KWAME NKRUMAH UNIVERSITY OF SCIENCE AND TECHNOLOGY

COLLEGE OF SCIENCE

FACULTY OF BIOSCIENCES

DEPARTMENT OF FOOD SCIENCE AND TECHNOLOGY

REPORTS ON 3RD YEAR INTERNSHIP PROGRAMME AT BLUE SKIES GHANA.

FTECH 376: FIELD REPORT (BLUE SKIES GHANA)

FTECH 374: FIELD MINI – PROJECT

BY

ALPHINA BURUWA ADOMAKO, 4107420

MAY, 2023

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 ACKNOWLEDGEMENT

My sincerest gratitude and appreciation goes to the Almighty God for his guidance, strength, and
help in making this internship period a success. I would like to thank my supervisor Prof. Isaac
Williams Ofosu for his support and help with my project.

Special thanks go to my supervisors at Blue Skies Mr Charles Adu, Mr Mawuli, Madam

Rosemary Twumasi and Mr.Eric for the support and love they showed me throughout my stay
and for assisting me with my project. I would also like to give thanks to Lemuel, Stephanie,
Dorcas and Hannah my colleagues for all their support during my stay at Blue Skies. I say may
God richly bless you all and replenish you with all that you have lost.

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 DECLARATION

I declare that I have wholly undertaken the study reported herein under the supervision of Dr.
Isaac Williams Ofosu, Mr. Charles Adu, Mr. Mawuli and Madam Rosemary Twumasi except for
portions where references have been duly cited; this report is the outcome of my internship I
undertook at Blue Skies Ghana.

…………………………….. ……..……………………………….
Date (Signature)
(ALPHINA BURUWA ADOMAKO)

…………………………….. ……..……………………………….
Date (Signature)
(PROF. ISAAC WILLIAMS OFFOSU)

Table of Contents
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ACKNOWLEDGEMENT.......................................................................................................2

DECLARATION......................................................................................................................3

LIST OF TABLES...................................................................................................................6

LIST OF FIGURES.................................................................................................................6

PART ONE...............................................................................................................................7

FTECH 376: FIELD REPORTS.............................................................................................7

1.0. INTRODUCTION.........................................................................................................7

1.1. ROUTINE....................................................................................................................10

1.1.1. FRUITS INTAKE SESSION..................................................................................10

1.1.2. LOW-RISK..............................................................................................................13

1.1.3. HIGH CARE............................................................................................................15

1.1.4. DESPATCH.............................................................................................................16

1.1.5. TASTE PANEL.......................................................................................................18

1.1.6. CLEANING PROCEDURES.................................................................................18

1.2. DEPARTMENTS........................................................................................................20

1.3. KNOWLEDGE AND SKILLS ACQUIRED............................................................20

1.4. CONCLUSION............................................................................................................21

1.5. REFERENCES............................................................................................................21

PART TWO............................................................................................................................22

FTECH 374 – FIELD MINI PROJECT..............................................................................22

ABSTRACT............................................................................................................................22

CHAPTER ONE.....................................................................................................................23

1.0 INTRODUCTION.......................................................................................................23

1.1 PROBLEM STATEMENT AND JUSTIFICATION..............................................25

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1.2 OBJECTIVE................................................................................................................26

1.3 SPECIFIC OBJECTIVES..........................................................................................26

CHAPTER TWO...................................................................................................................26

2.0 LITERATURE REVIEW...........................................................................................26

2.1 INTRODUCTION.......................................................................................................26

CHAPTER THREE...............................................................................................................29

3.0 MATERIALS AND METHODS...............................................................................29

3.1 MATERIALS...............................................................................................................29

3.2 METHOD.....................................................................................................................30

CHAPTER FOUR..................................................................................................................31

4.0 RESULTS AND DISCUSSION.................................................................................31

4.1 RESULTS.....................................................................................................................31

CHAPTER FIVE....................................................................................................................35

5.0 CONCLUSION AND RECOMMENDATIONS......................................................35

5.1 CONCLUSION............................................................................................................35

5.2 RECOMMENDATIONS............................................................................................35

REFERENCES.......................................................................................................................36

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 LIST OF TABLES
Table 1.0 Varieties of fruits used for production and their respective holding time ………11

Table 2.0: pH and concentration of solutions from washers in Factory 2…………………15

Table 3.0: Metal detection…………………………………………………………………21

Table 4.0: Areas involved in the first trial and their respective temperatures……………… 32

Table 5.0: Areas involved in the second trial and its respective temperatures……………. 32

LIST OF FIGURES

Fig1.0: Blue Skies Foundation logo …………………………………………………………… 7

Fig 2.0 Some awards won by Blue Skies Worldwide…………………………………………..8
Fig. 3.0 Products made in Blue Skies Ghana……………………………………………………8
Fig 4.0: Polyminium sheets…………………………………………………………………….27
Fig 5.0: Polystyrene sheets……………………………………………………………………..27
Fig 6.0: Dry Ice…………………………………………………………………………………30
Fig 7.0: Gel packs……………………………………………………………………………….30
Fig 8.0: A Graph comparing the temperature of fruits against the weight of gel packs for trial
1...33
Fig 9.0: A Graph comparing the temperature of fruits against the weight of gel packs for trial
2...34
Fig 10.0: Images of packed and sealed shipment ready to be transported to the airport………38

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 PART ONE

FTECH 376: FIELD REPORTS

1.0. INTRODUCTION
Blue Skies Ghana was established in the year 1997 by Dr. Anthony Pile, a British
entrepreneur. In 1997, he arrived in Ghana, secured land, and built a small company which is
now used as a Ripening room. Blue Skies Ghana began production in 1998 and dispatched its
first shipment to a retailer in UK. Blue Skies has branches in South Africa, Egypt, Brazil,
Senegal, UK and Benin. However, the headquarters of Blue Skies is located in the UK (John
et al, 2014). Blue Skies Ghana supplies its products to customers like; Waitrose, Amazon,
Morrisons, M&S, Asda, Albert Heijn, John Sainsbury, Tesco, Aldi, Delhaize and Betty
Bossy. Engineering, Production, Technical, Agronomy, Security, Health and Safety are
some departments found in Blue Skies Ghana. The mission of Blue Skies is to build together
a profitable enterprise where people respect each other, care for the environment and inspire
a legacy for the future. Blue Skies in partnership with Albert Heijn and Waitrose has a
foundation that aims at improving the lively hood of staff, farmers and the community it is in.
The foundation is called Blue Skies Foundation.

