipment d. to be familiar with the necessary safety precautions to observe 10. Which of the following equipment materials are porous to bacteria, absorb moisture and impart odor and color to the food? a. plastic b. metal c. stainless steel d. wood LET US APPLY WHAT YOU HAVE LEARNED Demonstration with Direct Observation: Demonstrate the proper use of blender using the guides below. 1. 2. 3. 4. 5.
Check and inspect the blender and outlets. Insert the plug of blender into the outlet. Switch – on the blender. Operate blender in accordance with manufacturer’s specifications. Clean and sanitize in accordance with the specifications.
Oral Interview for the Valuing Test: 1. In doing the activity, what work values did you observe? 2. What safety precautions did you do? Why?
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REFERENCES: Essentials of Food Safety and Sanitation by David McSwane, Nancy Rue and Richard Linton, Copyright 2003 Preservation of Philippine Foods by Sonia Y. de Leon and Matilde P. de Guzman Post Harvest Fisheries by Laurentina Paler – Calmorin, Copyright 2006 RESOURCES:
Interpreting manufacturer’s specifications Equipment/machine wear and tear process Equipment/machine parts dismantling and assembling Performing minor trouble shooting Reporting equipment/machine, tools and instruments’ breakdown and recording same in standard forms
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LESSON 3. PERFORM POST-OPERATION ACTIVITIES WHAT IS THIS LESSON ABOUT? The lesson deals on the study of inspecting and checking the condition of equipment/machines before and after preparation and performing minor trouble shooting. It also includes minor preventive maintenance and reporting the breakdown of equipment/machine, tools and instruments as well as recording same in standard forms. WHAT WILL YOU LEARN? At the end of the lesson, you should be able to: 1. switch off and unplug food processing equipment after operation in accordance with manufacturer’s specifications; 2. clean, sanitize and stow food processing tools, equipment and instruments according to manufacturer’s specifications and workplace policies and regulations; 3. perform minor preventive maintenance in equipment in line with organization’s maintenance system; 4. inspect and check main machine parts in line with organization’s policy; 5. monitor condition of machine parts to ensure availability in accordance with workplace rules and regulations; and 6. perform post operation activities regularly to ensure serviceability of equipment/machines. WHAT DO YOU ALREADY KNOW? Let’s find out what you already know about performing post operation activities with food processing tools, equipment, utensils and instruments Pre Test: Multiple Choice Directions: Carefully read the questions and choose the best answer from options given. Write only the letter of your answer in your test booklet. 1. Why do you need to inspect and check equipment/machines before, during and after using them? a. to make sure they are in good condition b. to determine defective machine parts c. to determine trouble shooting activities to perform d. all of these
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2. If you regularly inspect and check equipment/machines, which of the following could be determined? a. damaged or defective machine parts b. equipment/machines that breakdown c. c. both a and b d. total number of equipment/machines in the company 3. Your teacher assigned you to check machine parts which easily corrode or wear out due to rubbing surfaces. Which of these will you do as a preventive maintenance? a. wash and wipe dry b. apply lubricant like oil or grease c. remove the rusts with sandpaper d. replace those part 4. There is a strong odor of a gas coming from the LPG tank of the gas range in your Food Processing Laboratory Room, what do you think happened? a. the LPG tank has a leak b. The hose connected to the LPG might be leaking c. The LPG regulator is defective d. All of these 5. In order to prevent electrocution or fire due to short circuits, which of the following should you do before using any equipment/machine? a. check electrical outlets b. check plugs and switch of electrical equipment/machines c. check electrical cords d. all of these 6. The rivet of your can sealer is missing so you can not seal the tin cans filled with fish to be processed. What will you do to solve the problem? a. replace the missing rivet b. buy a new can sealer c. repack the fish in glass jars d. none of these 7. You are assigned by your teacher to maintain the good condition of your pressure cooker. What will you do? a. lubricate the metal – to – metal cover b. check the vents to make sure they are not clogged c. inspect and check to make sure that all parts are intact and in good condition d. all of these 8. Which of these is a manufacturer’s specification concerning the use of a freezer in the food processing plant? a. Switch off before unplugging b. Just unplug even if not switched off c. Do not defrost regularly 47
d. None of these 9. To prevent the metal surface of your gas range, oven and gas stove to corrode, which of the following should you do? a. wash with soap and water b. wipe off spilled food then wash and wipe thoroughly c. scrape the surfaces with spilled food then apply lubricants d. d. none of these 10. What could be the condition of an equipment if it is properly inspected, checked? a. repairable and serviceable b. defective c. both a and b d. none of these Test for Valuing: Complete the unfinished sentence below: After using equipment/machines, I must regularly perform post operation activities with utmost accuracy so that the equipment/machine will__________________________________________. LET US STUDY Let us define 1. Breakdown – is a mechanical failure causing a machine or equipment to malfunction. 2. Check – to test the accuracy; to examine something in order to establish its state or condition. 3. Corrosion – rusting or gradual wearing of machine parts due to chemical reaction between substances like iron and oxygen or other corrosive materials like salt, acids, etc. 4. Crack – a break or fissure on some parts of an equipment as in the body of a pressure cooker. 5. Electrocution – death or execution from electric shock. 6. Inspect – to carefully examine a machine or equipment in order to determine maintenance to undertake.. 7. Leak – a crack or hole through which a liquid or gas may accidentally pass. 8. Lubricant – a substance like oil or grease that coats or treats a machine to lessen friction and the wear and tear of machine parts due to constant rubbing of surfaces. 9. Preventive Maintenance – a system of maintenance that aims to minimize or eliminate breakdown in equipment and machinery by a program of regular inspection and repairs. 10. Repairs – to restore a machine or equipment that breaks down into good order or condition. 11. Switch – electrical device having two (2) states, ON (closed) OFF (open)., 12. Switch – off – to turn off an electrical device. 13. Stow – to pack or store in an orderly way. 14. Troubleshooting – systematic approach to locate the cause of a fault in an electronic circuit or system. 48
