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11 A Complete Course in Canning consists of Three Books. This is Book 11 The books are designed to be used together. However, the contents are separated in a manner so that they can be used separately. If Book I or I11 is desired, contact the publisher. The Contents of Book I include the following Chapters: Creating A Business Plan Plant Location And Construction Food Laws, Regulations And Standards Kosher And Halal Food Regulations A Food Labeling Guide; Water Energy Requirements And Supply Food Processing Residuals Treatment And Disposal Canning Operations; Equipment And Sanitary Design Process Room Operations Sterilization Systems; Cleaning And Sanitizing Warehousing Of Canned Foods Appendix, Glossary of Terms Figures, Charts, Tables The Contents of Book III include: Canning of Vegetables Canning of Fruits Canning of Juices and Fruit Drinks & Water Canning of Dry Pack Products Canning of Marine Products Canning of Meat and Poultry Products Canning of Soups Preserves (Jams),Jellies and Related Products Pickles Mayonnaise and Salad Dressing Products Manufacture of Canned Baby Foods Tomato Products Evaporated Milk Canned Meat and Vegetable Salads Appendix, Glossary of Terms Figures, Charts, Tables ... 111 BOOK 11 MICROBIOLOGY, PACKAGING, HACCP 8c INGREDIENTS A technical reference book and textbook for studentsof food technology,food plant managers, product research and development specialists, food brokers, technical salesmen, food equipment manufacturers, and food industry suppliers. Revised and Enlarged by DONALD L. DOWNING, PH.D. Professor of Food Processing New York State Agricultural Experiment Station Cornell University Geneva, New York A PUBLICATION OF CTI PUBLZCATIONS, INC. Baltimore, Maryland 212184547 USA 410-467-3338 FAX 410-467-7434 iv A COMPLETE COURSE IN CANNING While the recommendations in this publication are based on scientific studies and industry experience, references to basic principles, operating procedures and methods, or types of instruments and equipment, and food formulas are not to be construed as a guarantee that they are sufficient to prevent damage, spoilage, loss, accidents or injuries, resultingfim use of this information. Furthermore, the study and use of this Publication by any person or company is not to be considered as assurance that that person or company is proficient in the operations and procedures discussed in this publication. The use of the statements, recommendations, or suggestions contained, herein, is not to be considered as creating any responsibilityfor damage, spoiluge, loss, accident or injury, resulting from such use. COPYRIGHT 01996 BY CTI PUBLICATIONS, INC. all rights reserved No part of this book may be reproduced in any form or by any means-graphic, electronic, or mechanical, including photocopying, recording, taping, or information storage and retrieval system, without written permission from the publishers. ISBN Numbers are as follows: 0930027-256 0-930027-26-4 0930027-27-2 l%930027-2&0 - A COMPLETE COURSE IN CANNING, (3 Volume set), 13th Edition, 1996 Hardbound A COMPLETE COURSE IN CANNING, Volume I, 13th Edition, 1996, Hardbound A COMPLETE COURSE IN CANNING, Volume 11, 13th Edition, 1996, Hardbound A COMPLETE COURSE IN CANNING, Volume III.13th Edition. 1996, Hardbound Library of Congress Catalog-In-Publication Data A Complete Course In Canning and Related Processes - 13th Edition Revised and Enlarged by Donald L. Downing. P. cm. Includes bibliographical references and indexes. Contents: Book I. Fundamental Information On Canning; Book I1 Microbiology, Packaging, HACCP 8c Ingredients Book 111 Processing Procedures for Canned Food Products. ISBN 0-930027-25-6 (Set); ISBN 0-930027-26-4 (BK I); ISBN 0-930027-27-2 (BK 11); ISBN 0-930027-28-0 (BK 111) Canning and preserving. I. Downing, Donald L., 1931 TP371.3.C66 1996 664'.0282--dc20 96-8381 CIP V PREFACE This book is being presented in three parts: Book I, I1 and 111. Book I includes updated information on canning operations spanning from Business Plan, Plant Location and Construction Through Warehousing, and including, among other subjects, "Food Laws, Regulations and Standards," "Labeling," "Preparing Kosher Foods," "Processing Room Operations," and "Sterilization Systems"; Book I1 presents the subjects of "Microbiology of Canned Foods,""Packaging," "Quality Control," "HACCP," "Computer Aided Manufacturing," and "Ingredients," as they apply to food processing, and particularly to canning. Book I11 contains specific procedures for over 210 canned food products, and for salad dressing and pickle products. This 13th edition of A Complete Course in Canning contains chapters not included in previous editions. These are "Creating a Business Plan," "Kosher Food Manufacturing," "Labeling," "HACCP," and "Computer Aided Manufacturing." Further, the 13th edition contains several significantly expanded chapters. These are "Plant Location and Construction," "Food Laws," Regulations and Standards," "Microbiology of Canned Foods," "Metal Containers," "Glass and Plastic Containers," and "Ingredients." The Glossary of Terms has been enlarged to include many technical terms that have come into common usage in the food processing industry. These terms are found in federal and state regulatory literature, and quality control procedures, container specifications, descriptions of new technological methods, and in other food processing publications. All the material included in this edition has been reviewed and updated. This work could not have been done without the cooperation of many individuals and firms and the U.S.Food and Drug Administration. National Food Processors Association deserves special recognition, because information from several of its excellent publications was used, and because helpful advice on several topics was received from several of its scientists, as well as many others. It is hoped that this 13th edition of A Complete Course in Canning will be useful to food processors, to other persons associated with the food industry, and to students of food science and technology. The updating of this 13th Edition would not have been possible without the earlier work of Anthony Lopez, Ph.D., Professor Emeritus, VPI & State University who developed the 9th through 12th Editions. For this earlier work we are extremely grateful. Thank you Dr. Lopez. Lastly, I would like to thank my wife, Rochelle, Olga Padilla Zakour, and Julia Chia-Day Fu for their help during the preparation of the manuscript. Donald L. Downing Geneva, New York May 1996 This Book Belongs To: TABLE OF CONTENTS ........................................................................................ CHAPTER 1.MICROBIOLOGY OF CANNED FOODS ............. INTRODUCTION 1 11 Basic Considerations on pH Value .................................................................. 11 Influence Of pH On Food Microbiology and Spoilage ................................. 12 Effect of Temperature on Growth Of Microorgansims.................................. 14 pH And Growth of Closridium Botulinum ..................................................... 14 Acidity Classificationof canned Foods ........................................................... 14 Botulism .............................................................................................................. 15 Methods of Commercial Control of Botulism ............................................ 16 Botulism Outbreaks...................................................................................... 17 Spoilage of Canned Foods ................................................................................ 20 Low-Acid Canned Foods .............................................................................. 20 Acid Foods ..................................................................................................... 20 Types of Spoilage of Canned Foods ................................................................ 23 Swells .........:.................................................................................................... 23 Pinholing ........................................................................................................ 24 Flat Sours ........................................................................................................ 24 Stack Burning ................................................................................................ 25 Food Discoloration ........................................................................................ 25 Black Stains .................................................................................................... 26 Glass-Like Deposits in Canned Foods ......................................................... 26 Off Flavors ...................................................................................................... 26 Spoilage By Recontamination .......................................................................... 27 Precautions For Handling Filled and Sealed Containers .......................... 27 General Sources and Control Of Spoilage Due To Contamination ..............28 Specific Sources of Spoilage Due To Contamination ..................................... 31 Corn ................................................................................................................ 31 Peas, Beans, etc.............................................................................................. 31 Pumpkin ......................................................................................................... 32 Spinach ........................................................................................................... 32 Sources of Contamination Of Vegetables In General .................................... 34 Microbiological Standards For Ingredients..................................................... 35 Standards for Sugars and Syrups ................................................................ 36 VIII MICROBIOLOGY. PACKAGING. HACCP 8c INGREDIENTS . CHAPTER 2 HEAT PENETRATION DETERMINATIONS AND THERMAL PROCESS CALCULATIONS pH Classification of Canned Foods ............................................................ High-Temperature Short-Time Processing ................................................. Thermal Death Time .................................................................................... Heat Penetration Determinations .................................................................... Equipment ...................................................................................................... Procedure for Making a Heat Penetration (HP) Test ................................ Equipment Check .......................................................................................... Making the Heat Penetration Test .............................................................. Plotting Heat Penetration Curve ................................................................. Process Calculations........................................................................................... Methods of Analyzing Data ......................................................................... Standards ........................................................................................................ The Graphical or General Method ............................................................. The Formula Method ................................................................................... Simple Heating Curve .................................................................................. Broken Heating Curve ................................................................................. Summary ............................................................................................................. HTST Process Calculation ........................................................................... Symbols Used ................................................................................................. Computerized Data Acquisition and Evaluation of Thermally Processed Foods ........................................................................................ . ................................... 40 40 42 45 51 51 56 56 57 59 62 62 62 63 71 71 93 93 97 98 98 .............. 105 CHAPTER 3 METAL CONTAINERS FOR CANNED FOODS Tin Plate Cans ................................................................................................... Three-Piece Cans .............................................................................................. Types of Steel Plate .................................................................................... Soldered side seam ..................................................................................... Cemented side seam ................................................................................... Welded side seam ....................................................................................... Two-Piece Cans ................................................................................................. Draw and redraw ........................................................................................ Drawn and ironed ....................................................................................... Tin Free Steel (TFS) ........................................................................................ Recommended Can Sizes ........................................................................... Truck Trailer Shipping of Empty Cans ..................................................... Carload Shipping of Empty Cans .............................................................. Can Corrosion .................................................................................................. Fundamental Electrochemical Basis of Can Corrosion ........................... Internal Corrosion ...................................................................................... 105 105 106 106 108 108 110 110 111 112 112 114 123 124 125 126 TABLE OF CONTENTS METAL CONTAINERS FOR CANNED FOODS . Continued Factors Influencing Internal Corrosion ........................................................ External Corrosion ..................................................................................... Corrosion Attributable To Canning Practices .............................................. Fill and Vacuum ........................................................................................... Thermal Exhausting ................................................................................... Code Marking .............................................................................................. Faulty Closures............................................................................................. Washing the Sealed Can ............................................................................ Open Water Bath Operation ..................................................................... Steam Retort Operation ............................................................................. Contact with Rusty Iron ............................................................................. Contact with Alkaline Water ..................................................................... Improper Cooling ....................................................................................... Corrosive Water Supplies........................................................................... Scratches and Abrasions ............................................................................ Corrison Attributable To Storage Conditions .............................................. High Storage Temperature ........................................................................ Sweating ....................................................................................................... Other Causes of Rusting ............................................................................ Can Enamals (Linings, Coatings) ................................................................... Types of Enamels ........................................................................................ Application of Enamels .............................................................................. Desired Qualities of Enamels .................................................................... Trends ........................................................................................................... Evaluation of Enamels ................................................................................ Can Seam Inspection ...................................................................................... Visual Examination of Double Seams ....................................................... Tear-Down Examination of Can Seams .................................................... Essential and Optional Seam Measurements ........................................... Tearing Down The Double Seam For Inspection ......................................... Adequacy of Double Seams and Recognition of Defects ........................ Micsellaneous Information On Cans ............................................................. The Half-Size Steam Table Tray ..................................................................... Thermal Processing .................................................................................... Vacuum Determination .............................................................................. Double Seam Evaluation ............................................................................ Aluminum Cans ................................................................................................ Plant Handling of Aluminum Cans ........................................................... Corrosion Resistance.................................................................................. Liquid Nitrogen Injector System ............................................................... Ix 127 127 127 127 128 128 128 129 129 130 131 131 131 132 132 133 133 133 134 134 135 136 136 136 137 138 141 144 144 145 155 158 161 162 164 164 165 166 168 169 X MICROBIOLOGY. PACKAGING. HACCP 8c INGREDIENTS METAL CONTAINERS FOR CANNED FOODS . Continued Fruit and Vegetable Canning ..................................................................... Meats and Seafoods .................................................................................... Carbonated Beverages and Beer ............................................................... Non-Carbonated Beverages ....................................................................... Collapsible Tubes ....................................................................................... Flexible Packages and Semi-Rigid Containers .......................................... Shipping Cases ................................................................................................. Casing ........................................................................................................... . ............... . ............ 169 170 170 170 170 172 172 172 CHAPTER 4 GLASS AND PLASTIC CONTAINERS 173 Glass Containers ............................................................................................... 173 Vacuum Closures-General Characteristics.............................................. 174 Factors Affecting Vacuum Formation ....................................................... 174 175 Method of Cold Water Vacuum Check ..................................................... Vacuum Closure Application for Glass Containers ................................. 