Processing and Packaging of a Specified Prepared Chilled Food Product - Essay Example

Processing and packaging of a specified prepared chilled food product Chilled food includes a variety of products that come either as ready to eat or ready to heat meals. These foods contain various ingredients among which some are in their raw form while other are processed for pasteurization before packaging. Due to ease in their availability, these chilled foods are very much liked by their consumers. However, the assurance of standards during processing and packaging of such foods is an important issue that must be given special consideration (Phillips, 1996). Any mishandling or error during processing and packaging of these foods can tremendously affect the health of the customers. Further, the risk of microbiological attack during processing of these packaged food increases if they do not pass through specific requirements required at steps from processing to packaging. Storage of these foods even after packaging requires special attention in order to minimize microbial activities. Bumble Bee’s chicken salad is one of the most favorite meal preferred by many habitants because of the health benefits it offers. This product is commonly available in market and a large number of people favor chicken salad due to being aware of nutrition benefits that can be achieved with consumption of healthy foods like this one. The chilled and simple ready to heat foods are a subject of special interest because the temporally separated steps in their preparation, storage and distribution may expose these products to microbial contamination (Wiley, 1994). In addition, the requirement of no heat or light heat to some ingredients before consumption force one to ponder the safety status of such foods (Rosset et al., 2004). Keeping in mind the high rate of consumption and preference of chicken salad over other meals, the following study is designed to provide information regarding three major steps that ensure the safety of packaged chilled food items. The major aims are to identify and setting of specifications for the ingredients, the pre-processing and processing requirements and the identification of risks and monitoring throughout the preparation upto availability of a packed chilled food in market. Ingredients and setting of specifications: 1. Product: The product I am going to discuss in order to analyse its safety is Bumble Bee’s chicken salad. The customers prefer this chicken salad as a meal that requires less effort and promises good nutritional values. 2. List of ingredients: Bumble Bee’s chicken salad contain ingredients like cooked chicken, dressing (soybean oil, distilled vinegar, corn syrups, sugar, food starch modified, egg yolk, salt, mustard flour, paprika, garlic), celery, water chestnuts, cooked potato, tomato, salt and onion (Bumblebee). 3. General ingredients specifications list: According to a special issue on changing life style of consumers by Collins (1997), consumers prefer portable foods which claim restricted foodborne pathogens. The author also listed some of general specifications for packaged food such as proper preparation and sanitation. Generally, a very good inspection of all of the raw materials is a pre-requisite for preparation of a safe food. Proper washing of all washable ingredients and draining of excess water must be made. The temperature treatment for different ingredients is different and should be deal carefully as some ingredients lose their proteins when cooked on high flame. The extended shelf life for a product is dependent on good quality of the ingredients therefore, the safety and quality status for all ingredients must be determined with specific attention. The freshness and nutrition are the factors which guarantee increase consumption of a product. The fist-in, first-out principle for rotating stock of raw ingredients must be implemented to maintain freshness of product. When formulating a dressing, such ingredients must be prefer for selection that can resist spoilage of food; it will serve as an additional benefit for improving shelf life of a product. The conditions for storing prepared food at refrigeration temperatures must be monitored, as it will further reduce microbial growth. The vacuum packaging, pasteurization and chilling must be appropriate. In brief, general ingredient specification list includes a good inspection of raw materials, proper preparation and assemblage of all ingredients, suitable vacuum conditions, appropriate pasteurization and chilling time, packaging integrity, finished product temperature and storage temperature (Wiley, 1994). 