Fig 1.0 Blue Skies Foundation logo

Since 2016 to date, Blue Skies has won several awards like Recognition Award, Egypt
2016, ‘Supermarket Supplier of the Year, Worldwide 2017’, ‘Waitrose Way Award, Ghana
2017’, ‘Best Food Business in AGI Awards, Ghana 2017’, ‘Two FPC Fresh Awards, Ghana
2018’, ‘Great Taste Award, Worldwide 2018’, ‘Innovation of the Year at FPC Fresh Awards,
Worldwide 2019’, ‘Fruit Supplier of the Year at FPJ Awards, Worldwide 2019’ and Queen’s
Award, 2020.

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 Fig. 2.0 Awards won by Blue Skies Worldwide

Fig. 3.0 Products made in Blue Skies Ghana

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ix
 1.0.1. INDUCTION PROCESS
As part of the processes needed before working as an employee in Blue Skies Ghana, it is a
requirement to go through training sessions as well as medical procedures.
1.0.2. MEDICAL SCREENING
An appointment was scheduled with the doctor for medicals on the 16 th of May. Blood
samples were taken by the resident nurse and sent to the laboratory for testing. This was done to
know whether one was fit to work at Blue Skies Ghana. Medical results were ready on the 18 th of
May, 2023 and an individual interaction with the doctor was organized where the results were
explained.
1.0.3. OCCUPATIONAL HEALTH AND SAFETY TRAINING
This section was facilitated by Mr Wisdom. It entailed a general overview of the
Occupational Health and Safety Policies of the company, types of hazards normally experienced
at Blue Skies and the particular Personal Protective Equipment (PPE) worn per the department
you find yourself in. It also involved safety precautions to watch out for and some measures to
achieve the Occupational Health and Safety policy. Lastly, a video was shown on how
employees respond to a fire drill.
1.0.4. BASIC FOOD HYGIENE TRAINING
This training was facilitated by Mr. James Annor Yankson. This section of the training
involved a discussion on hygiene. For Blue Skies Ghana, hygiene is practiced from farm to
production site to retail shops to consumer. It is believed that in order to avoid contamination,
losses, complaints and trouble from any customer, food hygiene should be the number priority
that’s why annually, training sessions are organized for employees on Food hygiene. This
session also involved how microbial, chemical and physical contamination is reduced. The two
main Critical Control Points of the company which are, Sanitization at low risk and Metal
detection were explained during this training section. The various Threat Analysis Critical
Control Point and Vulnerability Analysis Critical Control Point was discussed as some of the
food safety management used in the company.

1.0.5. ETHICAL TRAINING INITIATIVE TRAINING

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 This section was facilitated by Mr Kenneth Arthur-Baah. This section involved ethics
that govern Blue Skies Ghana. Some of these ethics are trust, respect and the Blue Skies Culture.
Their culture is defined by the people. In Blue Skies Ghana, nobody is above anyone. Everyone
is accorded the same respect. There is respect for the community, respect for the land, respect for
each other and respect for oneself as well. We were taken through the Blue Skies Culture, the
right every employee has in the company and their duties. Lastly, the right of the employer and
the duty they have to perform to ensure the safety and well-being of employees was explained
thoroughly.

1.1. ROUTINE

1.1.1. FRUITS INTAKE SESSION

Overview
Before fruits are harvested and brought to the site, pre-harvest practices are checked by
agronomists to ensure that farmers are following the required procedures. Occasionally, farmers
are taken through training and Good Agricultural Practices (GAP) to obtain the desired yield.
After harvesting, the fruits are loaded onto trucks and brought to the production site. All fruits
brought to the site are sent to the Fruit Intake Assessment Team (FIAT). Local mangoes are
rinsed with water and then washed with ICA Prochloraz 450 EC and Teacher230 SC which are food-
grade chemicals. These chemicals are used to wash the fruits to prevent any microbial attacks.
After the washing process, mangoes are conveyed on a conveyer belt to a blow drier where the
fruits are dried and stored in a chiller with a temperature between 0 ℃ and 5 ℃ to prevent
microbial activities. The fruits are then brought to Intake for assessment. After intake
assessment, the fruits are sorted and stored in chillers until it’s ready for production. Every fruit
brought into the factory has its own specified holding time.

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Table 1.0 Varieties of fruits used for production and their respective holding time.

Fruits Holding Time Variety

(Days)

Mango 21 Kent

Keitt

Osteen

Pineapple 2 Sugarloaf

MD2

Smooth Cayenne

Coconut 21 West African Tall

Apart from checking the quality of fruit consignment, a destructive test called a ripening test is
also done to check the quality of day-old fruits being sent in for production. Brix is the sugar
content of the fruit. Therefore, a fruit with a brix of 17 is sweeter than a fruit with a brix of 12.