175 Auxiliary Equipment ..................................................................................175 Headspacer .............................................................................................. 175 Cocked-Cap Detector and Ejectors ....................................................... 175 Dud Detectors ........................................................................................ 176 Closures for Glass Containers-Applications ............................................ 176 176 Vacuum Sealing ........................................................................................... Shipping Containers and Casing ............................................................... 187 Commercial Packaging Of Food Products In Plastic Containers ................ 187 Consumer Acceptance ............................................................................... 188 Container Design/Structure ...................................................................... 189 Shelf Life Requirements/Product Compatibility ..................................... 190 192 Decorating Technique ................................................................................ 193 Filling Line Requirements ......................................................................... Sealing Techniques/Tamper Indication ................................................... 196 Warehousing and Transportation ............................................................. 198 Plastic Package Recycle Potential .............................................................. 199 CHAPTER 5 RETORTABLE FLEXIBLE CONTAINERS Introduction ................................................................................................. Products Packed in Retortable Flexible Containers ................................. Structure Of Flexible Containers .............................................................. Retort Pouch Forming, Filling and Sealing .............................................. Semi-Rigid Containers-Filling and Sealing ............................................. Formed Pouches .Forming, Filling and Sealing ...................................... 201 201 204 204 208 212 212 XI TABLE OF CONTENTS RETORTABLE FLEXIBLE CONTAINERS . Continued Equipment for Thermal Sterilization of Retortable Flexible Containers ................................................................................ 213 Heating Mediums for Sterilization............................................................ 215 Critical Factors In Thermal Processing Of Flexible Containers ............. 216 Quality Control Tests For Pouch Laminate. Pouch and Semi-Rigid Container ......................................................................... 218 Advantages And Disadvantages Of Retortable Flexible Containers ....... 221 . ............ CHAPTER 6 PACKAGES FOR ASEPTIC PACKAGING 225 225 Classification of Aseptic Packages ............................................................ Basic Characteristics of Packaging Materials for Aseptic Packaging ......226 Materials Used in the Manufacture of Packages for Aseptic Packaging.227 Sterlization Of Packaging Materials And packages ...................................... 229 Aseptic Packaging Systems ............................................................................. 230 The Tetra Pak System ................................................................................. 231 The Combibloc System .............................................................................. 234 The Combibloc Process ............................................................................. 234 The International Paper System ................................................................ 235 The Gasti System - American Can Company.......................................... 236 The Liqui-Pak System ................................................................................. 236 The Metal Box "FreshFill" System............................................................. 236 The Dole Corp .Hot Air Aseptic Packaging System for Fruit Juices ......237 The Container Sterilizing Unit .................................................................. 237 The Filling Section ..................................................................................... 237 The Cover Sterilizing Unit ......................................................................... 238 The Container Closing Section ................................................................. 238 Sterilization Of Equipment For Aseptic Packaging ...................................... 238 Testing and Start-up of an Aseptic Processing and Packaging Facility ..238 Aseptic Packaging Low-Acid Foods With Particulates.................................. 239 Aseptic Canning Sustems ............................................................................... 240 Sterilization of Containers ......................................................................... 245 Sterilization of Covers ................................................................................ 245 Aseptic Filling and Sealing Operations .................................................... 245 Summary of Products Packed by the Dole Aseptic Canning System .....246 Aseptic Packaging For Reprocessing ............................................................. 247 Aseptic Drum Fillers ....................................................................................... 248 "Tote" Type Containers .............................................................................. 248 FranRica "Quadraseptic" Drum and Tank Aseptic Filling System .........248 Automated Aseptic Filling of Drum Containers ...................................... 251 Removal of Filled Drum Container ........................................................... 253 XI1 MICROBIOLOGY. PACKAGING. HACCP & INGREDIENTS PACKAGES FOR ASEPTIC PACKAGING . Continued Filling of Flexible Plastic Bags ................................................................... 254 Scholle Aseptic Filling System For Bag-In-Box/Drum Packaging ............... 255 Aseptic Bulk Storage and Transporation ...................................................... 256 256 Bulk Storage Processing of Tomato Products .......................................... Bulk Tomato Paste Available in Rail Cars ................................................. 258 Tanks For Aseptic Storage For REprocessing ............................................... 