4. Specification for each ingredient: Among the ingredients in ready to eat Bumble Bee’s chicken salad, the proper preparation of chicken is very important. Before preparation, the receiving and storage of chicken at refrigerating temperature reduces microbial risks. Effort should be made for complete cooking of chicken. Consuming the undercooked chicken may lead to ingestion of microbes in consumer’s body (Luber, 2008). Bumble Bee’s chicken salad promises cooked chicken. The preparation of chicken meat by SV (Sous vide) technology can reduce the loss of heat sensitive nutrients, proteins and aromatic compounds (Ghazala et al., 1995). Likewise, the vacuum processing of meat reduces the growth of aerobic microbe (Creed, 1998). After preparation, chicken meat should be chilled and stored at refrigeration temperature. The use of SV technology helps to maintain the physical and chemical standards of chicken as the meat is cooked in its own juice, therefore, the aromatic compounds and proteins do not get damage. Discussing microbial aspect of prepared food, the vacuum processing and sterilization of food reduce chance of food spoilage due to microbial activities. The colour, odour, flavour and texture as indicating sensory standards are also retained by cooking meat in its own juice (Ghazala et al., 1995). The next important component of chicken salad is the dressing. The use of plant oil and vinegar in addition to the mentioned spices function as preservative of packaged food that is crucial for extending shelf life of the product. Use of oil extracted from plants is known for many antimicrobial properties (Wiley, 1994). Special consideration must be given to quality of oil used. Vinegar is useful for retaining the chemical environment of packaged food therefore, the use of distilled vinegar is recommended. Similarly, care must be taken for checking compatibility of packaging with the ingredients of dressing. The use of spices should be make after being assured of their quality. Eggs must be pasteurized before using in the salad. The pH after adding vinegar should be slightly acidic and must be analyzed after preparation (Wiley, 1994). The use of celery, tomatoes and onions must be made after getting approval of their disease free status. The shredded or chopped vegetables utilized in the preparation of chicken salad, even with presence of dressing are at the risk of deterioration due to biochemical, physical and microbiological changes. So, the chilled storage of packed food contributes major proportion in maintaining the stability of such products (Brocklehurst, 1994). The use of other ingredients like water chestnuts, potatoes also require good inspection for the quality status of their raw form. Care should be taken to allow slight water loss of water chestnuts during storage, which will allow maintenance of their chemical and physical standards. Potatoes must be pre-boiled and vacuumed before there further processing. Vegetative pathogens status should be monitored before processing any of the ingredient. Packaging specifications: According to Wiley (1994), the assemblage of processed and raw ingredients for packaging, must be done with special care of temperature and safety. Packaging integrity can be analysed by checking seal, vacuum treatment and the date code for the product. Packaging must include the date code for ‘use by’ and ‘best before’. The maintenance of temperature and sterilized conditions is also important during the process of packaging of the chicken salad. The detection of metals prior to final packaging of product is necessary to ensure the costumers’ acceptance. Storage conditions must be mentioned on the product in order to avoid temperature mishandling. Pre-processing and processing requirements: 1. Raw material: reception and storage: The raw materials must be bought from some well-known and approved source. As soon as the raw materials arrive, one must make hurry to inspect raw materials in order to be sure of damage and contamination free material. All the raw materials must be of good quality. In case of meat, special attention must be paid to reception and its storage at chilling temperature. Furthermore, the storage of meat or vegetables should be make possible at the same temperature at which they are provided that is, frozen material must be stored at frozen temperature and refrigerated material must be stored at refrigeration temperature. The storage at proper temperatures limit the risk of microbial contaminations. An attempt should be made to first use the raw material stock that arrives first that is first-in-first-out consumption of stock. Care should be placed for proper wrapping of raw materials as the odor of meat may make surrounding smelling (Wiley, 1994). 2. Hygiene requirements specifications: According to ECFF recommendations for the production of pre-packaged chilled foods (2006), maintaining proper hygienic environment is essential for health of customers. In order to fulfil hygiene requirements during pre-processing and processing of chicken salad, each of the wash-able ingredient must be washed thoroughly and properly. Washing of meat and vegetables should be made with plenty of water and in sinks that are prepared specifically for washing purposes. Water should be replaced as much as possible so that contamination due to microbial growth can be restricted. If disinfectants have to be used, appropriate disinfectants must be chosen and used according to manufacturer’s instruction. For the ingredients stored at chilling temperatures, chilled water for washing must be used. The cooking of cook able ingredients in the salad like chicken, potatoes and eggs should be done properly. The pasteurization of meat and eggs must be accomplished to restrict microbial activities. Try to keep all utensils clean and sterilized. Separate utensils to for prepared food and raw materials should be used in order to avoid cross-contamination. Maintaining good personal hygiene like frequent washing of hands, proper clothing and sterilization of gloves is equally important when one inquires about hygiene conditions of pre-processing and processing steps. In brief, keeping clean and cold while avoiding cross-contamination ensures maintenance of hygienic conditions required during manufacturing of chilled food products. 