Routine
At intake, I assumed the work of a Quality Assurance officer. When fruits arrived on site,
random sampling was done by quality assurance officers. Sampling was done from one end of
the truck through to the middle and the other end. The number of fruits per consignment
determined the number of fruits sampled. For a population less than 1000, 10 fruits were
sampled, if the population was between 1000-3000, 20 fruits were sampled, for populations of
3000 - 5000, 20 fruits were sampled and for populations greater than 5000, 25 samples were
taken.
For mangoes, the type of mango determines how the quality check would be done when a
consignment arrives. After fruit samples were taken, the external portion of the mango was
observed for any defect. For local mangoes, the mango was cut into halves making sure the seed
was divided. Defects like stone weevil infestations, tissue damage and many others were checked
and recorded. A little portion of the mango pulp was scraped and juiced into a cup. With the aid

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of a refractometer and pH meter, the brix and pH were checked. Local mangoes are normally
affected by stone weevils resulting in having a different method. For foreign mangoes, the
mangoes were peeled and observed for any defects. Approximately two-thirds of the mango was
cut to check if there were any internal defects as well. With the aid of the pH meter and
refractometer, the pH and the brix of the mangoes were checked and recorded. For ripening
checks, two-thirds of the mango was cut with a knife longitudinally. One-third from the right
side and one-third from the left side leaving the mid-section containing the seed. This was to
make visualization of any defects in the fruit easy. The pulp of the mango was squeezed into a
cup and the juice was used to determine the pH and brix of the mango. Internal and external
characters like colour and texture are checked and recorded alongside the pH and brix. After
pineapples were sampled, the crowns were detached. Approximately one-third of the part
attached to the crown was cut off with a knife and a small piece of the base of the fruits was also
cut off and the remaining portion was peeled. The fruit was assessed for any noticeable defects
like browning or bruises. The small portion was juiced into a cup and used to check the pH and
brix of the fruit. For passion fruits, a knife was used to cut through the fruit in a transverse
section. To determine degrees Brix, the juice was squeezed from one half of the fruit onto a
refractometer. More juice was squeezed from the same half into a cup to measure the pH using a
pH meter.

All fruit quality information assessed was recorded both manually and electronically in a
Consignment History Note (CHN). The electronic data recorded gives an average quality score
of the fruit assessed; if the score does not meet specifications, the technical manager was
consulted. For acceptance in such case, resorting must be done or the whole consignment would
be rejected.

1.1.2. LOW-RISK
Overview
At low risk, the first Critical Control Point (CCP) of Blue Skies which is sanitization
begins. Sodium hypochlorite, Citric acid, and VIC3 are the chemicals used for fruit sanitization.
Sodium hypochlorite is one of the most widely used sanitizers of fruits, vegetables and fresh-cut
produce (Karapinar et al., 2007). It maintains quality by reducing microbial populations and
controlling their growth. Whereas citric acid is an anti-browning agent. It lowers pH and
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prevents enzymatic browning. It acts by scavenging free radicals present to prevent polyphenols
from reacting with the fruits to result in browning (Ali et al., 2015).
There are three washers used in the sanitization process at low risk specifically in
Factory 2. They are the Andy washer, Non-washer and the Coconut washer. Each washer has its
specifications when it comes to how it is being operated and the amount of chemical used for the
sanitization. Both Andy washer and Non-Washer are used for the sanitization of all fruits except
coconut. For Andy Washer, a solution of 500ml of sodium hypochlorite and 250g of citric acid is
made in 2400L of water. For Non-washer, a solution of 1000ml of sodium hypochlorite and 500g
of citric acid is made in 5000L of water. When the concentrations of these solutions are not
within specification, citric acid is added but when the pH is not within specification, sodium
hypochlorite is added.
Coconut production begins at Low Risk. The coconut washer and the Prewash are used in
the sanitization of coconuts only. The coconuts are sawed and dried in an oven at a temperature
of 365°C for some minutes to make deshelling easier. The coconut water is poured out and the
shell is removed. After deshelling, the coconuts are sent to another bench where they are cut into
chunks or strips based on customer specification. Coconut cuts are dipped into the Coconut
prewash for 15mins and then passed into the Coconut washer for a second sanitization. The
sanitization process with the Coconut washer should last for 5 min to 8 hr. The prewash is a
solution of 150L of water and 450ml of VIC3 prepared in a tote bin. The concentration
specification for both Prewash and Coconut washers ranges from 250 ppm to 500 ppm. This is
checked using the peracetic acid test strips. Each colour formed at the tip of the peracetic acid
test strip represents a particular concentration value. The temperature specification must be
between 15-30 ℃ with a pH of 3-5 for both Prewash and Coconut washers. During the
sanitization process, the solution is changed once the concentration is above 500ppm or the
solution is too dirty. If the prewash solution concentration is below 250ppm, the original solution
is prepared aside and used as a top-up

Routine
For both Andy washer and Non-washer, the following process was used to check the pH
and concentration of both solutions. A small amount of the solution was fetched with a cup. With
the aid of a pipette dropper, 0.5 ml of the solution was measured into a cuvette. A tablet of DPD
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was added and crushed till it was dissolved in the solution. The solution was topped up with
distilled water to the calibrated mark on the cuvette. Another cuvette was also filled with the
original solution from the washers to the calibrated mark and used as a blank. The two cuvettes
were placed in a Lovibond Comparator and the concentrations were recorded. The pH of the
solution was checked with the aid of a pH meter. For the coconut sanitization solution, an
amount of the solution was fetched from the Prewash and the coconut washer. A peracetic acid
strip was dipped into the solution for about 10 s as a colour developed at the tip of the strip. The
colour at the tip was compared to the colour chart provided on the peracetic strip container and
the value was recorded. The temperature of the solution was also checked with a temperature
probe and the value was recorded. The probe of the pH meter was dipped into the solution to
check for the pH of the solution as well.

Results and Discussion

Table 2.0: pH and concentration of solutions from washers in Factory 2
WASHER pH CONCENTRATION(ppm)
Andy washer 6.25 120
Coconut washer 3.53 100
Non-washer 6.57 160

From Table 3.0, the solutions in all three washers are within specifications. In cases where the
concentration is above 200ppm for both Andy washer and Non-washer, the solution is diluted
with water and retested. However, in cases where the concentration is below 80ppm add citric
acid and when the pH is not within specification, sodium hypochlorite is added.