Equipment are essential machines in a food processing plant that are important in undertaking activities in line with processing foods like fish, meat, fruits and vegetables through salting, smoking, drying, pickling, freezing or canning. In every method of processing or preserving the food, different kinds of equipment are used. To ensure that there is a smooth operation of any equipment, they must be properly maintained. Proper maintenance starts with regular checking and inspection of their parts, proper use or operation/manipulation, and conducting post operation activities such as cleaning/sanitizing, applying oil and lubricants to machine parts before stowing or storing them until such time that they will again be used. Equipment/machines which undergo regular preventive maintenance have a longer serviceability and are more efficient in terms of their operation. Inspecting and Checking Condition of Equipment/Machines Before, During and After Operation All equipment/machines to be used in processing /preserving foods like fish, meat, fruits and vegetables must be inspected and checked to determine their condition prior to use and even after using them. Before they are to be stowed or kept after use, they must be inspected and checked to make sure they are in good condition and ready for use in the next processing operation. Religiously inspecting and checking the equipment/machines after use will help determine the presence of damaged or defective parts that need to be repaired or replaced. Inspecting and checking the equipment /machines will also help determine the presence of equipment/machines that breakdown and cannot be used in the next processing operation. Defective plugs, switch and other parts of equipment/machines that are electrically operated will also be determined and thus avoid accidents like electrocution and other hazards arising from short circuit, etc. Inspecting and checking the equipment before, during and after using them will also help in effectively planning and efficiently carrying – out trouble shooting and preventive maintenance activities which include checking the following: 1. Machine temperature – this is checked to avoid overheating 2. Hydraulic fluid – this must be checked to guarantee that the
equipment/machine which is operated by water or other liquids moving through pipes under pressure will function well 3. Wear and surface condition – this is being checked to make sure no machine parts are deteriorating or defective due to everyday use 4. Crack – this needs to be checked to see to it that there are no broken parts in an equipment or machine which will cause the breakdown of the machine or as a source of leak
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5. Leak detection – this is checked to prevent accidental release of
gas, water, oil, etc. from the machine 6. Vibration 7. Corrosion – this is checked to minimize wear and tear of parts
by washing, drying and lubricating machine parts. 8. Electric insulation – this must be checked to guarantee that there are no livewires exposed during the operation of an equipment which may result to short circuits or electrocution and even fire. All equipment/machines must be strictly inspected and checked for any defects like leaks, cracks, missing parts, etc. They must be repaired if necessary and discarded if no longer repairable and replaced with a new one. There must be a continuous inspection and checking of equipment/machines to guarantee regular preventive maintenance servicing based on the maintenance schedule for every equipment/machine. Below are some equipment used in processing foods that need to be regularly inspected and checked before, during and after operation: 1. The Can Sealer
2. The Pressure Cooker
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3. The Mechanical and Electric Smokehouses
4. The Freezer and Refrigerator
5. The Electric Fish Scalers
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6. The Oven and Gas Stove
Gas stove
7. The Food Processor/Blender and Juice Extractor
8. The Vacuum Packer
9. The Electric Polysealer
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Performing Minor Troubleshooting Troubleshooting on equipment or machines that breakdown is very essential in a food processing plant. This is a way by which faulty or malfunctioning or defective machine parts are diagnosed and their appropriate repair or replacement is effectively done. Performing minor troubleshooting of equipment or machines that breakdown ensures a longer capability of the equipment or machine to be operated or used. Minor troubleshooting must be done in accordance with manufacturer’s specification by a repairman who is an expert on the troubleshooting of equipment or machines that breakdown. Below are some minor troubleshooting activities that are undertaken: 1. Replacement of the defective parts of equipment like can sealer, pressure cooker, gas stove and gas range, etc. 2. Replacement of the missing parts of a can sealer, pressure cooker, gas range, gas stove, etc. 3. Replacement of defective or malfunctioning electrical cords, plugs and switch of electrically operated equipment like freezer, refrigerator, smokehouse, fish scalers, blenders, poly sealers, etc. 4. Applying lubricant to machine parts that are slightly undergoing corrosion or wear and tear. 5. Replacement of machine parts with cracks or leaks. 6. Replacement of leaking pipes in equipment requiring hydraulic fluid. Performing Minor Preventive Maintenance Preventive Maintenance is a system of maintenance that aims to minimize or eliminate breakdown in equipment and machinery by a program of regular inspection and repairs. This is done make sure that all equipment machines in the food processing plant are always in good condition and ready for use anytime. Regularly inspecting the condition of equipment or machines and promptly repairing those ones that breakdown will guarantee that the processing of food will be smoothly undertaken as required by the company thus, eliminating or minimizing the occurrence of accidents or faulty operation of equipment or machines. It is important to remember, however, that the preventive maintenance activities to be undertaken must be in conformity with manufacturer’s specification and in line with company’s policy. The following are some minor preventive maintenance done with equipment or machines: 1. Checking the switch, plugs and electrical cords of electrically operated equipment. 2. Checking the parts of some equipment or machines to determine if there are defects, wear and tear, cracks, leaks, rusts or corrosion. 53
3. Checking the equipment or machine thoroughly to make sure that all parts are intact. Missing parts will cause the equipment or machine to malfunction. 4. Cleaning, sanitizing and stowing all equipment or machines according to manufacturer’s specifications and workplace policies and regulations. 5. Regularly checking and inspecting main machine parts to guarantee that the machine is in top shape or condition. 6. Checking the condition of the machine and classify them as: a. Serviceable b. Repairable c. Defective 7. Applying lubricants like oil and grease that undergo corrosion and friction to prevent or minimize wear and tear of rubbing surfaces. 8. Checking machine temperature, hydraulic fluid, vibration, etc. 9. Performing proper cleaning, care and sanitation. Below are examples of how some equipment/ machines are properly maintained or cared for: The Pressure Cooker 1. Thoroughly wash with soap and hot clean water then drain completely before and after use. 2. Lubricate the metal – to – metal seal with cooking oil, petroleum jelly, Vaseline, etc. to prevent the cover from scratching or sticking. Check this seal from time – to – time during the canning process to be sure sufficient lubrication is present. Apply a thin film of lubricant to the edge inside the cooker where the inside wall begins to bevel. 3. Apply lubricant on the threads of the bakelite wing nuts; wipe away excess lubricant. 4. Always keep safety openings clear to make sure steam can pass through them. 5. Before and after using the cooker, clean the vent pipe by carefully inserting a thin piece of wire in the vent and run it gently in and out to be sure it is clear and unobstructed. Rinse with hot water. 6. Do not subject the cooker to sudden extreme temperature changes as this will cause expansion or contraction which can crack the cast aluminum pressure cooker. Do not add cold water to a cooker that boiled dry or cool a hot cooker suddenly by pouring cold water or wrapping it with wet cloth. 7. If you ever drop the cooker, it must be examined for damage. 8. Periodically wipe – off the metal – to – metal seal with a clean towel to remove any build – up of hardened lubricant. Avoid hard scrubbing of the metal – to – metal seal to prevent damage.
