CEBU INSTITUTE OF TECHNOLOGY

UNIVERSITY

MECHANICAL ENGINEERING DEPARTMENT

ME – 513

INDUSTRIAL PROCESS

Written Report

PROCESSED FOODS MANUFACTURING PROCESS

Title

Submited by:

Cabreros, Jake Lawrence P.

Cale, Joshua G.
Comendador, Patrick Niño A.
Despoy, Jimwell G.
Padigos, Glen Mark V.
Romero, Jose Paulo S.

Submitted to:
Engr. Roberto P Base Jr.
HOTDOG

I. INTRODUCTION
There are at least three basic needs that an individual must have; shelter, clothes and
Foods, with respect to the rapid phase of technological development nowadays people feel an
urge to keep up with this phase. They have this need to get everything they want in an instant.
Let’s take into account foods, most of the foods that we intake nowadays are processed in such
a way that it’ll no longer require longer time for it to be edible. All you have to do is to heat them
for a short period of time and you can have a meal that can fill your stomach. Best example of
processed foods that we can eat almost on-the-go are Hotdog and Smoked Ham.

Hot dogs are a processed meat product made by mixing chopped meat with various
curing ingredients, flavorants, and colorants. The meat is then stuffed in casings, cooked,
removed from the casing, and put in the final package. Although the technology for hot dog
making was developed thousands of years ago, these meat products continue to be a popular
summertime food. In fact, in America alone over 16 billion hot dogs are consumed each year.

The typical raw hot dog is a pink, cylindrical-shaped piece of meat. It is about 1.6 oz
(45.36 g) on average and contains anywhere from 0.175-0.245 oz (5-7 g) of protein. It also
contains about 0.455 oz (13 g) of fat, 450 mg of sodium and 150 calories. Since hot dogs are
meat products, they are an excellent source of nutrients including iron, zinc, niacin, riboflavin,
and B vitamins. When hot dogs are made using pork meat, they are good source of thiamin.
Since they are a pre-cooked food, they are less prone to spoilage than other types of meat
products. This makes them one of the safest meat products available.

Hot dogs are known by many different names including frankfurters, franks, red hots,
and wieners. While there are many varieties of hot dogs, one of the most famous is the Kosher
hot dog. These hot dogs are prepared in a manner, which follows 3,000 year old traditions that
comply with Jewish religious practices. Specially trained Rabbis oversee the entire kosher hot
dog making process. Ultimately, the main difference between a kosher and a regular hot dog is
that kosher hot dogs do not contain pork.
 II. HISTORY
The technology for making hot dogs and sausages was developed thousands of years
ago. This makes these products one of the oldest forms of processed food. The earliest record
of a hot dog type product dates back to 1500 B.C. in Babylonia. Sausages were mentioned in
Homer's Odyssey written during the ninth century B.C. These early forms of hot dogs were
made by grinding up meat, stuffing it in animal intestine and cooking it over a fire.

The exact origin of the product we call a hot dog is debated. Some claim that it was first
developed in Frankfurt, Germany, in 1484. Others claim that it was developed in Vienna,
Austria, and suggest that the term wiener reflects this point. Still others suggest that it was not
developed until the late 1600s when Johann Georghehner (who was from Coburg, Germany)
produced a sausage product known as the dachshund sausage.

In 1852, a butchers' guild in Frankfurt produced a spiced, smoked sausage product

which they named frankfurter after their hometown. It was slightly curved in shape and was
often called the dachshund sausage. The product was brought over to America by Charles
Feltman and Antoine Feuchtwanger. Feltman sold frankfurters and sauerkraut from a pushcart
in New York's Coney Island. He opened up the first Coney Island hot dog stand in 1871. Shortly
thereafter, he started selling the frankfurters with milk rolls, which were the precursors to hot
dog buns. The buns that we use today were probably first introduced in St. Louis by
Feuchtwanger in 1904. He was a sausage concessionaire who loaned white gloves to his
customers to hold the hot sausages. Since most of his customers did not return his gloves he
worked with a baker to develop a bun, which people could use to hold their sausages.

In 1893, sausages became a popular food at baseball parks. They were first introduced
in the St. Louis Browns ballpark and then spread to the rest of baseball. The term hot dog was
coined in 1901 by a sports cartoonist named Tad Dorgan. He was at the New York Polo
Grounds, where he had heard some vendors selling red hot dachshund sausages. This
prompted him to draw a cartoon of a real dachshund covered with mustard on a bun. Since he
did not know how to spell dachshund he wrote on the caption "get your hot dogs." The cartoon
was a hit and the name persisted.
 III. RAW MATERIALS

MEAT

The primary ingredient in hot dogs is the meat. The U.S. Department of Agriculture
requires that meats used for hot dogs must be the same type of quality ground meat sold in
supermarkets. While pork is most often used, other types may be used such as beef, chicken or
turkey. Sometimes variety meats like livers are used however, the hot dog producers must
clearly label the product with the statement "with variety meats" or "with meat by-products." The
proteins and fats of which meats are composed are responsible for meat characteristics. For
example myofibrillar proteins give meat its texture and structure. Myoglobin and hemoglobin
proteins create the natural color of the meat. Fats in the meat give the characteristic flavor.