1.1.3. HIGH CARE

Overview
As the name suggests it is the most hygienic and cleanest place in the factory because that
is where production of all fruits except coconut begins. Colour code for High Care is Red. Fresh-
cut fruits experience maximum exposure at high care therefore, hygiene is very crucial. There are
two entry procedures that all staff and visitors must follow. All footwear must be removed and
white boots must be worn. Clean mob caps must be worn to cover the ears. Hands must be
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washed thoroughly, dried with a tissue and sanitized. A clean red coat, a pair of gloves and an
armlet are worn. Lastly, an apron is worn and hands are sanitized. In high care, activities are
segregated and the hygienic processes are strictly followed to minimize cross contamination.
Working staff are assigned to specific duties and are not permitted to move to unauthorized
sections. Segregation is held in esteem to the extent that, food handlers and waste handlers
cannot mingle with each other’s work. Trays used for peeled fruits are red and green for whole
fruits. This is to prevent cross-contamination. Fruits are cut manually into chunks and fingers
based on customer specifications. Cut fruits are transferred into trays and weighed into various
packages (pots) according to the customer's specifications. Fruits are then passed onto a
conveyor belt for sealing and labeling.
Metal detection the second critical control point (CCP) which cannot be neglected is
performed at High care. All the equipment used at the factory is made of stainless steel which
can find its way in food when a minute portion is scraped off. Before and during the final
processing stage of the cut fruits, an integrity test was performed on the metal detectors using
Non-ferrous metal, Ferrous and stainless steel. These metals were deliberately put on some
sealed samples by trained personnel and allowed to pass on the conveyor belt to check if the
metal detector would sense and push off the product with metal traces in them. After this stage
fruits were received, packed and taken to the Blast chiller to chill to a minimum temperature less
than 5°C before being forwarded to the Dispatch.

Routine
After the products were sealed, five of the products are passed through the metal detection
machine for the machine to learn the products which is about to go through the machine. After
the machine has learned the products, products are received back from the Assembly area,
sanitized and used for metal detection. Three of these products are taken and the test sticks
(Ferrous, Non-ferrous, Stainless steel) are positioned on them. The head of the product was
rejected due to the presence of the test sticks and pushed into the bin of the metal detector. This
test was performed every 30mins and also with the last 3 products at the end of the run.

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Results and Discussion
Table 3.0: Metal detection

TIME 8:30 am 9:01 am

METAL 2.5 mm ferrous Rejected Rejected

DETECTOR
REJECT TEST 3.0 mm non-ferrous Rejected Rejected

4.0 mm stainless steel Rejected Rejected

From Table 4.0, all fruit pots were rejected indicating that the metal detector passed the
metal detection reject test. However, if any of the fruit pots were not rejected, it would indicate
that the machine has failed the metal detection reject test. In such cases, the machine is stopped
and the Engineers are called to fix it.

1.1.4. DESPATCH
Overview
Despatch is made up of three sections. They are the Airfreight container room, Assembly
area and Labelling area. This is the last sector of the processing line. Room temperatures for
these sections are; Assembly Area 8 oC to 10 oC, Airfreight Container Room 0 oC to 5 oC and
Labelling Area 8 oC to 10 ℃. When sealed products are passed through the metal detection
machine, it is being received at the Assembly area and kept in a blast chiller to meet the required
temperature before being packed into boxes and then arranged in a PMC or AKE container
which is then placed into the trailer responsible for transporting the fruits to the airport for
exportation.
Label control is also done at the assembly area. It starts from the print room where the
labels are printed and checked before being sent to High Care for use. At the despatch area, four
things are mainly checked. They are, the quality of the products, how safe the product is for
consumption, the authenticity of the product and lastly the legality of the product. The Daily
Manufacturers’ Specification (DMS) is a document containing everything one needs to know
about a particular product. From the particular batch of fruits used in the production, customer
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name, the date of production, the use by date, the weight of the product, the number of pots
found in a particular secondary package (box), the box type, the line in which the product was
sealed and labeled on, the content on both top and based labels, the temperature of fruits and the
names of the officiating personnel at every stage. The Daily Manufacturing Specification (DMS)
is also reviewed at Despatch to ensure amendments are effective, labels used are correctly done
in terms of position and colour, the right dates as to when products are to be used and all the
content on the DMS are accurate.

Routine
As a quality assurance(QA) officer, you must examine the quality of the product by
determining if there are any defects in the product such as bruised fruits, browning spots,
underweight or overweight pots and correct colour coding. Another duty is to determine if the
products are safe for consumption. This is about checking the used by date if it's correctly
calculated. Again, the quality assurance officer must check the product's authenticity before it
leaves the site. This means checking both the inside and outer labels. The inner labels refer to the
top and bottom labels found on the primary package and the outer label is found on the
secondary package thus the crates. This process involves verification of the content on each label
if it corresponds to the customers' specification and the daily manufactures specification (DMS).
Lastly, a QA must ensure that the labels are not swapped. If something like this is to happen
legal actions can be taken against the supplier.

1.1.5. TASTE PANEL

A taste panel is a group of people that help assess finished products that have been
produced on a particular day (P+1) with respect to the various raw materials used for production.
They do this with the help of their senses (touch, smell, taste, sight). They assess if the products
are good based on some features such as appearance, taste, smell and feel. The taste panel also
assesses products that have reached their used by dates (EOL- End of Life). For EOL (end of
life) products, they are assessed to see if they are still in good shape to be consumed with respect
to their smell, taste, appearance and feel. So basically, the taste panel does a sensory evaluation
on already existing products to confirm if the products reach customer specifications.