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9. Prevent discoloration by scrubbing with an aluminum cleaner or soap impregnated steel wool cleaning pad. Pitting of the cooker is prevented by washing, rinsing, and drying the unit thoroughly every after use. 10. Always store the cooker in a dry area when not in use. The cover should be stored separately from the cooker or upside down on the cooker to allow air circulation. Always be sure cover and cooker are thoroughly dry to protect against pitting and corrosion. 11. Protect the metal – to metal seal from being struck and dented. The Can Sealer The parts of an automatic manual can sealer are easier to dismantle and assemble as compared with the automatic electrically operated sealing machine. However, when dismantling or assembling the parts of the can sealer, careful handling is required to make sure all parts are properly in place and not a single part is misplaced or lost. Before assembling the parts, these must be done: 1. Check that all parts are present. 2. Lubricate parts that rub each other to prevent friction that leads to wear and tear of surfaces. 3. Lubricate the crankshaft, the seaming head, bevel gears, clamp, etc. Wipe away excess lubricant. 4. Wash the chuck and the base plate after sealing tin cans with soap and clean water to remove oil, sauce and brine that spilled on them. Rinse thoroughly. Wipe dry with a clean towel. 5. Store in a clean dry place. 6. Replace all damaged, missing or defective parts. The Freezer 1. Use the freezer in accordance with purpose described in the user’s manual. 2. Properly install the freezer in accordance with installation requirements. 3. Switch control to OFF before unplugging. 4. Unplug the freezer before cleaning, before repairing any parts by a qualified repairman. 5. Always grip plug firmly and pull straight out from the outlet, when unplugging. 6. When moving the freezer away from the wall, be careful not to roll over or damage the power cord. 7. Immediately repair or replace all electric service cords that have become frayed or otherwise damaged. Do not use a cord that shows cracks or abrasion damage along its length or either the plug or connector end.
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8. After the freezer is in operation, do not touch the cold surfaces, particularly when hands are damp or wet. Skin may adhere to these extremely cold surfaces. 9. Operate freezer away from explosive fumes. 10. Refrain from using electrical devices or sharp instruments in defrosting your freezer. 11. The freezer must be properly grounded when installed. 12. Defrost regularly. 13. Clean the interior to prevent food from being contaminated during storage. Remove detachable parts and wash in warm water and baking soda solution (Use 1 tablespoon of baking soda per liter of water). Follow the same procedure for cleaning the door gasket, wire basket, and all plastic parts. 14. Clean exterior surfaces with warm water and dish washing detergent. Dry and polish with a soft cloth. Do not wipe with soiled dish washing cloth or wet towel. This may leave residue that may corrode the paint. Do not use scouring pads, bleach or cleaners because they scratch and weaken the paint finish. 15. In case of brownouts, turn the temperature control to OFF and unplug your freezer to avoid OVERLOADING your compressor when power is restored. The Refrigerator The refrigerator which has an automatic defroster should be thoroughly cleaned every week by wiping off containers of food and removing all foods that cannot be used. Refrigerators which do not have automatic defrosters should be defrosted whenever the frost on the frosting unit is over ¼ inch thick. When caring for your refrigerator follow the procedure below: 1. Wipe up spilled food immediately. 2. Wash inside shelves and trays at least twice a week with 1 table spoon baking soda dissolved in 1 liter clean water. 3. Rinse and dry thoroughly. 4. Flush drains/defrost weekly. When defrosting the refrigerator follow these steps: 1. 2. 3. 4. 5.
Turn off the electric current. Remove all ice trays and frozen foods from the freezing unit. Wrap frozen foods in newspaper to keep them from thawing. Put the drip tray in the proper place to catch the melted ice. Place pans of hot water in the lower part of the freezing unit. Allow the ice to melt. Never use a sharp or pointed object to remove the ice. 6. Remove the food in the lower part of the refrigerator. 7. Wipe the inside portion of the freezing unit as well as the refrigerator with water to which 1 teaspoon baking soda has been added for each quart. 56
8. Turn on the current and return the food to the refrigerator. Properly use the refrigerator by following these steps: 1. 2. 3. 4.
Study the booklet which is supplied by the manufacturer. Keep the temperature between 35ºF and 45ºF. Allow the food to cool before putting it in the refrigerator. Open the door only when absolutely necessary and keep it open as short a time as possible. 5. Put leftovers in small dishes and use them as soon as possible to avoid overcrowding the refrigerator. 6. Remove food from paper bags before storing in the refrigerator. 7. Do not store unopened cans of food in the refrigerator unless they are to be chilled for the next meal. 8. Store foods in covered dishes or glass jars to prevent odors from spreading. 9. Avoid getting grease on the gasket around the door. 10. Decide on a definite place in which to keep each kind of food, and put the foods in the same places each time so that you will not waste time in looking for them. The Gas Range and Gas Stove In caring for your cooking equipment, follow the steps below: 1. Remove all burnt sediment and wipe grease from top of stove after each use 2. Scrape grease from cracks, openings, and hinges. 3. When cool, wash top of stove. 4. Keep burners clean. Gas burners can be soaked and scrubbed with a stiff brush. 5. Wipe with a clean cloth dipped in a sanitizing solution. Use and Care of the Gas Range and Gas Stove When using the range, remember to: 1. use utensils that are large enough to prevent the boiling food from spilling over the range top or oven; 2. keep a dish on the range top for the spoon that you use in stirring food; 3. avoid putting anything hot on porcelain enameled surfaces or putting cooking utensils across them the heat may cause the surface to chip or crack; 4. arrange pans in the oven so that the air can circulate around them; and 5. wipe the chromium trimming with a damp cloth and polish it with a dry cloth.