3. Process flow diagrams: The risk of contamination in pre-packaged chilled food items varies according to hygienic environment of the manufacturing industry and maintenance of temperature atmosphere during transportation for the purpose of distribution (Yamina et al., 2014). The damage due to contamination of microbes can reach upto levels where consumer suffers from digestive and nervous disorders, and even face death in some cases. Reception and storage of raw materials, inspection of every ingredient and detailed analysis physical, chemical, sensory and microbiological standards ensures the safety of any packaged food. The ingredients of packaged chilled chicken salad like chicken and potatoes must be heat treated at 70 °C for at-least 2 to 5 minutes. This required specific area so that cross-contamination of microbes can be avoided. Cooking chicken with SV technology enables manufacturer to get cooked and tendered chicken without damaging the taste and nutrients. If the chicken is not processed for sterilization, it may significantly affect the health of consumers. Similarly, the potatoes must be processed at temperature of about 70 °C for 2 to 5 minutes before their slicing. The implementation of HACCP (Hazard Analysis Critical Control Point) system has been a major step to ensure the safety of packaged food. Functioning as a tool for controlling food hazard HACCP analysis puts special consideration on raw material processing as the taste and safety of end product is mostly dependent on proper processing of raw materials. Codex Alimentarius Code of Hygienic Practice for Refrigerated Packaged Foods with Extended Shelf Life (CAC/RCP 46-(1999)) also demonstrates the utilization of proper sanitary conditions and temperature requirements to guarantee safety of packaged foods. The effective processing of raw vegetables like onion, tomato and celery requires complete washing and drainage of excess water. A food business operator (FBO) is responsible for assurance of safety of packaged food. Dressing in this chicken salad is quite acidic due to use of distilled vinegar (acetic acid) and conditions for transportation and distribution should be managed so that dressing does not loses its chemical standards (the acidic pH). A lot of expertise is needed when it comes to preparation and distribution of packaged chilled food items and FBO is responsible for checking that if procedure from pre-processing to packaging are implying good manufacturer practices (GMP), good hygiene practices (GHP), and HACCP system. The color, odor and taste of packaged premixed chilled chicken salad may indicate of the food is unsafe or spoiled by microbial activities. Appropriate packaging with brief description of storage conditions and verification of seal can significantly minimize the contamination risks in chilled chicken salad. Identification of risks and monitoring throughout: The sensitivity of chilled foods to contamination and growth of microbes is very high. Some of microorganisms that are able to grow in chilled environment include Listeria monocytogenes, Clostridium botulinum and Bacillus cereus and therefore, impose high risk for deterioration of these chilled foods (Gram et al., 2002). Other than microbiological risks, there exists other types of risks, like physical and chemical risks which have significant impact on the quality and safety of packaged chilled foods. In addition, the presence of allergens (like yoghurt and eggs for some people) may also cut down the value and safety status of a chilled packaged food product and therefore, appropriate labelling of ingredients on packaged foods is necessary (ECFF Recommendations, 2006). It is essential to characterize all the possible risks that can spoil packaged chilled foods and to do necessary steps that can prevent food spoilage. However, the risks may vary from product to product due to heterogeneity in raw materials and processing conditions. Therefore, assessment of severity for all the potential risks that are capable to destroy food, is equally important in order to get assurance regarding good quality of food. Appropriate monitoring requires the inspection of raw materials as soon as they arrive to manufacturing industry. Special attention is required at the time of reception of ingredients and their storage, afterwards. The first-in, first-out rotation of raw materials is necessary to prevent chances of increasing contamination with increase in storage time. In case of vegetables, the manufacturer may prefer the purchase of disease resistant varieties of plants. Similarly, the purchase of meat should be make from some reputable source working with proper hygienic environment, so that the risks of food-borne diseases are minimum. The heat processing of meat and vegetables (that cannot be consumed in their raw form) reduces the risks of food spoilage due to pathogens and other organism’s upto a level which is tolerable. The addition of preservatives play an important role