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1.1.6. CLEANING PROCEDURES
Adenosine Triphosphate (ATP), is an energy molecule found in all living cells that allows
cellular metabolism to take place. In food processing, there are many forms of organic matter
such as debris and bacteria left on surfaces. This organic matter can become a point of cross-
contamination which could probably lead to food contamination and food spoilage if food
contact surfaces are not well cleaned. In addition, contaminated surfaces and equipment can also
lead to rapid microbial contamination. Therefore, if food is going to be in contact with the
surface, it is essential to rid the risk of contamination from that surface by cleaning it thoroughly.
It is widely known that where there is ATP, there is a higher chance of the presence of
microorganisms. Thus, the higher the ATP level, the higher the probability of Bacteria and other
microorganisms being present. Therefore, the surface would need to be recleaned before
swabbing is done to obtain lower ATP levels. General cleaning is done every Thursday. Clean-
Out-of-Place occurs every Thursday whiles Clean-In-Place takes place every day except
Thursdays.

Routine

During processing, a cleaning team was responsible for all in-process cleaning but at the
end of production which was at 6 pm, production was stopped and cleaning began. As a Quality
Assurance Officer, it was my duty to supervise the cleaning process making sure every tool and
equipment was cleaned properly and ensuring the use of the right detergent. Four stages were
used in the cleaning process. They were:

 Pre-rinse – Surfaces of tools and equipment were rinsed with water. This washed away
some of the dirt making cleaning easier.
 Main clean – Surfaces and corners of all tools and equipment were scrubbed with a
solution of 1% Diverclean in 150 L of water.
 Rinse – Surfaces were rinsed with water. This helped to get rid of all foam on surfaces.
 Inspection – Quality Assurance Officer went around to check if every tool and equipment
has been cleaned properly.

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  Disinfection – The tools were now rinsed with a sanitizer containing 1% Active in 150 L
of water.

After cleaning was done, a sanitization process called foaming was done. 1% Active is
poured into the foaming machine and the foam generated was poured over every tool/equipment
on the production floor. The foam was left for 15mins to ensure the efficacy of the sanitizer and
then rinsed with water. Approximately 50 g of chlorine was dissolved in 100 L of water. This
solution was poured at the edges of the factory.

An ATP Hygiene test was done at the end of cleaning to give a clear indication of
cleaning efficacy. This test was used to measure levels of ATP on a surface, and thus the
cleanliness levels of the production floor. The ATP test provided accurate results that define,
monitor and maintains cleaning standards within a facility. The presence of ATP on a surface
indicated improper cleaning and the presence of contaminants, including food residue, allergens,
and/or bacteria (Bakke, 2022). This implied that the potential for the surface to harbor and
support bacterial growth was high. Adenosine Triphosphate (ATP) test was done with an MVP
icon and a surface sampling device which was a self-contained device used with the MVP icon
for quality and HACCP related hygiene monitoring of the environment. The MVP device had a
range of numbers that indicated Pass (values < 2.5), Warn (values between 2.5-3.0) and Fail
(values >3.0). When Warn or Fail is detected, staffs are to clean again to Pass the test.

1.2. DEPARTMENTS

The Agronomy department focuses on the cultivation of fruits on Blue Skies' farms. They
work closely with farmers to ensure that the crops are grown using sustainable practices and
meet the required quality standards. This includes guiding soil management, pest control and
irrigation techniques.

The Engineering department is responsible for maintaining and repairing the machinery
used in production. They ensure that all equipment is in optimal condition to maximize
efficiency and minimize downtime.

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 The Production department oversees the day-to-day operations of the production facilities.
They coordinate with other departments to ensure that production targets are met while
maintaining high-quality standards. This includes managing inventory, scheduling production
runs, and implementing quality control measures.

The Technical department plays a critical role in ensuring raw material and product quality
within the company. They establish quality standards for raw materials, conduct tests and
analyses to verify their quality, monitor the fruit production process, and perform inspections
on finished fruit products. By implementing robust quality control measures, the technical
department helps maintain customer satisfaction, minimize product recalls, and uphold the
reputation of the organization.

Security is a critical aspect of Blue Skies operations. The Security department is responsible
for ensuring the safety and security of the facilities, employees, and products. They
implement measures to prevent theft, vandalism, and unauthorized access to the premises.
This includes monitoring surveillance systems, conducting regular security audits, and
training staff on security protocols

1.3. KNOWLEDGE AND SKILLS ACQUIRED

 Communication skills
 Teamworking skills
 Problem identification skills
 Working effectively with little supervision
 Knowledge of the basic food hygiene principles
 Knowledge of the different varieties of mango, pineapple and passion fruit.
 Knowledge of the 2 Critical Control Points (CCP) at Blue Skies Ghana.
 Knowledge of the relevance of firm perforations.
 Knowledge of how a comparator is used to check the concentration of solutions
 Knowledge of how to use the refractometer to check the brix of a fruit
 Knowledge of why Dipping and Flushing of fruits is done.

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1.4. CONCLUSION
This industrial attachment at Blue Skies Ghana has provided me with the opportunity to work
in an actual working environment. Working in Blue Skies has exposed me to a lot of
knowledge and has also enhanced my communication and team working skills. It has allowed
me to apply the theoretical knowledge taught in class to practical situations and has
broadened my knowledge in my field of study.

1.5. REFERENCES
 Ali, H., M., El-Gizawy, AM., El-Bassiouny, R.E., I (2015)"Browning inhibition
mechanisms by cysteine, ascorbic acid and citric acid, and identifying PPO-catechol-
cysteine reaction products”. Journal of Food Science Technology 52, 3651-3659.
https://doi.10.1007/s13197-014-1437-0.
 John-Paul Ferguson and Laurent De Clara (2014) “Blue Skies: Connecting African
Farmers to Global Markets”. Case No. IDE08, pp16
 Karapinar, M., Sengun(2007) “Antimicrobial effect of Koruk (unripe grape-Vitis vinifera)
juice against Salmonella typhimurium on salad vegetables”. Food Control; 18:702–706
 Mikio Bakke (2022) “A Comprehensive Analysis of ATP Tests: Practical Use and Recent
Progress in the Total Adenylate Test for the Effective Monitoring of Hygiene”, Journal
of Food Protection, Vol. 85, No. 7, p1079–1095

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 PART TWO

FTECH 374 – FIELD MINI PROJECT

TITLE: Optimizing the Quantity of Gel Packs to Improve Product Temperatures During
Transportation.