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Cleaning the Top of a Gas Range and a Gas Stove 1. Remove the burners and the rack and scrub them with warm, soapy water and scouring pad. 2. Clean the holes with a hair pin or wire. Do not use a toothpick. 3. Rinse with clear, hot water, and dry the rack; turn the burners of the oven upside down. 4. Return the burners and the rack to the range as soon as they are dry. Note: Be sure that the gas pipe does not have leaks. Cleaning the Units of an Electric Cooking Range 1. Turn on the high heat so that any food on the units will burn off. 2. Cool, and then brush each unit with a soft non-metallic brush. Never clean the unit with a metal brush, a fork, a knife, or a sharp metal tool. 3. Use steel wool or a cloth for units which are enclosed.
The Oven Follow these steps when cleaning your oven: 1. Use a pancake turner to remove food immediately after it has spilled on on the oven. 2. Clean the oven thoroughly with a special cleaner when it is cool. 3. Wipe the oven with soapy water. Rinse with clean water and dry. 4. Turn on the oven for a few minutes to dry all parts so that they will not rust. 5. Be sure the gas tank and hose do not have any leaks. Reporting the Breakdown of Equipment/Machine, Tools and Utensils The person in charge of inspecting and checking equipment/machines used in processing foods like fish, meat, fruits and vegetables must make the necessary report regarding the breakdown of equipment/machine, tools and utensils and furnish the report to the person responsible in scheduling the trouble shooting and repair of any equipment/machine, tools and utensils that breakdown. In preparing such report, it is necessary to follow the prescribed format required by the company or organization. This is done to rigidly monitor the condition of all equipment/machines to ensure their serviceability in accordance with workplace rules and regulations. Through the prepared reports, a conclusion as to the condition of equipment/machines can be accurately made as to: a) serviceable, b)repairable and c) defective. The compiled reports will provide a ready database as to the needs of the company in terms of: 58
1. machine parts to be purchased; 2. expenditures incurred for repair and purchase of machine parts; and 3. labor requirement for preventive maintenance and trouble shooting. A Sample Report on Equipment/Machine Breakdown Remarks Daily Inspection Report Condition
Date: and Before Operati on
During Operati on
After Operati on
Recomm endations
Can Sealer Pressure Cooker Mechanical/Electric Smokehouse Freezer Refrigerator Electric Scaler Oven Gas Range Gas Stove Food Processor/Blender Juice Extractor Vacuum Packer Electric Polysealer Inspected by:_______________________ Reviewed by: _______________________
LET US REMEMBER The use of appropriate equipment in top condition is of primary importance in the production of good food. Standardized equipment, a variety of knives, the right kitchen tools, utensils, and appliances all contribute to the production of processed food with an excellent quality. It is therefore important to religiously conduct post operation activities to make sure that equipment/machineries are properly inspected, checked, cleaned and sanitized and subjected to preventive maintenance in accordance with manufacturer’s specification and company policies. The Preventive Maintenance to be performed includes checking the following: 1. Machine temperature 2. Hydraulic fluid 59
3. 4. 5. 6. 7. 8.
Wear and surface condition Crack Leak detection Vibration Corrosion Electric insulation
HOW MUCH HAVE YOU LEARNED? Post Test Multiple Choice Directions: Carefully read the questions and choose the best answer from options given. Write only the letter of your answer in your test booklet. 1. Why do you need to inspect and check equipment/machines before, during and after using them? a. to make sure they are in good condition b. to determine defective machine parts c. to determine trouble shooting activities to perform d. all of these 2. If you regularly inspect and check equipment/machines, which of the following could be determined? a. damaged or defective machine parts b. equipment/machines that breakdown c. c. both a and b d. total number of equipment/machines in the company 3. Your teacher assigned you to check machine parts which easily corrode or wear out due to rubbing surfaces. Which of these will you do as a preventive maintenance? a. wash and wipe dry b. apply lubricant like oil or grease c. remove the rusts with sandpaper d. replace those parts 4. There is a strong odor of a gas coming from the LPG tank of the gas range in your Food Processing Laboratory Room, what do you think happened? a. the LPG tank has a leak b. The hose connected to the LPG might be leaking c. The LPG regulator is defective d. All of these 5. In order to prevent electrocution or fire due to short circuits, which of the following should you do before using any equipment/machine? a. check electrical outlets b. check plugs and switch of electrical equipment/machines c. check electrical cords d. all of these
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6. The rivet of your can sealer is missing so you can not seal the tin cans filled with fish to be processed. What will you do to solve the problem? a. replace the missing rivet b. buy a new can sealer c. repack the fish in glass jars d. none of these 7. You are assigned by your teacher to maintain the good condition of your pressure cooker. What will you do? a. lubricate the metal – to – metal cover b. check the vents to make sure they are not clogged c. inspect and check to make sure that all parts are intact and in good condition d. all of these 8. Which of these is a manufacturer’s specification concerning the use of a freezer in the food processing plant? a. Switch off before unplugging b. Just unplug even if not switched off c. Do not defrost regularly d. None of these 9. To prevent the metal surface of your gas range, oven and gas stove to corrode, which of the following should you do? a. wash with soap and water b. wipe off spilled food then wash and wipe thoroughly c. scrape the surfaces with spilled food then apply lubricants d. d. none of these 10. What could be the condition of an equipment if it is properly inspected, checked? a. repairable and serviceable b. defective c. both a and b d. none of these LET US APPLY WHAT YOU HAVE LEARNED Demonstration with Direct Observation and Questioning: Demonstrate how to perform preventive maintenance for these equipment/machines: 1. Can Sealer 2. Pressure Cooker Note: Your teacher will observe you while performing the tasks and be ready to answer these questions: 1. What important preventive maintenance did you conduct? Cite and explain briefly each of them.
