COC 2 Fermentation and Pickling

CORE COMPETENCIES
UNIT OF COMPETENCY : Process Food by Fermentation and Pickling
MODULE TITLE : Processing Food by Fermentation and Pickling

Page | 1
UNIT CODE : AGR741301
UNIT DESCRIPTOR: This unit deals with the skills, knowledge and attitudes
required to process foods by Fermentation and Pickling
L.O.1 Prepare Equipment, Tools and Utensils
LEARNING CONTENT:
1.1 Identify and prepare the different equipment, apparatus, tools and utensils for
salting, curing and smoking.
1.2 Perform proper cleaning operation and sanitation of the different equipment,
apparatus, tools, and utensils
1.3 Perform proper cleaning operation and sanitation of the work area
1.4 Check and calibrate the different equipment, apparatus, tools, utensils for the
process.
Performance Criteria:
1.1 Equipment and tools for salting, curing and smoking are prepared
in accordance with manufacturer’s specifications.
1.2 Equipment for the above food processing methods are checked,
sanitized and calibrated in accordance with manufacturer’s
specifications.
1.3 Kitchen utensils for the above food processing methods are readied
and sanitized in accordance with manufacturer’s specifications.
1.4 Office equipment and materials/ supplies needed are prepared in
accordance with approved specifications.
INFORMATION SHEET 1.1-1

GLOBAL i.t. Studies Inc. Prepared by:
Simeon Lee Building Abella Naga City JOMAR D.P. SABENIANO
Tel. No. 881-7767 Noted by: DIXIE C. DIAZ
WEEK 1 ( MODULE 1)
PROCESS FOOD BY FERMENTATION AND PICKLING
PRICIPAL AND ADMINISTRATOR
TOOLS, EQUIPMENT AND MATERIALS USED IN PROCESS FOODS BY
SALTING, CURING AND SMOKING
Page | 2 Tools
Plastic rectangular perforated trays
ginamit laganan kan

mga raw materials o ingredients sa pag food
processing
Long handled ladles (SS)

Ginagamit pang saldok sa mga kakanun o ingrediets
Heavy duty buttom pan (SS)
ginagamit nin lutuan nin mga

lulutuon na raw materials o sangkap
Pairing knives ginagamit na

WEEK 1 ( MODULE 1)
pang-ubak o pang giris
Page | 3
Knives SS
Ginagamit sa pang ubak o pang giris sa darakulang

raw material;
Peelers ginagamit nin pang

uabak nin prutas
Measuring spoons, sets SS
Ginagamit pansukol kan mga solidong ingredients
Measuring cups for liquid (plastic)

WEEK 1 ( MODULE 1)
Page | 4
ginagamit pang
sukol sa mga liquido ingredients
Clocks/timer ginagamit
bilang orasan
Mixing bowls, stainless steel
ginagamit sa mga mislahan o

haluaan kan mga ingredients sa pag processo kan kakanun
Heavy duty plastic chopping board( HDPE)

WEEK 1 ( MODULE 1)
Page | 5
chopping boards
ginagamit bilang tadtataran

Dial thermometers ginagamit sa pagsukol kan temperatura
kan kakunun
Jar lifter ginagamit nin pankua nin mga steriladong
garapon na gagamiton laagan
Wire baskets ginagmit bilang basket pag dakul na

WEEK 1 ( MODULE 1)
Page | 6
ilalaag
Casseroles stainless steel

ginagamit lutuan depende sa dakul kan lulutuon
Spoon, basting ginagamit na pansukol o maski anus
a pag processo kan kakanun
Food tongs ginagamit pangkua nin kakanun

WEEK 1 ( MODULE 1)
Page | 7
Steamer ginagamit sa
pag steam kan mga gulay o prutas
SS spatula ginagamit sa pang

halo kan kakan ingredients o kakanun
Utility trays
ginagamit para maging laganan kan mga ginagamit

sa pag luluto
Colanders, stainless steel

WEEK 1 ( MODULE 1)
Page | 8
ginagamit paturuan
Washing vat ginagamit

sa pag huhugas kan mga prutas o gulay
Funnel SS ginagamit dae mauli an pinapalis
Equipment

WEEK 1 ( MODULE 1)
Page | 9
Smoke house
ginagamit sa pag luluto kan process smoke fish
Refrigerator ginagamit
laganan kan mga refrigerated foods , prutas asin iba
pa
Freezer ginagamit na
laganan kan madaling maraot na raw material para
haloy an sbuhay.

