Summary

This document provides an overview of food processing and control, including topics such as classification of food products, physical properties of food, batch and continuous processes, and process control approaches. The information could be used for educational purposes or in a food processing industry context.

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FOOD PROCESSING FAT3103 Chap 2: Ts Dr Maryana Mohamad Nor FAT 3103 FOOD PRODUCT DEVELOPMEN WEEK 1 RECAPP T...

FOOD PROCESSING FAT3103 Chap 2: Ts Dr Maryana Mohamad Nor FAT 3103 FOOD PRODUCT DEVELOPMEN WEEK 1 RECAPP T TECHNOLOGY FAT 3103 FOOD WEEK 1 PRODUCT DEVELOPMEN T TECHNOLOGY WEEK 1 FAT 3103 FOOD PRODUCT DEVELOPMEN T TECHNOLOGY WEEK 1 Classification of Food Products ▫ Properties of Foods ▫ Food Biotechnology New Product Success Equation Factors Relating to New Product Failures Basic Food science Effects of processing ▫ sensory characteristics of foods ▫ nutritional properties Classification of food 1 2 3 4 5 6 Physical properties of f ood 1. Freezing, Melting, and Boiling Point 2. Heat Transfer. 3. Size and Thickness. 4. Deformation. 5. Moisture Content 6. Density and Specific Gravity 7. Refractive Index. 8. Water Activity (aW) 9. Viscosity 5 WEEK 2 LEARNING OUTCOMES 2.1Types of control systems 2.2 Batch and continues process 2.3Automatic process control a. Advantage vs disadvantages b.Components FP FP PD team is a group of different specialists responsible for the new product design, development, and launch. Food Processing Food processing is any action or procedure that changes the initial food or raw materials used to produce food I don’t want to alarm you, but without process control, you’d be dead. Why in process control????? minimize costly errors and reduce the risk of food safety and wholesomeness defect. Process control in food safety describes engagement with processes, procedures, and practices that help monitor and ensure the safety and quality of food during production and processing. Process control? Used in ….. oil refining, chemical processing, car manufacturing, temperature control, food and beverages industries process control hierarchy Scheduling & Optimation Supervisory control & process diagnostic Basic closed-loop control Sensing, measurement and data collection 2.1 Types of Control system Control: To maintain desired condition in a physical system by adjusting selected variable in the system 2 types: Manual and Automatic a. Manual Control System In manual control, an operator periodically reads the process parameter which requires to be controlled and, when its value changes from the set value, initiates the control action necessary to drive the parameter towards the set value a simple example of manual control where a steam valve is adjusted to regulate the temperature of water flowing through the pipe the success of manual control operation depends on the skill of individual operators in knowing when and how much adjustment to make. This is possible in plants where there are few processing steps with infrequent process upsets and the operator has sufficient time to correct before the process parameter overshoots acceptable tolerance. b. Automatic process control The process parameters measured by various sensors and instrumentation may be controlled by using control loops. A typical control loop consists of three basic components Sensor: the sensor senses or measures process parameters and generates a measurement signal acceptable to the controller. Controller: the controller compares the measurement signal with the set value and produces a control signal to counteract any difference between the two signals. Final control element: receives the control signal produced by the controller and adjusts or alters the process by bringing the measured process property to return to the set point An automatic control system can be classified into 4 main types: 1.on/off (two position) controller 2. proportional controller (P-controller) 3. proportional integral controller (PI controller) 4. proportional integral derivative controller (PID controller). 1.on/off (two position) controller simplest automatic controller 2. proportional controller (P-controller) most commonly used controllers; it produces an output signal to the final control element that is proportional to the difference between the set point and the value of the measured process parameter given by the sensor. COS(t) is the controller output signal at any time t, COS(NE) is the controller output signal when there is no error, KC is known as the controller gain or sensitivity (controller tuning parameter) and Et is the controller error or offset. The proportional controller gain or sensitivity (KC) can also be expressed as: The P-controller will therefore respond aggressively like any simple on/off controller, with no offset, but a high degree of oscillations. 3. Proportional Integral Controller The PI controller produces an output signal to the final control element PI control is a form of feedback control. It provides a faster response time than I-only control due to the addition of the proportional action. PI control stops the system from fluctuating, and it is also able to return the system to its set point. PI controller – integral of error continually increases and decreases with time 4. Proportional Integral Derivative Controller (PID) In line with the PI controller, the PID controller produces an output signal to the final control element. Proportional-integral-derivative control is a combination of all three types of control methods 2.2 Batch and Continuous Process in Food Plant Automatic batch blending refers to a process in which ingredients are combined in predefined quantities and mixed together automatically to create a final product. This blending method is commonly employed in various industries, including manufacturing, food processing, pharmaceuticals, and chemicals. Batching and continuous (blending) are two essential processes in a food plant, crucial in product consistency, quality, and efficiency. Dairy & Dairy Alternatives, Bakery & Confectionery Coffee & Tea, Juices & Beverages Oils, Sauces, Pharmaceutical A batch process involves a set of ingredients and a sequence of one or more production steps that follow a pre- defined order. A