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2. Why do you think it is important that you should subject the can sealer and the pressure cooker to preventive maintenance? Explain. 3. As a food processor, do you think it is important that you possess the knowledge and skill in performing post operation activities after using equipment/machines? Why? Practical Examination/Performance Test Activity: Perform Post Operation Maintenance on the following: 1. Gas stove 2. Blender 3. Refrigerator You will be rated by your teacher according to the following: 4 – Can perform the skills without supervision and with initiative and adaptability to problem situations 3 – Can perform the skills satisfactorily without assistance or supervision 2 – Can perform the skills satisfactorily but requires some assistance and/or supervision 1 – Can perform parts of the skills satisfactorily, but requires considerable assistance and/or supervision Oral Examination for the Valuing Test: 1. Why is it important that a report concerning equipment/machines that breakdown be prepared? Discuss briefly. 2. Why is important that you should be knowledgeable and skillful in performing minor preventive maintenance and troubleshooting on equipment/machines in the food processing plant? RESOURCES: Manufacturer’s specification may include but not limited to:
Handling requirements Operating requirements Discharged level Reporting Positioning Refilling 62
REFERENCES: Handout on Operating a Can Sealer Manual for The All American Pressure Canner/Cooker Manual on The Use and Car of GE Upright Freezer Manual on the Use and Operation of an Automatic Master Can Sealer Post Harvest Fisheries by Laurentina Paler – Calmorin, Copyright 2006. Other Sources http://www.image.google.com http://www.foodsaving.com
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Answer Key Lesson 1 1. 2. 3. 4. 5.
d c b d b
6. c 7. b 8. d 9. c 10. d
Lesson 2. 1. 2. 3. 4. 5.
d c a a c
6. a 7. b 8. a 9. b 10. d
Lesson 3. 1. 2. 3. 4. 5.
d c b d d
6. a 7. d 8. a 9. b 10. c
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Republic of the Philippines
Department of the Education PUBLIC TECHNICAL-VOCATIONAL HIGH SCHOOLS
Unit of Competency: Use Standard Measuring Devices and Instruments Module No.: 3
Module Title: Using Standard Measuring Devices and Instruments
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Module 3 QUALIFICATION TITLE
:
FISH PROCESSING NC II
UNIT OF COMPETENCY
:
THE USE OF STANDARD MEASURING DEVICES AND INSTRUMENTS
MODULE TITLE
:
USING STANDARD MEASURING DEVICES AND INSTRUMENTS
NOMINAL DURATION
:
20 Hours
CERTIFICATE LEVEL
:
NC II
WHAT IS THE MODULE ABOUT? This module covers the knowledge, skills and attitudes required for the use of standard measuring devices and instruments in the workplace. It also covers the identification of standard measuring devices and instruments and the procedure for using measuring devices and instruments. WHAT WILL YOU LEARN? Upon completion of this module, you should be able to: 1. identify standard measuring devices and instruments; 2. review procedure in using standard measuring devices and instruments; and 3. follow procedure in using measuring devices and instruments.
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LESSON 1. IDENTIFY STANDARD MEASURING DEVICES AND INSTRUMENTS WHAT IS THIS LESSON ABOUT? The lesson deals on how to identify standard measuring devices and instruments; identification, preparation and calibration of standard measuring devices and instruments and procedure in cleaning, sanitizing, calibrating and stowing the equipment and instruments. WHAT WILL YOU LEARN? At the end of the lesson, you should be able to: 1. identify and classify standard measuring devices and instruments according to manufacturer’s specifications; and 2. check, sanitize and calibrate properly the devices and instruments for measuring prior to use. WHAT DO YOU ALREADY KNOW? Let’s find out if you can use the standard measuring devices and instruments. Pre-Test Multiple Choice – Directions: Read and understand the questions below. Select the best answer for each item then write your choice on your test booklet. Do not write anything on the module. 1. What device is used to measure the strength of a brine solution? a. Salinometer c. both a and b b. Thermometer d. none of the above 2. What a. b. c. d.
is the function of the refractometer? Measures the sugar content of sap and syrup Measures the temperature of the food / fish Used in wrapping the food / fish None of the above
3. Why is cleaning and sanitizing the equipment is important in fish processing because ____________. a. It lengthens the shelf-life of the product. b. Has zero involvement in the outbreak of food poisoning c. Reduces the risk of contamination d. All of the above 4. Which of the following is the cheapest and most easily available sanitizer in the market? 2
a. b. c. d.
Bar soap Powdered Soap Chlorine None of the above
5. What is used in measuring the volume of the liquids. a. Salinometer b. Cylinder c. Refractometer d. None of the above 6. The standard measuring instrument used in Fish Processing is ___________________. a. Salinometer b. Refractometer c. Thermometer d. All of the above 7. What type of water is used in calibrating the refractometer? a. Distilled water b. Sea water c. Water from the faucet d. None of the above 8. What a. b. c. d.
device is used to measure the temperature of fish or food? Thermometer Salinometer Refractometer None of the above
9. What a. b. c. d.
device is used to measure the weight of fish or food? Thermometer Weighing scale Measuring cup None of the above
10.
How many drops of sap or syrup sample are needed in testing the refractometer? a. one b. two c. three d. none of the above
LET US STUDY
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Let us define Calibrate –to set or determine the accuracy of the measuring device. Equipment – things that provide specific service or function. Sanitize – to disinfect. Specification – a detailed itemized description of dimension plans, materials and other requirements. Standard – a basis of comparison or established criterion. Stowing – arranging compactly or packing.
Specifications and Functions of Measuring Devices and Instruments 1. Standard Measuring Devices a. Weighing Scales and Balances – used to measure the weight of fish and other fishery products.
b. Measuring Cups of Varying Capacities for Dry Ingredients – used to measure dry ingredients in small quantities.
c. Measuring Cups of Varying Capacities for Liquid Ingredients – used to measure liquid ingredients in small quantities.
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2. Standard Measuring Instruments a. Salinometer – used to measure the salinity of the water.
b. Thermometer – used to check the temperature of the food, during cooking, etc.
c. Refractometer – used to measure the sugar concentration of sap and syrup of food.
d. Cylinders – used for measuring the volume of liquids
e. Beaker – Used for mixing liquids, can also be used as container
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f. Flasks – used for distillation process
B. Cleaning and Sanitizing Equipment and Instruments Chlorine is one of the cheapest and most easily available sanitizers in the market. It is popularly used in the treatment of water for both household and plant. Likewise, chlorine is also used to sanitize processing equipment. Area / Materials to be Sanitized
Volume of Water
Volume of Chlorine
Time (Minutes)
Hand Dip
5 gallons
10.8 ml
2-5 minutes
Equipment
5 gallons
54 ml
2-5 minutes
Floor
5 gallons
125 ml
20 minutes
For Food Processing: Washing of vegetables and poultry
5 gallons
27 ml
2-5 minutes
1. Procedure in Cleaning Equipment and Instruments: a. Wash all the equipment or instruments with soap. b. Rinse with clean water. c. Sanitize by dipping into approved sanitizer solution. d. Remove from the solution. e. Allow to air dry. 2. Procedure in Sanitizing: a. Prepare all the materials needed. b. Measure a certain volume of chlorine and water. c. Mix and dip the equipment / instruments to the mixture. d. Remove from the sanitizer solution. e. Dry thoroughly.