WEEK 1 ( MODULE 1)
Page | 10
Stoves ginagamit nin

lutuan
Trolley ginagamit laganan

kan mga naluto o naprocesseso kakanun o mga
ingredients para mapadali an pag dadara
Cap sealer pan sarado nin

takop kan finish product.
Pressure cooker pan luto sa mga medyo kaipuhan

WEEK 1 ( MODULE 1)
Page | 11
lutuong marasy
jacketed kettle pag luto sa mga dae medaling lutuon
asin pirming mainit an luto
refractometer (0-70o brix)

WEEK 1 ( MODULE 1)
Page | 12
Headspace gauge
Vernier caliper
Gas tank liquid or gas flammable materials na

gamit sa pagluluto
Vacuum gauge
nagsusukol kan kantidad kan pressure

WEEK 1 ( MODULE 1)
Weighing scales (10 kg. capacity)
Page | 13
pang darakulang
pag kilo
Food processor, set
Stainless steel blender pag durog oh pag halo kan
mga prutas sa madaliang paagui.
Digital weighing scales 1 – 2 kg cap with 2 decimal

graduation gamit sa pag kilo na nahiling ang decimal.
Tools, Equipment , Materials

WEEK 1 ( MODULE 1)
Measuring spoons
Salinometer with cylinder
Weighing scale (10-50 kgs)
Sticker labels
Aprons
Whetstone
Spatula
Freezer Upright
Page | 14 Weighing scale (1- 6 kgs) Fish
Hair Nets
Chopping boards
Food trays
Refrigerator
Refractometer 50 pcs.
Fruit
Mouth Masks
Calculator
Colanders
Cooler box
Polysealer
Vegetables
Rubber Boots
Stove
Trays
bottles
pH meter
Titration set-up
Gloves
White board,
Containers for salt, condiments, spices
Whiteboard eraser
Vegetable Cutter (Food Processor)
White board pens
Polyethylene bottle (PEB)/ Polypropylene (PP)
TRAINING MATERIALS
Mixing Containers/Vats
Probe thermometer 5 copies • books/ reference
NYPE pouch 5 copies • manual
Knife 5 copies • videos
Food processing
-is the transformation raw ingredients, by physical or chemical changes into food. ... It
combines raw ingredients to produce marketable food products that can be easily prepared
and served by the consumer.
clean·li·ness
Cleanliness is both the abstract state of being clean and free from germs,
dirt, trash, or waste, and the habit of achieving and maintaining that
state. Cleanliness is often achieved through cleaning.
PROCEDURAL ENFORCEMENT GUIDELINE of 7’s from 5’s of

Good Housekeeping
WEEK 1 ( MODULE 1)
Policies
1. Definition of Terms:
a. Seiri ( Organization) - identification of the best physical organization of
the
workplace.
Page | 15 b. Seiton (Orderliness) – series of steps by which the optimum identified in
Seiri
are put into place.
c. Seiso ( Cleanliness) – establish the maintenance of a clean environment as
an
ongoing, continuous programme.
d. Seiketsu (Routine clean-up) –introduction of a formal, rigorous review
programme to ensure that benefits of the first three 7S are maintained.
e. Shitsuke (Discipline-Habit) – set of approaches use to win heart & minds,
to
make employees want to keep applying best practices in office organization
&
housekeeping.
f. Anzen-sei (Safety) – component requiring attention to safe setting
g. Seishin (Spirit) – understanding the impact of company culture and
importance of respect for employees.
2. All employees are required to conform with the proper guidelines in the
implementation of the 7S program.
3. A reward system will be granted & funded from the proceeds of the sale
from the
War on Waste (WOW) programme.