ABSTRACT
The transportation of temperature-sensitive goods is a critical challenge faced by various
industries, including pharmaceuticals, food and biotechnology. Proper temperature maintenance
is crucial to ensure the integrity and quality of these products during transit. Gel packs and dry
ice are commonly used as refrigerants to regulate temperatures in cold chain logistics. However,
determining the optimal quantity of these cooling agents to achieve the desired temperature
range while minimizing cost and environmental impact is a complex task. This project aims to
explore the effective use of gel packs and dry ice to maintain fruit temperatures below 5 ℃
without causing freezing damage. Maintaining low temperatures is crucial for preserving the
quality and extending the shelf life of fruits but the traditional cooling methods can eventually
result in freezing, leading to texture and flavour deterioration. By utilizing dry ice which
sublimes directly from solid to gas and gel packs, this research investigates the feasibility of
achieving optimal fruit temperature conditions while preventing freezing damage. The
experimental data was analyzed to determine the correlation between cooling agent quantities
and transit temperatures. The results indicated that the use of 60 kg gel packs proved effective in
maintaining the desired temperature range.

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 CHAPTER ONE

1.0 INTRODUCTION
The United Fresh Produce Association defines fresh-cut products as fruits or vegetables that
have been trimmed, peeled, or cut into 100% usable products. These products are bagged or pre-
packaged to provide high nutrition, convenience, and flavor while maintaining freshness. Proper
storage conditions, such as temperature, are crucial for preserving fruits and preventing
premature spoilage. The ideal temperature range for fresh-cut fruits is between 0 ℃ to 5 ℃
(Thompson et al.,2003), which slows down bacteria growth and maintains their quality.
However, exposure to ambient or high temperatures can accelerate spoilage and enzymatic
browning. Proper temperature management is essential from production to transportation for
product quality. Conventional cooling methods can lead to freezing, negatively impacting fruit
texture, flavor, and overall quality. Proper insulation and the addition of refrigerants like gel
packs, dry ice, and water packs can help maintain the temperature below 5 ℃ and maintain the
cold chain in the long run.

A gel pack is a plastic sack or bag filled with a refrigerant gel, meant to provide cooling. The
gel is made of hydroxyethyl cellulose, polymer and silica coated with vinyl (Erik, 2017). They
can be divided into the reusable type and the instant type. The instant type is generally limited to
medications while the reusable type is used to keep food cool in portable coolers or in insulated
shipping containers to keep products cool during transport (Singh et al., 2008). When the gel
pack is placed in contact with a warmer object or environment, it absorbs heat from the
surrounding environment or objects it is in contact with. Thereby keeping the surrounding area
or object cool for an extended period. Dry ice is a solid form of carbon dioxide, colourless,
odourless, non-flammable and can lower the pH of a solution when dissolved in water,
forming carbonic acid (H2CO3) (Yaws et al., 2001). Dry ice is commonly used as a cold source
inside the insulated cold-storage packages which are often transported via air freights.
Unfortunately, dry ice sublimation leads to the freezing of fruits around it, thus the need to use a

xxiv
limited amount. To ensure the safe use of dry ice, it is essential to follow proper handling
procedures, use appropriate personal protective equipment, and work in well-ventilated areas and
dispose of dry ice responsibly.

Insulation of shipping containers is important for the prevention of condensation and

prevention against different temperatures. Thus the use of polystyrene and polyminium sheets to
insulate shipping containers in Blue Skies. Polyminuim and polystyrene sheets are used as part
of a cold chain to help maintain product freshness and efficacy (Matsunaga et al., 2007).
Polystyrene sheets are materials commonly lightweight and provides excellent thermal
insulation, making them ideal for keeping products at a stable temperature during transit.
Additionally, polystyrene sheets are resistant to moisture, ensuring that the goods remain
protected from any potential damage caused by humidity or condensation (William et al., 1979).
In Blue Skies, Polystyrene sheets are wrapped around the prepared container whiles the
polyminium sheet is placed at the sides of the container.

Fig 4: Polyminium sheets Fig 5: Polystyrene sheets

To track the fruit temperatures, a temperature logger is normally added to the shipment.
A digital temperature logger is a portable measurement instrument that is capable of
autonomously recording temperature over a defined period. It is enclosed to monitor the
temperature inside the container for its entire shipment. The data can be retrieved, viewed and
evaluated after it has been recorded. Temperature-sensitive products such as fruits,
pharmaceuticals and some chemicals are often monitored during shipment and logistics
operations (Wessel et al., 2011). Exposure to temperatures outside of an acceptance range, for a
critical period, can degrade the product or shorten shelf life (Raab et al., 2011).

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 1.1 PROBLEM STATEMENT AND JUSTIFICATION
The cold chain system of fruit processing is essential to Blue Skies Ghana due to its no
preservatives policy. It was observed that the use of 20 kg gel packs was insufficient in
maintaining product temperatures (0℃ to 5℃) during transportation. However, an increase in
the number of gel packs used per shipment which can maintain product temperature is not
practised. Too often, it's been observed that product arrival temperatures are too high because
little gel packs are added to the shipment affecting product quality. This compromises the quality
of fresh-cut fruit, leading to product recalls and disposal. If this issue is not addressed, it
challenges SDG goal 2 as it leads to food waste.

1.2 OBJECTIVE
To determine the appropriate number of gel packs on shipments that would be needed to
sufficiently maintain desired product temperatures.