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Calibrating Measuring Devices and Instrument 1. Procedure in Calibrating a. Weighing Scale Check the accuracy; see to it that the hand is pointed at zero on an empty weighing scale. b. Salinometer Check the accuracy by measuring 20o salinometer brine solution. Check if the salinometer records the reading correctly. c. Refractometer Place a drop of water (preferably distilled) on the dark circular or rectangular area and close the cover. A shadow or dark area is visible on the scale inside the eyepiece. Turn the calibration screw until the shadow falls on the zero mark. Open the refractometer cover and dry the cover and glass prism using soft tissue paper or a cotton cloth. d. Thermometer Check the accuracy by dipping it in hot foods, if the mercury rises to desired temperature Stowing Equipment and Instruments Procedure: 1. Wash the equipment and instruments with soap. 2. Rinse thoroughly with clean water. 3. Sanitize big dipping or soaking in a sanitizing solution. 4. Rinse with clean water. 5. Drain. 6. Dry thoroughly (Air Dry). 7. Wipe with a clean piece of cloth. 8. Check the accuracy of the equipment/instruments. 9. Pack/store/keep in a clean dry cabinet.
Procedure in Cleaning, Sanitizing, Equipment and Instruments. 1. 2. 3. 4. 5.
Calibrating
and
Stowing
Wash the equipment and instruments with soap. Rinse with clean water. Sanitize by dipping or soaking in sanitizer solution. Remove from the sanitizer solution. Rinse with clean water. 7
6. Dry thoroughly (air dry). 7. Check the accuracy of each equipment and instruments. 8. Pack and keep in a clean cabinet. LET US REMEMBER Equipment and instruments used in fish processing must be properly cleaned, sanitized and calibrated prior to use. Sanitizing reduces the risk of contamination. Valuing Care should be taken in handling and using equipment and instruments. HOW MUCH HAVE YOU LEARNED? Post Test A. Multiple Choice Directions: Read and understand the questions below. Select the best answer for each item then write the letter of your choice on your answer sheet. Do not write anything on the module. Write your answer in the Test booklet. 1.
What device is used to measure the strength of brine solution? a. Salinometer c. both a and b b. Thermometer d. none of the above
2.
What is the function of the refractometer? a. Measures the sugar content of sap and syrup b. Measures the temperature of the food / fish c. Used in wrapping the food / fish d. None of the above
3.
Cleaning and sanitizing the equipment is important in fish processing because ____________. a. It lengthens the shelf-life of the product. b. Has zero involvement in the outbreak of food poisoning c. Reduces the risk of contamination d. All of the above Which of the following is the cheapest and most easily available sanitizer in the market? a. Bar soap b. Powdered Soap c. Chlorine d. None of the above What is used in measuring the volume of the liquids. a. Salinometer b. Cylinder
4.
5.
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c. Refractometer d. None of the above 6.
What measuring standard is used in fish processing? a. Salinometer b. Refractometer c. Thermometer d. All of the above
7.
What type of water is used in calibrating the refractometer? a. Distilled water b. Sea water c. Water from the faucet d. None of the above
8.
What device is used to measure the temperature of fish or food is: a. Thermometer b. Salinometer c. Refractometer d. None of the above
9.
A a. b. c. d.
10.
How many drops of sap or syrup sample are needed in testing the refractometer? a. one b. two c. three d. none of the above
device used to measure the weight of fish / food Thermometer Weighing scale Measuring cup None of the above
B. Alternative Response Place a check () if the statement is correct and cross () if it is not. Write your answer on a separate sheet of paper. _______ 1. Check, sanitize and calibrate properly all the devices/ instruments for measuring food/fish prior to use. _______ 2. It is important that the sample is very fresh in measuring the sugar concentration. _______ 3. Wash all the equipment before using them. _______ 4. Detergent soap is used to sanitize processing equipment. _______ 5. Only one drop is needed for a sample in testing the refractometer. 9
LET US APPLY WHAT YOU HAVE LEARNED A. Practical Test and Written Examination: 1. Activity: Clean and sanitize the following devices and instruments 1. 2. 3. 4. 5. 6. 7.
Measuring Cups Weighing Scales Salinometer Refractometer Cylinders Beaker Flasks
2. Prepare a written procedure of the activity you performed. B. Observation and Questioning: Demonstrate how to calibrate a weighing scale. Then answer the following: 1. How did you calibrate the weighing scale? 2. Why do you need to calibrate the weighing scale?