Procedures
1. Organization (Sorting) – must clearly distinguish needed from unneeded
items &
eliminate the latter.
a. Only use materials, equipment & supplies that are needed, when they
needed,
b. Eliminate excess & obsolete equipment, appliances & inventory
c. Improve inefficient space utilization.
d. Eliminate space taken up by unneeded items.
e. Remove outdated papers & files.
f. Reduce cabinets, shelving, lockers containing files.
g. Look in unlabeled boxes, shelves, bottom of location.
h. Eliminate outdated posters, wall boards, slogans & banners.
2. Orderliness (Simplifying) – keep needed items in the correct place for easy
&
Immediate retrieval
a. Put everything in useable place.

WEEK 1 ( MODULE 1)
b. Make every item visible, reachable, & available when needed.
c. Locate missing documents, instructions, keys, office stationeries &
inventory.
d. Define clear, shiny, well-marked aisle-ways.
e. Color code areas.
Page | 16 f. Post slogans & banners,.
g. Limit work in process.
h. Post Standard Work Documents.
3. Cleanliness (Sweeping) – keeping the workplace swept & thoroughly clean.

a. The cleaner the better
b. Clean areas where red-tagged items were removed.
c. Remove dirt, oils, scraps, garbage.
d. Clean on a daily basis.
e. Audit the cleaning process
f. Improve equipment maintenance.
g. Clean aisles, machines, desks; assign cleaning responsibilities.
h. Create target areas: equipment, floors, machines & desks
i. Cleaning checklist; correct deficiencies; correct root causes of unclean
items.
j. Verification of review procedures; create target areas.
4. Routine Clean-up (Standardizing) – standardize clean-up & organization

through guidelines
a. Maintain & control continual improvement achievements.
b. Ensure systematic organization, sorting, & dusting clean are
synchronized.
c. Plan, allocate, act & verify.
d. Step 1 – Who does what & when
e. Step 2 – Allocate – Assign resources to tasks.
f. Step 3 – Act – Perform tasks & integrate into daily operations.
g. Step 4 – Verify – Ensure effectiveness.
5. Discipline Habit (Self Discipline) – make a habit of maintaining

established 5S
procedures & discipline through verification & checklists.
a. Practice prevention, discipline, & accountability.
b. Ensure control of systematic organization, orderliness & cleanliness.
c. Persevere & sustain discipline to ensure improvements are maintained.
d. Identify how action are to be accomplished
e. Develop standard worksheets.
f. Follow-up on action & responsibilities.
g. Hold people accountable.
h. Lead by example
i. Persistently communicate & advertise.
j. Perform a gap [analysis on defects & identify corrective actions.
6. Safety (Risk Elimination) – attention to safety throughout the other steps.

a. Workplace must maintain order throughout the workplace.

WEEK 1 ( MODULE 1)
b. Freedom from unacceptable risk of harm from clean & orderly
environment.
7. Spirit (Sustain) – To make explicit the reliance on the people factor and
the
Page | 17 need to continually keep in mind as other steps are undertaken.
a. Continuously perform the 7S activities.
b. Seek further improvement.
Food contact surfaces and large utensils/machines