CURING SOLUTION

The meat is mixed with a curing solution to improve the taste and increase the shelf life.
A major ingredient in this curing solution is salt. It is used to make the meat easier to work with,
improve flavor, and inhibit bacterial growth. Water is another component of the curing solution. It
has a variety of functions including helping create the necessary meat emulsion and adding to
the meat's juiciness. Sodium nitrite is included in the curing solution to retard the development
of rancidity and stabilize the meat color. Curing accelerators such as sodium ascorbate or
sodium erythorbate may also be added to preserve the color of the meat during storage.

SUGAR AND CORN SYRUP

Sugar and corn syrup are used to give hot dogs a sweeter taste.

FLAVORANTS

Flavoring is added to give hot dogs their characteristic taste. The flavorants may be
natural or artificial, but typically a mixture of the two is used. Natural flavorants include herbs
and spices such as pepper, nutmeg, ginger, cumin, and dill. Artificial flavoring compounds
include organically synthesized esters, ketone and amino acids. Monosodium glutamate is an
artificial flavor that is often used to intensify the flavor of the meat.

EXTENDERS

Hot dogs can contain extenders, which are non-meat ingredients that increase the
number of hot dogs that can be made from a set amount of meat and improve the nutritive
value. Extenders come from plant and animal sources and include things such as non-fat milk,
cereal, soy protein and whole milk.

IV. THE MANUFACTURING PROCESS

1. Meat Processing

The production of hot dogs begins with the preparation of meat. After it passes
inspection, the incoming meat is cut into small pieces and placed in a stainless steel mixing
container. The container is equipped with high-speed choppers, which can reduce the size of
the meat pieces even further. The other raw materials including the curing ingredients,
flavorings and ice chips are blended in this container until a fine emulsion, or batter, is
produced. This once stuffed, the hot dogs are cooked. Their casings are removed and the hot
dogs are vacuum-packed to preserve their flavor.

Once stuffed, the hot dogs are cooked. Their casings are removed and the hot dogs are
vacuum-packed to preserve their flavor batter has a smooth paste-like consistency, which
makes further processing easier.

1. Linking

After the batter passes quality control checks, it is pumped into an automatic
stuffer/linker machine. In this machine, batter is put into tube-shaped, cellulose casings. These
casing are then twisted at precise points to produce a long linked strand of equally sized hot
dogs. Most casing are removed later in the process however, some manufacturers continue to
use natural casings, which remain on and are eaten along with the hot dog. This more
traditional method of hot dog making is done by smaller manufacturers and tends to cost more.

2. Cooking

The linked hot dog strands are then conveyed to a large smokehouse. Here, they are
thoroughly cooked under controlled conditions. The manufacturer has the opportunity at this
point to impart a different flavor on the hot dogs by using a variety of smoke sources. The
cooking times vary depending on the recipe however, typically it takes about an hour.

3. Final processing

When the cooking is done, the hot dog links are moved via a conveyor to an automatic
peeler. During their trip, they are showered with water to help equalize their internal
temperature. In the peeler, the cellulose casings are cut away leaving only the bare hot dogs. It
should be noted that this step is skipped by manufacturers who use natural casings.

4. Packaging

From the peeler, the individual hot dogs are transported to the packaging machinery.
Here, they are lined up and placed on a plastic film. The films are folded and vacuum-sealed to
preserve the hot dog's flavor and increase shelf life. Printed on the films are all of the graphics
and required text needed for marketing. The sealed packages are moved to a stamping
machine, which prints on a freshness date. They are next transported to boxing devices, put on
pallets and shipped in refrigerated trucks to local supermarkets. The entire process of hot dog
making from receiving the meat to boxing up the hot dog takes only a few hours.

V. MACHINERIES

Meat Grinder

Also called as “meat mincer” the main machine that will cut the meat into pieces. The
operator puts small cuts of meat into a funnel, which is placed on the top of the grinder. From
there the material goes on a horizontal screw conveyor. This screw conveyor, which can be
powered by electric motor, squashes and partially mixes the meat. At the end of the screw
conveyor there is a knife installed directly in front of the fixed hole-plate. At this opening the
minced meat comes out of the machine. The fineness of the meat depends on the size of the
holes of the plate.