1.3 SPECIFIC OBJECTIVES

 To determine impacts of different amount of gel packs (Control(20 kg),60 kg,80 kg) on
product temperatures
 To determine whether longer transit hours would affect arrival temperatures

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 CHAPTER TWO

2.0 LITERATURE REVIEW

2.1 INTRODUCTION
Once fruits are harvested, their source of water and minerals ends. Fruit tissues begin to
senesce rapidly and continue to respire, using available and stored sugars and organic acids.
Postharvest quality loss is primarily a function of respiration, onset or progression of ripening
(climacteric fruit), water loss (transpiration), and enzymatic discoloration of cut surfaces, decay
(microbial), senescence and mechanical damage suffered during preparation, shipping, handling,
and processing (Schlimme et al., 1994, Watada et al., 1996). This makes it critical that
temperature dependent events related to respiration, water loss, pathological decay, and ethylene
production be strictly regulated during production and shipment (or storage) of the fruit. In
maintaining the temperature of fruits from production to transportation, the cold chain system
must be uninterrupted. Cold chain refers to the uninterrupted series of refrigerated processes and
activities that keep the temperature of perishable products within a specified range from
production to consumption. Unlike other companies, Blue Skies adds no preservatives to its
products making temperature perform a vital role in maintaining product quality. To maintain the
cold chain during the transportation of fresh-cut fruits, the source of cold that can maintain the
desired temperature range of the products needs to be considered. Eutectic plates, cryogenic
refrigeration, gel packs or dry ice can be used to provide cooling during transportation (Olivo,
2022). Dry Ice is a solid form of carbon dioxide, colourless, odourless, non-flammable and can
lower the pH of a solution when dissolved in water or forming carbonic acid (H2CO3) (Yaws et
al., 2001). It works using the principle of sublimation. Gel packs, however, are plastic sacks or
bags filled with a refrigerant gel, meant to provide cooling. The gel is made of hydroxyethyl
cellulose, polymer and silica coated with vinyl (Erik, 2017). When the gel pack is placed in
contact with a warmer object or environment, it absorbs heat from the surrounding environment
or objects it is in contact with. Dry ice and Gel packs are commonly used as cold sources
(refrigerants) inside the insulated cold-storage packages which are often transported via air
freights.

xxvii
Insulation of shipping containers is important for the prevention of rapid condensation of cooling
refrigerants. Thus the use of polystyrene foam and polyminium sheets to insulate shipping
containers in Blue Skies. Polyminuim sheet and polystyrene foam are used as part of a cold chain
to help maintain product freshness and efficacy (Matsunaga et al., 2007). Polystyrene sheets are
resistant to moisture, ensuring that the goods remain protected from any potential damage caused
by humidity or condensation (William et al., 1979). Polyminium sheets are made of
compressions of tiny bubble foams. Containers such as PMC and AKE are used in Blue Skies
Ghana as a way to also maintain the cold chain. Refrigerated vehicles like trailers are used to
transport shipments from the factory to the airport. The use of these things to maintain the cold
chain is called cold chain logistics. Cold chain logistics involves the use of refrigerated vehicles,
containers, storage facilities, and packaging materials that can control the temperature and
humidity of the products (Ambaw et al, 2021).

2.2 BODY

Thermal abuse is a primary concern during the distribution of temperature-sensitive goods such
as pharmaceutical, food, electronic and horticulture products. It is a term used to describe the
exposure of fresh-cut fruits to temperatures that are higher than their optimal storage
temperatures (Chaves et al,2022). It can cause rapid deterioration of the quality and safety of the
products, as well as shorten their shelf life. Temperature plays a crucial role in determining the
quality and shelf life of fruits. Different fruits have varying temperature requirements for optimal
storage and preservation. Temperature greatly influences the ripening process of whole fruits.
Once fruits are kept under temperatures between 0℃ and 5℃, the ripening process slows down
and fruit shelf life is extended (Thompson et al.,2003). However, when exposed to high
temperatures, can increase the respiration rate and metabolic process of fresh-cut fruits that can
reduce product quality by causing browning, softening, wilting, decay and microbial growth.
However, unlike whole fruits, fresh-cut fruit is highly perishable and susceptible to microbial
spoilage, enzymatic browning, water loss, and physiological changes. Low temperatures can
slow down these undesirable processes and maintain the freshness, appearance, texture, flavour,
nutritional value, and hygiene of the products (Jiao et al., 2021). Temperature also influences the
flavour and aroma profiles of fruits. When fruits are exposed to extremely high temperatures, it
leads to flavour degradation in some fruits (Paliyath et al.,2012). The recommended storage

xxviii
temperatures for fresh-cut fruits vary depending on the type of fruit(Queensland Government,
2017) but generally range from 0℃ to 7℃(Elizabeth et al., 2012). To track the fruit
temperatures throughout the transportation period, a temperature logger or sensor is normally
added to the shipment. Temperature loggers or sensors are used to record the temperature and
humidity of the product and the environment it’s in during transportation (Ambaw et al.,2021). It
is enclosed to monitor the temperature inside the container for an entire shipment.

2.3 CONCLUSION

Thermal abuse can occur during any stage of the cold chain, such as harvesting, processing,
packaging, transportation, distribution or retailing. Some of the factors that can contribute to
thermal abuse are inadequate cooling, improper insulation, equipment failure, human error, or
environmental conditions (Chaves et al,2022). Therefore, avoiding thermal abuse and
maintaining the cold chain is essential for ensuring the quality and safety of fresh-cut fruits. An
uninterrupted cold chain system can reduce the food loss and waste that occur due to
deterioration or damage of the products during transportation. It saves cost, resources and
energy, as well as contributes to environmental sustainability and food security (FAO,2019).

xxix
 CHAPTER THREE

3.0 MATERIALS AND METHODS

3.1 MATERIALS
In the optimization of the number of gel packs to improve product temperatures during product
transportation, Gel packs, Dry Ice, PMC pallets, Polyminium sheets, Polystyrene sheets and a
Temperature logger.

Fig 6: Dry Ice Fig 7: Gel Packs

3.2 METHOD

3.2.1 TEMPERATURE READING

The temperature readings of the Labelling area, Blast chiller, and Airfreight container was taken.