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RESOURCES: The following resources are needed:
Standard Measuring Devices o o o o
Standard Measuring Instruments o o o o
Weighing scales and balances Measuring cups of varying capacities for dry ingredients Measuring cups of varying capacities for liquid ingredients Measuring spoons
Salinometer Thermometer of varying temperature Refractometer of varying range Glasswares like cylinders, beakers, flasks of varying graduations
CDs, DVDs CD/DVD player LCD screen and projector
REFERENCES: Calmorin, Laurentina P., Post Harvest Fisheries, Mandaluyong City, Philippines, National Bookstore Inc., 2006 Lagua, Rosalinda T., Food Preservation for Filipinos, 1977 Mendoza, Leonarda, Fishery Arts for Secondary Schools, 1980
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LESSON 2. REVIEW THE PROCEDURE IN USING STANDARD MEASURING DEVICES AND INSTRUMENTS WHAT IS THIS LESSON ABOUT? The lesson deals with reviewing the procedure in using the standard measuring devices and instruments. This includes procedure in using standard measuring devices and instruments. WHAT WILL YOU LEARN? At the end of the lesson, you should be able to: 1. recall the procedure in using the standard measuring devices and instruments according to manufacturer’s specification, and 2. consult printed procedure / brochures / catalogue according to specified food processing methods. 3. practice accuracy in using standard measuring devices and instruments. WHAT DO YOU ALREADY KNOW? Pre-Test Multiple Choice Directions: Carefully read the questions below. Select the best answer from the options given and write the letter only on your answer sheet. 1. Why is it important to review all procedures in using standard measuring devices? a. to ensure proper use of standard measuring devices b. to enable a food processor to use the appropriate measuring device c. to enable a food processor to work systematically and accurately d. all of these. 2. Your teacher instructed you to measure the salinity of a brine you will use in curing fish, which of the following will you do? a. recall and master the procedure in using a salinometer b. review and master the procedure in using the thermometer c. review the procedure in using a psychrometer d. review the procedure in using a refractometer
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3. You were assigned to monitor the temperature of the smoke inside the smokehouse. What will you do to correctly perform your assigned task? a. recall and master the procedure in using a weighing scale b. review the procedure in using a refractometer c. review the procedure in using a thermometer d. master the procedure in using a salinometer 4. What will happen if you failed to follow the correct procedure in measuring liquids? a. the obtained measurement is inaccurate b. the work is not properly done c. both a and b d. none of these 5. Which procedure will you master if you want to measure the sugar concentration of a fresh sap or syrup? a. procedure of using a thermometer b. procedure of using a salinometer c. procedure of using an anemometer d. procedure of using a refractometer LET US STUDY Let us define Brine solution - a solution of salt and water. Brochure - a pamphlet Catalogue - a systematic arrangement of listed items giving descriptive details. PPT - parts per thousands Standard - an authorized unit of weight or measure. Procedure in Using Standard Measuring Devices and Instruments Below are some procedure in using standard measuring devices and instruments: 1. Salinometer a. Prepare brine solution. b. Pour brine solution in a cylinder. c. Dip salinometer in brine solution. d. Record the reading. e. Clean after using. 13
2. Thermometer a. Dip thermometer in boiling liquids. b. Record the reading by OC or OF c. Clean after cleaning. 3. Refractometer a. Place a drop of fresh sap or syrup sample on the refractometer. b. Close the cover. c. Quickly read the scale (the line on the top of the darker area). Readings should be taken to the nearest 0.1 percent. d. Dry with tissue paper and rinse with water after each reading. 4. Glass-wares like cylinder, beaker, flask a. Pour liquid ingredients into the cylinder, beaker or flask. b. Bring the cylinder to eye level. c. Get the reading at the lower meniscus. d. Record the reading. e. Clean after using. It is important to review all procedure regarding the use of all standard measuring devices to ensure that they will be properly use in accordance with manufacturer’s specification. Being familiar with the procedure on using a standard measuring device like a salinometer, thermometer, weighing scale or a measuring cup or spoon will enable a food processor to use the appropriate measuring device as called for in a food processing activity. It also enables him to work systematically and accurately. LET US REMEMBER Follow the required procedure in using the standard measuring devices and instruments according to manufacturer’s specification in order to accurately use them and obtain desired results. Valuing Always practice accuracy in using instruments when measuring ingredients.
measuring
devices
and
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HOW MUCH HAVE YOU LEARNED? Post Test Multiple Choice - Directions: Carefully read the questions below. Select the best answer from the options given and write the letter only in your test booklet. 1. Why is it important to review all procedure in using standard measuring devices? a. to ensure proper use of standard measuring devices b. to enable a food processor to use the appropriate measuring device c. to enable a food processor to work systematically and accurately d. all of these. 2. Your teacher instructed you to measure the salinity of a brine you will use in curing fish, which of the following will you do? a. recall and master the procedure in using a salinometer b. review and master the procedure in using the thermometer c. review the procedure in using a psychrometer d. review the procedure in using a refractometer 3. You were assigned to monitor the temperature of the smoke inside the smokehouse. What will you do to correctly perform your assigned task? a. recall and master the procedure in using a weighing scale b. review the procedure in using a refractometer c. review the procedure in using a thermometer d. master the procedure in using a salinometer 4. What will happen if you failed to follow the correct procedure in measuring liquids? a. the obtained measurement is inaccurate b. the work is not properly done c. both a and b d. none of these 5. Which procedure will you master if you want to measure the sugar concentration of a fresh sap or syrup? a. procedure of using a thermometer b. procedure of using a salinometer c. procedure of using an anemometer d. procedure of using a refractometer
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B. Alternative Response Directions: Write TRUE if the statement is correct and FALSE if it is incorrect. Write your answers on a separate sheet. _______ 1. When measuring the temperature of boiling water, you have to dip the thermometer into it. _______ 2. A food processor does not need to review or recall the procedure in using standard measuring devices. _______ 3. To accurately get the salinity of a brine, it must be placed in a graduated cylinder with the salinometer. _______ 4. When cleaning a refractometer, tissue paper could be used. _______ 5. Liquids are usually measured with glass wares like beaker or graduated cylinder to obtain their volume. LET US APPLY WHAT YOU HAVE LEARNED Practical Test with Observation and Questioning: 1. Activity: Apply the procedure in using the following devices and instruments: 1. 2. 3. 4.