Mixing Bath

A large mixing machine that mixes all the ingredients to produce a smooth paste-like
batter. And also, water is added to the mixing bath to make the hotdog juicier.

Vacuum Machine

This machine pure raised the meat bath and reduced steam and air usage and creates
no product damage, while maintaining high capacity capabilities.
Stuffing Machine

This machine, batter is put into tube-shaped, cellulose casings. These casing are then
twisted at precise points to produce a long linked strand of equally sized hot dogs. This machine
can twist 5 and a quarter inches which is the length of one hotdog. It takes just 35 seconds to
make a chain of hotdogs that would span a soccer field twice.

Linking Machine

Three of hotdog chains linked together from the stuffer machine to make an even longer
strain.

Smoke House

In smokehouses, under controlled temperature (170°F), the hot dog is fully cooked and
hard-wood smoked for texture, color and a delicious flavor. After passing through the smoke
and cook cycle, and being showered in cool water (room temperature), the hot dog goes into the
peeler.

Conveyor

Conveys the hotdog to the smoke house from the linker machine then from smoke
house to the peeler machine.

Automatic Peeling Machine

In the peeler, the cellulose casings are cut away leaving only the bare hot dogs using a
tiny knife inside the peeling machine and slits each cellulose casing along the top. This machine
can peel 700 hotdogs per minute.

Packaging Machine

Packaging machinery is used throughout all packaging operations, involving primary

packages to distribution packs. This machine can pack 300,000 an hour that is equivalent to
2,500,000 per shift.

VI. Quality Control

Quality control is an extremely important factor in any food processing facility. For health
and safety reasons, the government regulates all of the raw materials that are used in the hot dog
making process. The meat in particular is heavily regulated because the use of poor quality meat
represents a significant health risk. Most manufacturers use only high quality meats to assure that
their hot dogs are of similar quality. Upon receipt of the raw materials, they are checked for things
such as pH, % moisture, odor, taste, and appearance to ensure they meet the previously set
specifications. Additionally, the processing equipment is sterilized and checked before any
processing can begin. During manufacture, the meat emulsion is continuously checked to assure
that all the ingredients are put in at proper proportions. Since hot dogs are eaten, steps must be
taken to ensure that they will have an appealing taste and be free from contamination. For this
reason, tests similar to the ones run on the initial raw materials are performed on the final product

SMOKED HAM

I. INTRODUCTION
Smoked ham on the other hand is a popular serving of meat, cut from the pork leg. It is
cured with salt and spices, then subjected to slow and steady heat for varying periods. The
smoking is carried out in a special chamber called a kiln.

II. HISTORY
Foodstuffs were originally smoked as a means to preserve them. The practice may have
started as early as the Stone Age and was probably discovered by accident when food was left
out in the sun. The discovery of fire would have made the smoking of foods more prevalent.
Throughout the centuries, until the development of refrigeration, smoking and salting meat for
future use was a regular practice. Chemicals released from the wood during the smoking
process slows the growth of microorganisms. Likewise, in curing, salt reduces the amount of
available water for bacteria to grow. Pork has always been a popular meat for many civilizations
due to the ease of raising pigs and preserving the meat. People began raising pigs about the
same time that they established group settlements. By 600 B.C.pig breeding was a thriving
industry. Pigs were brought to the New World by Spanish explorer Hernando de Soto in the
sixteenth century and soon became a major commodity here as well. A number of cultures,
such as Orthodox Jews and Muslims, forbid the eating of pork. This food prohibition dates to
ancient times when Egyptians only ate pork during the feats of the god Osiris.
 III. RAW MATERIALS

PIG

Today, pigs are raised around the world, primarily in areas of temperate climates and
dense human populations. China and the United States are the largest producers of pigs. Pig
breeding incorporates a combination of pen-rearing and pasture-feeding. Domesticated pigs are
fed a diet consisting of corn, grain, roots, and fruits. Domestic pigs generally reach their market
weight of 175-240 lb (79.4-108.9 kg) between the ages of five and 11 months. At that time they
are taken to the slaughterhouse. The specific cuts are then created from the carcasses. The
ham portion, cut from the leg, is then cured and smoked.

BRINE SOLUTION

Before smoking, the pork is submerged in a brine solution containing water, salt, and
sugar. Pickling spices (mace, allspice, cloves, cinnamon, peppercorns, and bay leaves) and
garlic may also be added.

WOOD

Using the correct type of wood is essential to successful smoking. The wood must be
one that burns slowly and steadily. Non-resinous woods, such as beech, oak, chestnut, and
hickory are the most common types used for smoking. Aromatic herbs such as juniper, laurel,
sage, and rosemary may also be added. Conversely, woods containing resin, such as pine, will
impart a bitter taste to the meat. Smoking kilns are built in a variety of fashions. They can be
brick chimney-like structures or stainless-steel drums. The inside can be fixed with racks or
hooks. The fuel is loaded into the bottom and covered with a perforated plate so that the smoke
can filter through to the ham. The ham is injected with brine, then soaked in a brine solution.
The ham is then hung and smoked in a kiln.