should be washed, rinsed and sanitized by hand, using the
three-bucket system.
Three-bucket System
Wash (Red Bucket) Use water that is as hot as you can tolerate to activate
the detergent. Wash the item or surface of the item with a cloth, brush or
approved scouring pad.
Rinse (Gray Bucket) Rinse the item or surface with hot clean water
utilizing a clean cloth.
Sanitize (White Bucket)
The sanitation solution should be mixed to contain 200 ppm of chlorine —
1/2 oz. of bleach (30 ml) to 2 gallons of water (8 liters).
Use the chlorine cap for measurement. The sanitizing solution must have
a temperature of at least 24°C (75°F).
Sanitize the cleaned item or surface by swabbing with a clean cloth that
has been immersed in this solution.
Leave the surface slightly damp to permit the chlorine to effectively
sanitize and air dry.
Only food-contact surfaces must be sanitized.
Use a towel to dry any of the equipment or food contact surfaces. All food
service surfaces must air-dry after they have been wiped with sanitizing
solution. Sanitize .
A.Washing Utensil in Three compartment Sink
Step 1: Scrape - Remove excess food that may deactivate the detergent.
Step 2: Wash (Sink 1) - Thoroughly wash in a hot detergent solution, at
about 120°F (49°C), in the first sink.
Step 3: Rinse (Sink 2) - Rinse until item is free of detergent in clean hot
water, at about 120°F (49°C) to HOT (60°C) in the second sink.

WEEK 1 ( MODULE 1)
Step 4: Sanitize (Chemical) (Sink 3) - Immerse in a solution that has a
concentration of 50 ppm chlorine for at least 7 seconds, and is a
temperature of 175° or above.
Step 5: Air-dry - Do not wipe any item with a cloth to dry it. Store inverted
Page | 18
(upside down) in area specially designed/used for cleaned & sanitized
equipment/utensils. a.. Washing Manual in Three compartment Sink
Washing Manual – Method
Pre-Wash/Scrape
Wash with Detergent and Warm Water (49°C /120°F) Rinse Sanitize
with Approved Sanitizer Air Dry
Use chlorine test strips to accurately measure the concentration of the
sanitizing solution, in parts per million (ppm).
Ensure that the detergent dispenser is full.
Use a measurement cup for the chlorine or the “cap” of the bleach
container. Have one person handle soiled equipment only and never touch
clean equipment.
Have another person take items that have been cleaned and sanitized
from the air drying area directly to the shelving units for storage.
Have the shelving units cleaned and sanitized daily. ALWAYS
Put or temporarily store pots and pans on the floor. Use a spraying hose
for cleaning surfaces of walls.
Use stainless steel scouring pads.
allow any rust or grease build-up to be visible on any equipment. Items
with this build-up are to be cleaned with the appropriate detergents.
Check the strainers, spray arms and rinse jets for blockage after each
meal service.
As dishes pass through the machine, they are washed with detergent and
hot water. They are then rinsed with clean hot water, and sanitized with hot
water in the last section of the machine
Step 1: Scrape - Remove excessive food soil that may deactivate the
detergent.
Step 2: Pre-Wash - Pre-wash all dishes and utensils before washing.
Step 3: Racking - Properly rack all dishes. Leave enough space between
plates so that they are exposed to the unobstructed spray from spray arms
and rinse jets. Glasses, cups and bowls should be placed upside down so
they will not fill up with water.
WEEK 1 ( MODULE 1)
Step 4: Washing - 120°F (49°C) or above.
Step 5: Final Rinse - 165°F (74°C) for stationary/single rack machines. -
180°F (66°C) for all other machines.
Step 6: Air Dry - Do not wipe dry. Store in areas specially designed/used
Page | 19
for cleaned & sanitized equipment/utensils.
b. Mechanical Utensil Washing
Step 1: Scrape
Step 2: Pre-Wash .
Step 3: Racking
Step 4: Washing
Step 5: Final Rinse
Step 6: Air Dry Mechanical Utensil Washing
ALWAYS
Ensure that the detergent and the rinsing agent dispensers are full.
Ensure that the machine is cleaned properly after each meal service.
Dispose of all chipped china or glassware right away, and advise your
supervisor.
Soak the internal shields/curtains of dishwasher in a sanitizing solution
at the end of each day.
Clean and check all storage shelving units and their contents.
Clean the machine weekly with scale remover. Run it for 20 minutes with
the chemical, and then drain it. The machine must then be re-filled and
turned on to remove the chemical.
Three cycles of filling, switching on and draining are necessary before the
machine can be used to clean any equipment.
Assure the final rinse is reaching the proper temperature.
If the machine does not reach the proper final rinse temperature, you
must immediately inform your supervisor
1. Heat
Chemical Sanitizing Method
2. Hot water
Chlorine Quats
Micro bac II