3.2.2 SAMPLE PREPARATION

Temperature readings of products were measured in the blast chiller and products with
temperature readings below 5 ℃ were released for packaging. Products were packed into boxes
and labelled. Among the products, three were selected at random and placed in a temperature
sample labeled box. The temperature of those products was taken and recorded.

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3.2.3 SHIPMENT PREPARATION

A PMC pallet was insulated with polyminium sheets and boxes were packed on it. While boxes
were being packed unto the PMC pallet, gel packs were arranged in the shipment. Temperature
samples were placed in shipment with one at the buttom, one in the middle and the last on one
top. A temperature logger was placed on top of the prepared shipment and then insulated with a
polyminium sheet. The whole shipment was covered with polystyrene sheets to complete the
insulation process. This process was done for all three shipments. The first shipment contained
20 kg gel packs, the second shipment contained 60 kg gel packs and the third contained 80 kg gel
packs.

3.2.4 FINAL TEMPERATURE READINGS

Upon shipment's arrival, products were transported in a trailer to Heathrow, where products were
released to the rightful customers. Temperature readings of the temperature sample were
measured and results were sent to Ghana.

CHAPTER FOUR

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 4.0 RESULTS AND DISCUSSION

4.1 RESULTS
Table 4.0: Areas involved in the first trial and their respective temperatures

AREA TEMPERATURE(℃)

Labeling area 9.6

Blast Chiller 1.4

1.1

Airfreight container room 4.2

Trailer 0.4

Table 5.0: Areas involved in the second trial and their respective temperatures

AREA TEMPERATURE(℃)

Labeling area 8.2

Blast Chiller 2.0

2.8

Airfreight container room 4.8

Trailer 0.6

The temperature of the labeling area, blast chiller, airfreight container room and trailer was
measured and recorded for both trials as seen in Tables 4 and 5. From the temperatures in Tables
4 and 5, it can be concluded that the temperatures of these areas were within specification. This
cannot negatively affect product quality. In situations where specifications are not met, more
cooling refrigerants are added to shipments to help keep the temperature of products within 0 ℃
to 5 ℃.

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 TEMPERATURE OF FRUITS
12

10

0
Control( 60 kg 80 kg
20 kg)
WEIGHT OF GEL PACKS
INITIAL FINAL

Fig 8: A Graph comparing the temperature of fruits against the weight of gel packs for trial 1.

From Fig 8, there was an increase in product temperature of products with 20 kg gel
packs. This is as a result of an inadequate number of gel packs. The number of gel packs in a
shipment is determined by the number of products found. The temperature of products in the
shipment with 60 kg was within specifications. Ideally, fresh-cut fruits should be stored at a
temperature ranging from 0 to 5 ℃ (Thompson et al, 2003). Products had initial temperature
reading of 1.9 ℃, 2.1 ℃, 1.4 ℃ and the final temperature 3.4 ℃, 5.1 ℃, 4.7 ℃. Therefore, the
quality of product in shipment two (60 kg) was not compromised. Products in shipments with 80
kg gel packs was made to experience longer transit to see if the number of gel packs used would
be sufficient to maintain product arrival temperatures. An increase in product temperatures was
noticed from Fig 8 upon product arrival. The increase was a result of the shipment experiencing
longer transit hours in Dubai which has a higher temperature. The quality of temperature-
sensitive products can be affected by the length of transit time. The longer the transit time, the
higher the risk of temperature excursions and the greater the impact on product quality (DHL,
2022).

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 14

12
TEMPERATURE OF FRUITS

10

0
Control( 60KG 80KG
20 kg)
WEIGHT OF GEL PACKS
INITIAL FINAL

Fig 9: A Graph comparing the temperature of fruits against the weight of gel packs for trial 2.

From Fig 9, there was a rapid rise in product temperature for shipment with 20 kg gel
packs. Product temperatures recorded before packing was 2.6 ℃, 3.0 ℃, 2.9 ℃ but upon arrival
recorded temperatures were 12.9 ℃, 8.9 ℃ and 12.5 ℃. For shipments with 80 kg gel packs,
there was a slight increase in product temperatures where the initial temperatures were 2.1 ℃,
1.9 ℃ and 1.6 ℃ with final temperatures of 4.9 ℃, 6.2 ℃ and 8.5 ℃. However, shipments
with 60 kg gel packs had product temperatures within specifications. Due to an inadequate
number of gel packs the first shipment (20 kg gel packs) saw a rapid increase in product
temperature. The number of products and the number of gel packs were not proportional thus the
increase in arrival temperature. All three shipments experienced same transit hours, however, the
gel packs used in the third shipment (80 kg) were not fully frozen resulting in them melting
faster.

At the end of both trials, it was noticed that longer transit hours affect product
quality. Thus the need to add more cold refrigerant to help withstand transit temperatures. The
quality of the products in both trials was maintained but gel packs above 60 kg were effective in
preserving fruits quality, reducing spoilage and extending shelf life during transportation.

xxxiv
 CHAPTER FIVE

5.0 CONCLUSION AND RECOMMENDATIONS

5.1 CONCLUSION
The utilization of 60 kg gel packs for maintaining fruit temperatures proved to maintain
temperature below 5 ℃ without freezing damage during transportation. The shipments with
longer transit hours experienced an increase in product arrival temperatures. Thus the need to
increase the number of gel packs in shipment which would experience longer transit hours.
Maintaining the cold chain during the transportation of fresh-cut fruit is essential for ensuring the
quality and safety of the products, as well as reducing the environmental and economic impacts
of food loss and waste.

5.2 RECOMMENDATIONS
These findings can be used as a practical guideline for Blue Skies Ghana and other
industries relying on temperature-sensitive shipments to enhance product quality, reduce
operational costs and promote sustainability in cold chain transportation. Further research is
encouraged to explore the applicability of these findings to develop more sophisticated models to
account for varying conditions.

xxxv
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