in resisting changes in color, odor and taste of packed chilled foods and therefore, demands special consideration for their selection and usage. The controlling factors like use of pasteurized meat, vinegar to provide acidic pH, addition of preservatives and other natural products like soy oil, function in a combination to control microbes’ growth and contamination and therefore prevents the spoilage of packed premixed chilled chicken salad (Labuza et al., 1992). Physical risks to packaged chilled food arise because of any foreign particle like the trace of metal, wood, glass or bone. Therefore, controlled monitoring of raw materials from their arrival upto processing is obligatory to reduce the damage to packed foods due to physical risks. Chemical risks include contaminants in the environment that may be either residues of cleaning agents and lubricants during the steps of washing and slicing or residues of pesticides and pest controlling chemicals that come along with vegetables. Chemical risks may also be avoided by adapting good manufacturing processes, selecting a reputable supplier for raw materials and critically evaluating the safety of raw materials (ECFF recommendations, 2006). The basic control measures, in order to prevent potential risks that can spoil packed ready to eat chilled food, include strict inspection on the formulation of product, specific characters of preservatives that have to be added, and evaluation of processing and packaging factors. After the complete processing, a comprehensive analysis of end product must be carried out to determine if there is any variation in the quality. The maintenance of proper hygienic environment throughout the processing and during packaging is compulsory for assurance of least counts of microbes’ in packed chilled food (Wiley, 1994). The appropriate storage conditions labeled on packed chilled food further minimizes the risk of microbial contamination after processing and packaging. The declared minimal shelf life may be lost when improper storage conditions are used or when the storage conditions are not mentioned on product. Maintenance of appropriate temperature and sterilized environment during pre-processing and processing steps followed by controlled sterilized and chilled atmosphere during packaging and storage results in the effective storage of packed food. The regulation of temperature and sterilized conditions throughout, retards many of the risks generated due to microbial, physical, chemical and biochemical factors. Of particular importance are the risks associated with food spoilage and deterioration by microbial activity. It has been well-investigated that the growth of microbes occur slowly at chilled temperatures and therefore, the reactions responsible for food spoilage are inhibited at-least to such levels where food becomes safe for long periods of time. The distribution of processed and packed chilled foods at low temperatures (i.e. refrigerating temperatures) after controlled packaging ensures safety and quality of food at the time of consumption and therefore, must be monitored throughout distribution chain (Labuza et al., 1992). It can be concluded that the contribution of chilled temperature environment plays a significant role in dealing with the identified microbiological, physical and chemical hazards that have potential to spoil packaged chilled food items. Furthermore, it’s the proper maintenance of sterilized conditions following strict inspection of quality of raw materials that ensure the production of safe food. The regulation of refrigerating temperatures during distribution and storage is equally important as chilling temperature prevent growth of microbes on pasteurized processed food. References BROCKLEHURST, T. F. (1994) Delicatessen salads and chilled prepared fruit and vegetable products. In: Chapman & Hall (eds.) Shelf Life Evaluation of Foods. US: Springer (pp. 87-126). BUMBLEBEE (N.D.) Ready-to-eat kits [Online] Available from. http://www.bumblebee.com/products/ready-to-eat-kits/bumble-bee-chicken-salad-with-crackers-kit/ CREED, P. G. (1998) Sensory and nutritional aspects of sous vide processed foods. In: Ghazala S. (ed.) Sous Vide and Cook Chill Processing for the Food Industry. Gaithersburg, MD., USA: Aspen Publishers. Codex Recommended International Code of Practice – General Principles of Food Hygiene (CAC/RCP 1-1969, Rev. 3 (1997), Amd. (1999) ECFF Recommendations for the production of prepackaged chilled foodGHAZALA, S., RAMASWAMY, H. S., SMITH, J. P. & SIMPSON, M. V. (1995) Thermal process simulations for sous vide processing of fish and meat foods. Food Research International. 28 (2). pp. 117–122. GRAM, L., RAVN, L., RASCH, M., BRUHN, J. B., CHRISTENSEN, A. B. & GIVSKOV, M. (2002) Food spoilage—interactions between food spoilage bacteria. International Journal of Food Microbiology. 78 (1–2). pp. 79–97. LABUZA, T. P., BIN, F. & TAOUKIS, P. S. (1992) Prediction for Shelf Life and Safety of Minimally Processed CAP/MAP Chilled Foods: A Review. Journal of Food Protection. 9. pp. 741-750. LUBER, P. (2009) Cross-contamination versus undercooking of poultry meat or eggs — which risks need to be managed first? International Journal of Food Microbiology. 134 (1–2). pp. 21–28. PHILLIPS, C. A. 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