259 Regulations That Apply To Aseptic Processing And Packaging Systems ..260 . .................................... CHAPTER 7 IN-PLANT QUALITY CONTROL Organization Of Quality Control ................................................................... Personnel Requirements ............................................................................ Laboratory Facilities ................................................................................... General Operations ................................................................................... Control Of Factory Operations ...................................................................... Daily Sanitation Survey .............................................................................. Daily Plant Inspection ................................................................................ Examination of Line Samples .................................................................... Examination of Water ................................................................................ Testing Canned Foods ..................................................................................... Vacuum ......................................................................................................... Headspace .................................................................................................... Fill of Container - Cans ............................................................................ Fill of Container-GlassJars ........................................................................ Fill of Containerjuice Products ................................................................ Fill/Drained Weight ................................................................................... Cut-Out-Brix................................................................................................. Flavor ............................................................................................................ Net Weight ................................................................................................... pH Measurement ........................................................................................ Total Acidity ................................................................................................. Purchasing Raw Products For Canning ......................................................... The Past And Future Of Quality Control ..................................................... . CHAPTER 8 HAZARD ANALYSIS AND CRITICAL CONTROL POINT INSPECTION (HACCP) Hazard Analysis And Critical Control Point System .................................... 1.0 Executive Summary ................................................................................... 2.0 Definations ................................................................................................. 3.0 Purpose and Principles ............................................................................. 4.0. Explanation and Application Of Prinicples ........................................... ......................................................... 261 261 263 263 264 265 266 267 269 270 271 271 272 272 274 274 274 276 278 278 278 278 278 279 285 287 288 290 291 291 TABLE OF CONTENTS XI11 . HACCP Continued 4.1.Assemble the HACCP team ................................................................ 293 4.2.Describe the food and the method of its distribution..................... 293 4.3.Identify the intended use and consumers of the food..................... 293 4.4.Develop a flow diagram which describes the process...................... 293 4.5.Verify flow diagram............................................................................ 294 4.6.Principle No. 1. Conduct a hazard analysis....................................... 294 295 4.7.Principle No . 2. Identify the CCPs in the process............................ 4.8.Principle No. 3. Establish critical limits for Preventive Measures Associated With Each Identified CCP................................. 296 4.9.Principle No. 4. Establish CCP monitoring requirements...............299 4.10.Principle No. 5. Establish corrective action to be taken when monitoring indicates that there is a deviation from an established critical limit............................................................................................. 301 4.11. Principle No. 6. Establish effective record keeping procedures 302 that document the HACCP system....................................................... 4.12.Principle No. 7. Establish procedures for verification that the 302 HACCP system is working correctly..................................................... Appendix A. Examples of Questions to be Considered in a Hazard Analysis .............................................................................. 303 Appendix B. Harzard analysis and assignment of risk categories ..........306 Appendix C. Examples of a Flow Diagram for the Production of Frozen 308 Cooked Beef Patties ............................................................................... Appendix D. Examples of HACCP Records ............................................. 308 . CHAPTER 9 CONSUMER COMPLAINTS AND MARKET RECALL Organization ................................................................................................ Recording Complaints ............................................................................... Responding to Complaints ........................................................................ Product Tampering .................................................................................... Product Recalls ................................................................................................. Introduction ................................................................................................. Preparing For A Recall ................................................................................... Recall Team ...................................................................................................... Information Required ................................................................................ Blue Prints and Flow Diagrams ................................................................. Ingredient Identification ........................................................................... Supplier. Vendor and Raw Material Records ........................................... Production and Distribution Records ....................................................... Distribution List .......................................................................................... Product Coding Program .......................................................................... Other Aspects .............................................................................................. ...309 309 310 310 312 312 312 316 316 317 317 318 318 318 318 318 318 XIV MICROBIOLOGY. PACKAGING. HACCP & INGREDIENTS CONSUMER COMPLAINTS AND MARKET RECALL . Continued Description of Recall Strategy Elements .................................................. The Recall Procedure .................................................................................... Identification of a Potential Recall Situation ........................................... Assessment of a Potential Recall Situation ............................................... Steps to Conduct a Recall .......................................................................... Suggestions .................................................................................................. . .........329 CHAPTER 10 COMPUTER-INTEGRATED MANUFACTURING Computer Technology .................................................................................... Hardware ...................................................................................................... Software........................................................................................................ Networks ...................................................................................................... Vision systems .............................................................................................. Intelligent systems....................................................................................... Use In The Food Industry .............................................................................. Information Systems ................................................................................... Purchasing, Sales and Distribution ........................................................... Production Control .................................................................................... Quality Assurance ...................................................................................... Product Development ................................................................................. Nutritional labeling .................................................................................... Application Considerations ............................................................................ Review current process .............................................................................. Assignment ................................................................................................... Implementation and Evaluation ................................................................ . 319 320 320 320 321 323 ................................................................ CHAPTER 11 INGREDIENTS Food Additives .................................................................................................. Functions of Additives ............................................................................... Safety of Additives ...................................................................................... When Additives Should Not Be Used ....................................................... Salt, Salt Tablets, And Combinations Tablets In Canning ......................... Brine ............................................................................................................. Brine Dispensing ........................................................................................ Potassium Chloride .................................................................................... Measuring Salt Content .............................................................................. Tablets and Tablet Depositors ................................................................... Dry Bulk Dispensing .................................................................................. 329 329 329 329 330 330 331 331 331 332 334 334 334 334 334 335 335 337 337 338 340 340 341 342 342 344 344 344 345 TABLE OF CONTENTS xv INGREDIENTS . Continued Carbohydrates In Canning And Preserving .................................................. 346 Sweetners ..................................................................................................... 347 Introduction ............................................................................................ 347 Dextrose (d-Glucose) ............................................................................. 348 Levulose (d-Fructose) ............................................................................ 350 Sucrose .................................................................................................... 350 Invert Sugar ............................................................................................. 351 Corn Syrup (Glucose Syrup)................................................................. 351 High Fructose Corn Syrup .................................................................... 354 Maltodextrins .......................................................................................... 356 Starch ............................................................................................................ 356 Starch Modifications ............................................................................. 360 Bleaching ................................................................................................. 360 Viscosity Reduction ............................................................................... 360 Crossbonding .......................................................................................... 361 Stabilization............................................................................................. 362 Summary ................................................................................................. 363 Use of Modified Starches ...................................................................... 363 Sorbital And Mannitol .................................................................................... 364 Spices, Essential Oils And Oleoresins, Soluble and Drug Extractives ........365 Spices ............................................................................................................ 365 Quality Evaluation of Spices ...................................................................... 366 Microbiology of Spices ............................................................................... 