Salinometer Thermometer Refractometer Cylinder
2. Answer the following: 1. What kind of measuring devices did you use? 2. When using these measuring devices and instruments, what will you do to obtain accurate measurements? RESOURCES: The following resources are needed: Standard instruments may include but not limited to the following:
Salinometer Thermometer of varying temperature range (0°C-300°C) Refractometer of varying range (0°-90°B) Glasswares like (cylinder, beakers, flasks) of varying graduation
REFERENCES: Calmorin, Laurentina P., Post Harvest Fisheries, Mandaluyong City, Philippines, National Bookstore Inc., 2006 Lagua, Rosalinda T., Food Preservation for Filipinos, 1977 Mendoza, Leonarda, Fishery Arts for Secondary Schools, 1980 16
LESSON 3. FOLLOW PROCEDURE IN USING MEASURING DEVICES AND INSTRUMENTS WHAT IS THIS LESSON ABOUT? The lesson deals on how to follow procedure in using measuring devices and instruments. This includes the proper way of using measuring devices and instruments and procedure in cleaning, sanitizing and calibrating equipment and instruments. WHAT WILL YOU LEARN? At the end of the lesson, you should be able to: 1. observe strictly the methods / practices of using measuring devices and instruments according to manufacturer’s specifications and workplace requirements; 2. clean, wipe dry and stow measuring devices and instruments after use to ensure conformity with the workplace requirements; and 3. accurately follow procedure in using measuring devices and instruments. WHAT DO YOU ALREADY KNOW? Let’s find out how much you already know regarding procedures in using standard measuring devices and instruments. Pre-Test Multiple Choice Directions: Carefully read the questions and choose the best answer from the options given. Write the letter of the correct answer on your answer sheet. 1. Which is the proper way of using weighing scale? a. Calibrate the weighing scale. b. Put the food to be weighed on the plate of the weighing scale. c. Record the obtained weight d. All of these 2. If you will measure sugar and other dry ingredients, which of the following will you use? a. measuring spoon b. measuring cup c. weighing scale d. spatula 17
3. To get the accurate measurement of salt you measured with a measuring cup, which of the following will you do? a. level-off with a metal spatula or straight-edged knife b. do not level c. bring measuring cup at eye level d. compress the content 4. Where should you keep measuring devices? a. Inside a wet or moist cabinet b. Inside a clean dry cabinet c. In plastic bags d. On top of the table 5. When recording the weight measured with a weighing scale, what unit of measurement is used? a. pound b. gram c. kilogram d. both b and c LET US STUDY Let us define Conformity - the behavior that agrees with the accepted or conventional standards Device - formed by design or invented for specific use Graduation - means to divide into or mark with degrees Instrument - a tool or utensil Workplace - a place where any work is carried on Proper Way of Using Measuring Devices and Instruments 1. Measuring Devices a. Weighing Scales Put the food on the plate of weighing scale, record the reading in grams or kilograms. b. Measuring Cups for Dry Ingredients Gently spoon the ingredients into the cup, piling high or filling the cup to overflowing, then level off with a metal spatula or straight-edged knife. 18
c. Measuring Cups for Liquid Ingredients Pour liquids on level surface of measuring cups. Have the measuring lines at eye level to be sure of the exact measurement. 2. Measuring Instruments a. Salinometer. 1. Prepare the brine solution. 2. Pour the solution on the cylinder. 3. Dip salinometer on the solution, let it float. 4. Record the reading by degrees salinometer. 5. Wash the salinometer after using. b. Thermometer 1. Dip thermometer in hot liquids or solid foods. 2. Record the reading by degrees Centigrade or degrees Fahrenheit 3. Wash after using. c. Refractometer Place a drop of sap on the refractometer, close the cover and quickly read the scale (the line at the top of the darker area). Reading should be taken to the nearest 0.1 percent. It should be dried with tissue paper and rinsed with water after each reading. Procedure in Cleaning, Sanitizing, Calibrating and Stowing Equipments and Instruments 1. Wash the equipment or instrument with soap. 2. Rinse with clean water. 3. Sanitize by dipping or soaking in a sanitizing solution. 4. Remove from the sanitizing solution. 5. Rinse with clean water. 6. Dry thoroughly (air dry). 7. Check the accuracy of each equipment and instruments. 8. Pack and keep in a clean cabinet.
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LET US REMEMBER All methods/practices of using measuring devices and instruments must strictly be observed according to the manufacturer’s specifications and workplace requirements in order to ensure that the desired measurements will be accurately obtained. Valuing Clean all the measuring devices and instruments after use. HOW MUCH HAVE YOU LEARNED? Post Test A. Multiple Choice Directions: Carefully read the questions and choose the best answer from the options given. Write the letter of the correct answer in your test booklet. 1. Which is the proper way of using a weighing scale? a. Calibrate the weighing scale. b. Put the food to be weighed on the plate of the weighing scale. c. Record the obtained weight d. All of these 2. If you will measure sugar and other dry ingredients, which of the following will you use? a. measuring spoon b. measuring cup c. weighing scale d. spatula 3. To get the accurate measurement of salt you measured with a measuring cup, which of the following will you do? a. level-off with a metal spatula or straight-edged knife b. do not level c. bring measuring cup at eye level d. compress the content 4. Where should you keep measuring devices? a. Inside a wet or moist cabinet b. Inside a clean dry cabinet c. In plastic bags d. On top of the table
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5. When recording the weight measured with a weighing scale, what unit of measurement is used? a. pound b. gram c. kilogram d. both b and c B. Alternative Response Directions: Put a check () if the statement is correct and cross () if it is not. Write the correct answers in your answer sheet. 1. Observe strictly the methods / practices of using measuring devices according to manufacturer’s specifications and workplace requirements. 2. Clean, wipe, dry and stow measuring devices and instruments after use to ensure conformity with the workplace. 3. Workplace is a place where any work is carried on. 4. Have the measuring lines at the eye level to be sure of the exact measurement. 5. Level off dried ingredients with your hand in measuring them. LET US APPLY WHAT YOU HAVE LEARNED Practical Test with Interview, Observation and Oral Questioning: Activity: Show the proper way of using and cleaning of the measuring devices and instruments present on your table. Answer the questions your teacher will ask you orally. RESOURCES: The following resources are needed:
Measuring devices o o o o
Weighing scales of various capacities and sensitivities Measuring cups of varying capacities for dry ingredients Measuring cups of varying capacities for liquid ingredients Measuring spoons
Measuring instruments o o o o
Salinometer Thermometer of varying temperature range Refractometer of varying range (0-90B) Glasswares like (cylinders, beakers, flasks) of varying graduations 21
REFERENCES: Calmorin, Laurentina P., Post Harvest Fisheries, Mandaluyong City, Philippines, National Bookstore Inc., 2006 Lagua, Rosalinda T., Food Preservation for Filipinos, 1977 Mendoza, Leonarda, Fishery Arts for Secondary Schools, 1980
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Answer Key Lesson 1. A. 1. a 2. a 3. a 4. c 5. b Lesson 2. 1. d 2. a 3. c 4. c 5. d
6. d 7. a 8. a 9. b 10.a
B.
1. 2. 3. 4. 5.
1. 2. 3. 4. 5.
False True True False True
Lesson 3. 1. 2. 3. 4. 5.
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