IV. THE MANUFACTURING PROCESS

Brining the ham

Before the ham can be smoked, it must be soaked with a salt solution. First the solution
is injected from a brine pump into the thickest part of the meat, preferably near the bone. Similar
to a hypodermic needle, the brine pump has a long hollow tube with rows of holes down the
sides. As the plunger is depressed, the brine is forced through the holes into the meat tissues.
 A typical brine solution might be composed of 5 gal (19 1) of water, 5 lb (2.3 kg) of salt, 1
lb (0.5 kg) of white sugar, and 1 oz (28 g) of saltpeter (sodium nitrate). If a mild cure is desired,
the ratio is 1 fl oz/lb (28 g/0.5 kg) of meat. For a stronger cure, the ratio is increased to 1.5 fl
oz/lb (42.5 g/0.5 kg).

Soaking the ham

The ham is then immersed in the remaining brine for a period of 10-16 days depending
on weight. The ham and the brine are inspected daily. The brine is overhauled, or turned over,
every three days. Overhauling prevents the brine from becoming weak on top and heavy on the
bottom. A large wooden paddle is used to remix the brine.

Rinsing and drying the ham

After the brining is complete, the ham is rinsed thoroughly with fresh water.It then is
hung or loaded onto racks to dry for a period of a few days to several weeks. During the drying
period, a crust may form on the ham. This crust is shaved off and discarded.

Smoking the ham

Several hams are smoked together. They can be hung from meat hooks in a large kiln or
placed on racks in smaller smokers. The smoker is kept at a temperature of 70-80°F (21-26°C).
Wood chips are used rather than logs to create a slow burning fire. The chips are stirred, or
stoked, regularly. The amount of time that the ham remains in the smoker is determined by the
desired intensity of flavor. That period can be as little as 48 hours or as much as six weeks.

When smoking is completed, the hams are packaged in shrink wrap and shipped in
refrigerated trucks to retail outlets and restaurants.

V. MACHINERIES
Automatic Trimming Machine

Is like a peeler machine that skins down the back portion of the hind-leg. In keeping the
traditional style, the machine leaves just a small amount of skin in the thin part of the leg called
the shank. The Circular Wizard does its magic by removing all but a thin layer of fat.

Mixing Bath
 A mixing machine that mixes all the ingredients for the curing solution made of water,
sugar, salt and a few secret ingredients. This mixture gives a trademark flavor and pinkish color
of the meat.

Injection Machine

This machines has 138 needles that injects the curing solution to the meat, as the meat
passes below they are thoroughly and evenly injected with solution and all that piercing
tenderizes the meat.

Stuffing Horn Machine

A machine that fires each ham into a heat resistant net. Workers sealed each with an
aluminum clip then cut-off the excess netting. By hanging them in the cooking racks with nets
keeping it nice and round.

Smoke House

The cooking racks was transferred into the smoke house or cooking oven. Woodchips
go into the oven smoker to start up the smoke house. For the next 12 hours the ham is slowly
cooked into a temperature ranging 150°F to 180°F this tenderizes the meat.

Automated Vacuum Chamber

Each ham was positioned in the bag for sealing then an automated vacuum chamber
descends over each bag and sucking out the air and sealing the plastic.

Packaging Machine

After from the automated vacuum chamber the sealed ham was conveyed for packaging
and putting the product logo and put into the boxes.

VI. QUALITY CONTROL

Pig farming and pork production is closely regulated by government agencies such as
the United States Department of Agriculture (USDA). For example, according to USDA
standards, a cut of meat marketed as ham must come from the hind leg of a hog. Meat cut from
the front leg cannot be called a ham, but rather a pork shoulder. Additionally, the use of
hormones in pig farming is illegal.
 Pigs are extremely susceptible to several diseases, including foot-and-mouth disease,
anthrax, and hog cholera. To prevent the occurrence of these diseases, pigs are often treated
with antibiotics. In those cases, a withdrawal period is required between the time the drugs are
administered and the time that the animals are slaughtered. The USDA's Office of Food Safety
and Technical Service conducts random tests at slaughterhouses to test the pork for antibiotic
residues.

Government agencies also set rules for the operation of slaughterhouses. In the United
States, the Federal Meat Inspection Act of 1967 includes guidelines set out in the Humane
Slaughter Act of 1958. Under these regulations, animals must be rendered unconscious before
they are killed. This is accomplished by stunning or gassing the animals.