set amount of product(s) are produced at the end of each sequence to make up a single batch. The processing of subsequent batches will only begin once all of the set amounts of products have been produced. All of the raw materials are introduced at the beginning of the production process, and the finished products are completed after a certain period. The continuous process moves raw material from the start of the process through each production step to a final product. Rather than waiting until the unit of product is complete, raw material is fed and processed continuously to produce additional units of product. Continuous has a constant flow of raw materials into production, generating a constant flow of products, and is also known as the non-stop production cycle Advantages NO Batch Continuous 1 More control over quality and better Better process control traceability and real-time process monitoring 2 Shorter production time Higher volume production 3 Lower cost equipment Smaller storage space 4 Lower chance of contamination since all Reduced processing and products move along the production holding time process at the same time Challenges NO Batch Continuous 1 Greater storage space needed for Less flexibility and longer to set up in-between production stages 2 Batch errors can lead to greater More risk in production startups and waste and production cost shutdown 3 Increased employee downtime Requires frequent employee training due to waiting between processes and education and meticulous quality control 4 Improperly planned batch The high initial cost of investment processes can lead to bottlenecks that limit production 5 Higher chance of contamination with products moving through the same process each time Batching the process of weighing, measuring, or mixing specific quantities of ingredients together to form a batch. In a food plant, batching ensures that the correct proportions of ingredients are used to maintain product consistency and meet specifications. Batching can be done manually, semi- automatically, or fully automated, depending on the plant's production scale and needs. STEPS: — TO CONTROL A BATCH PROCESS identify the variables that need to be controlled, Define the Process Parameters such as temperature, pressure, flow rates, or ingredient quantities. Set Operating Procedures (SOP) Monitor Process Variables using sensors, gauges, or instrumentation Establish Control Strategies Use automation systems such as programmable logic controllers (PLCs) or distributed control Data Acquisition and Analysis systems (DCS) to implement these strategies. Adjust Process Parameters Maintain Equipment and Calibration Document and Learn Training and Skill Development: Regulatory Compliance and Safety METHODS OF BATCH PROCESS CONTROL 1. Programmable Logic Controllers (PLCs):- PLCs, or programmable logic controllers, are commonly used in batch process control due to their flexibility, reliability, and ease of programming. easily programmed to handle complex sequencing and timing requirements, which are often required in batch processes. offer a high degree of flexibility and can be easily reprogrammed or modified to accommodate changes in the process requirements 2. DCS (Distributed Control System):- DCSs are well-suited for batch process control because they allow for the control and monitoring of multiple process variables simultaneously, such as i. temperature, ii.pressure, iii.flow rate, iv. chemical concentrations. manages the execution of each step, monitoring process variables and adjusting process conditions as necessary to ensure that the process is proceeding according to the recipe provide valuable data logging and reporting capabilities, allowing operators to track process performance over time and identify help to improve process efficiency, reduce areas for improvement costs, and increase product quality and 3. PID (Proportional-Integral-Derivative):- During this process, a PID controller can be used to maintain the system at the desired setpoint. PID (Proportional-Integral-Derivative) control is a widely used technique in process control to maintain a process variable (such as temperature, pressure, flow rate, or level) at a desired setpoint. 2.3 Automatic process control Automatic control has been developed and applied in almost every sector of the industry. The impetus for these changes has come from: ❖ increased competition that forces manufacturers to produce a wider variety of products more quickly ❖ escalating labour costs and raw material costs ❖ increasingly stringent regulations that have resulted from increasing consumer demands for standardised, safe foods and international harmonisation of legislation and standards. Automation means that every action that is needed to control a process at optimum efficiency is controlled by a system that operates using instructions that have been programmed into it. The advantages of automatic process control can be summarised as: ❖more consistent product quality (minor variations in processing that would cause changes to product quality are avoided) ❖greater product stability and safety ❖greater compliance with legal and customer specifications ❖more efficient operation ❖verification of correct inputs by operators (e.g. checking that operators specify the correct weight and types of ingredients) ❖better use of resources (raw materials, energy, labour, etc.) ❖reduced effluents or more uniform effluent loads ❖increased production rates (e.g. through optimisation of equipment utilisation) ❖improved safety (automatic and rapid fail-safe procedures with operator warnings in case of, for example, a valve failure or excessive temperature rise). The main disadvantages relate to the social effects of reduced employment when the number of operators required to process a food is reduced. Other disadvantages include: ❖not suitable for processes in which manual skill is necessary or economically more attractive ❖higher set-up and maintenance costs ❖increased risk, delays and cost if the automatic system fails ❖the need for a precise understanding of the process for programming to achieve the required product quality ❖reliance on accurate sensors to precisely measure process conditions. Conclusion ? 48

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