366 Essential Oils and Oleoresins .................................................................... 367 Soluble Extractives ..................................................................................... 368 Spray-dried Extractives ............................................................................... 368 Buying........................................................................................................... 368 Storage .......................................................................................................... 368 Textured Vegetable Proteins ........................................................................... 369 Monosodium Glutamate ................................................................................. 372 Water Soluable Gums (Hydrocolloids).......................................................... 375 Agar .............................................................................................................. 379 Gum Arabic .................................................................................................. 379 Gum Ghatti .................................................................................................. 381 Gum Karaya ................................................................................................. 381 Furcellaran ................................................................................................... 382 Guar Gum .................................................................................................... 383 Locust Bean Gum ....................................................................................... 384 Gum Tragacanth .......................................................................................... 385 Xantham Gum ............................................................................................. 386 XVI MICROBIOLOGY. PACKAGING. HACCP 8c INGREDIENTS INGREDIENTS . Continued Alginates ....................................................................................................... Carrageenan ................................................................................................. Uses in Canned Foods ................................................................................ Gelatin .......................................................................................................... Gel Strength ................................................................................................. Gelatin Desserts ........................................................................................... Jellied Meats ................................................................................................. Gelatin for Fruit Juice, Wine and Beer Clarification............................... Emulsifers (Surfactants) .................................................................................. Color Additives ................................................................................................. Certified Color Additives........................................................................... Classification of Certified Food Color Additives ..................................... Problems with Food Color Additives ........................................................ Use of Certified Color Additives in Processed Foods ............................. Preservatives ..................................................................................................... Antimicrobial Agents ................................................................................. Antibiotics .................................................................................................... Antioxidants ................................................................................................. Sequestering Agents ................................................................................... Chelating (Sequestering)Agents ................................................................... Basic Concepts ............................................................................................. Regulatory Status........................................................................................ Applications ................................................................................................. Acidulants ......................................................................................................... Flavor Modifications .................................................................................. Aiding Preservation ................................................................................... Other Functions .......................................................................................... Malic Acid .................................................................................................... Fumaric Acid ................................................................................................ Adipic Acid .................................................................................................. Succinic Acid ................................................................................................ Citric Acid .................................................................................................... Phosphoric Acid .......................................................................................... Firming Agents ................................................................................................. Alternative Sweetners And Fat Replacers ..................................................... Alternative Sweeteners and Bulking Agents ............................................. Fat Replacers ................................................................................................ 387 388 388 389 392 393 394 395 395 397 399 400 401 402 403 404 406 406 407 408 408 410 410 412 412 413 413 414 414 414 415 415 416 416 417 417 419 TABLE OF CONTENTS APPENDIX ............................................................................................... Temperature Conversion Table ................................................................. Table of Conversion Factors-English to Metric ....................................... Metric Conversion Table ............................................................................ Decimal Equivalents (Millimeters to Inches)............................................ Decimal Equivalents (Inches to Millimeters)............................................ Table of Metric Weights and Measures ..................................................... Tin Plate Basis Weights .............................................................................. Case Equivalents .......................................................................................... Can Dimensions and Conversions-English to Metric ............................. Container Dimension Conversion Chart .................................................. Sodium Chloride Brine Tables .................................................................. Normal pH Ranges of Commercially Canned Foods .............................. Sterilizing Values (Fo)For Some Commercial Processes ......................... ........................................................................... SUBJECT INDEX ..................................................................................... FIGURE!3/TABLES/CHARTS INDEX .................................................... GLOSSARY OF TERMS XVII 441 421 425 429 430 431 432 433 434 435 436 438 440 442 443 475 483 HISTORICAL AND BASIC INFORMATION ON CANNING The name of this book, A Compkte Course in Cunning, indicates that it is intended as a source of information on canned foods. The reader will find here factual and reliable data on all the important facets of canned foods, such as product formulas, manufacturing procedures, food laws, sanitation, sterilization,spoilage, containers, food plant characteristics, warehousing and others. At the dawn of this 20th century, when this work first appeared as a serial article in the pages of The Cunning T r d , the claim "Complete"seemed boastful, if not questionable. Looking back to the years 1902 and 1903, it is easy to see that the Industry, if not then in its infancy, was at best in its kindergarten age and the amount of production was but a fraction of today's. Factory equipment and layout were crude andjust commencing to develop; quality and grades of products were as varied and as numerous as the producers, since food laws were then nonexistent. Science, as applied to canning and food preservation, wasjust looming on the horizon. There were no set, definite formulae, except those which experiencehad taught through dint of heavy cost, and which were accordingly carefully nursed and protected by their possessors, the "expert processors." These "expert processors" lorded over the work and the men who employed them, and refused to divulge their "secrets." Losses from spoilage, as well as from poor quality, were accepted as normal. Yet, in 1900, in point of numbers, there were as many canners, preservers, picklers, etc., in the business as there are today, and there were no frozen foods. Necessarily their outputs were smaller, but so was the market. Profits were uncertain, and the business mortality heavy, but there was no lack of hope or of optimism, as witnessed by the eagerness of new men or firms to step into the shoes of those who were forced out or gave up. Years before, the late Editor and founder of The Cunning Trade (now called Food Production Management), apparently the first man in the world to have a deep-rooted conviction that canned foods were of real genuine value and held wonderful possibilities,had said "The day will come when canned foods will be the pantry of the world." There were men in the industry at that time who had little or no faith in the goods they produced, but there were enough to keep the ranks well filled, and the amount of goods produced was on a steady increase. At the turn of the century, the industry had little or no scientific knowledge or assistance to depend upon. Today, it is soundly based upon scientific principles developed at its own National Food Processors Association laboratories, and at government, industry, and university laboratories. The 2 MICROBIOLOGY,PACKAGING, HACCP & INGREDIENTS National Food Processors Association laboratories are rated foremost among the world food industry research and service laboratories, with major laboratories in Washington, DC, California, and the Northwest. Services are rendered to members of the Association. Can making companies,glass container manufacturers,and other packaging firms, also, have very well equipped laboratories where, not only container research is done, but where technical services are provided to customers on product quality, processing, formulation, and container usage problems and opportunities. The U.S. Departments of Agriculture and the Interior, and the Food and Drug Administration have important laboratories in Washington, DC and a number of other laboratories in different regions of the country. These laboratories work on basic food preservation problems, as well as on processing techniques, new product development, food plant sanitation and product adulteration problems, and food analysis methods, all with the objective of helping to place high quality food products in food markets. The States have their own food laboratories, concerned principally with sanitary conditions and quality control of products manufactured and sold within their borders. Each State also has one or more Agricultural Experiment Stations which study growing conditions in particular areas of that State and do applied research on the processing of the crops grown in the State, as well as on other problems of the food industry. Food processors and producers should realize numerous and significant services are provided by the State Agricultural Experiment Stations and Extension Services. They should especially consult those state agencies in the selection of seed and plants, the use of fertilizer, plant and animal disease and pest control, and food technology problems. Those who are just entering, or intend to enter, the food processing business should consult those agencies on the proper location of the plant, availability of labor and raw materials, applicable federal and state laws and regulations, processing line specifications, markets, and other factors. WHY THIS BOOK? Under such conditions as existed in 1902-03,was the publisher not rather presumptuous in publishing a compilation of formulae, and particularly in terming it "complete?" However, having related the subsequent progress, in both production and scientificattainments, the first edition of A Complete Course in Cunning was published. The fact that there were no definite formulae obtainable, in printed form or otherwise at that time, brought the canners of that day, and the new men wishing to enter the industry in particular, to The Cunning Trade, as the sole
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