WEEK 1 ( MODULE 1)
Storing cleaned equipment • Must be clean • Must be dry •
Moisture encourages bacteria to thrive • Store so it cannot be contaminated
• Protect from contamination • Ready for use next time • Bowls turn upside
down • Dust does not settle on food surface.
Page | 20
Cleaning, Washing and Sanitizing

It is our obligation, not our option, to serve safe food!
Our guests will judge our company and our service by observing the
appearance and behavior of the staff members serving them.
The best protective measure against food-borne illness is good
personal hygiene.

WEEK 1 ( MODULE 1)
It is our obligation to prevent food-borne illness by building a
sanitary barrier between the product and the people who prepare, serve and
consume the product.
Page | 21
Self-Check 1.2-1
Essay:
1.What is the importance of the 7’s in food processing ?
2. What are the 3 bucket system in cleaning ? explain.
3. How do you store equipment’s and tools?
L.O.2 Prepare Raw Materials
Learning outcome:

WEEK 1 ( MODULE 1)
• Methods of inspecting /sampling deliveries
• Sorting and grading raw materials
• Procedures of preparing raw materials
• Methods of accomplishing forms and checklists of raw materials as
Page | 22 received and rejects
• Procedures on reporting of defects, breakdown and other irregularities
during the activities to immediate head/ supervisor
• Recording and reporting of inputs
• Food safety principles and practices on alcoholic and acetic acid
fermentation
• Hazard Analysis & Critical Control Points (HACCP) basic principles
• Sanitation Standard Operating Procedures (SSOP)
• Waste management
• Occupational Safety and Health Standards (OSHS)
• Guidelines: o 7S (sort, systematize, sweep, standardize, selfdiscipline,
safety and security) of Good Housekeeping
PERFORMANCE CRITERIA:
2.1 Raw materials are sorted and graded according to approved criteria
and enterprise requirements
2.2 Sorted and graded fresh fruits and vegetables are weighed, washed,
peeled, cut and sliced according to required sizes and shapes
2.3 Fish and other marine products are cleaned, eviscerated, cut and
washed according to specifications.
Information sheet 1.1-2

WEEK 1 ( MODULE 1)
Key considerations to assure a solid receiving inspection
setup
The important considerations are as follows:
Page | 23
A set of requirements (checklists, approved samples for comparison,
examples of common defects…)
1. A way to focus on the most important criteria

2. A procedure to follow, step by step
3. A way to report findings and help with traceability
4. A way to drive improvement in the supplier base, when needed
1. How to define receiving inspection requirements?
You need a checklist that is based on the product specifications and other
elements. It is good if you have an approved sample of each item you
inspect, too. Certain aspects of the requirements can’t be communicated in
written specifications: exact color, touch & feel, etc.
2. How to identify the most critical parts and the highest risk?
This is extremely important since you don’t want an inspector to spend a lot
of time checking low-risk batches and unimportant criteria.
• Based on the product risk: reduce the inspection level

• Based on the supplier risk: reduce the inspection severity
When it comes to the product risk, you probably need to look at the overall
risk to your business. Talk to customer-facing staff, talk to your quality
manager, talk to some production people, and you should have an idea.
Sometimes, it is actually a regulatory requirement. For example, inspection

is required on brake systems in an American automotive factory, but more
trivial elements are usually not checked.
Ideally, the designers have identified what is ‘critical to quality’ for each
product.
When it comes to supplier risk, it is often more difficult to assess.

WEEK 1 ( MODULE 1)
Typical KPIs to follow, when it comes to supplier quality performance, would
be:
• % passed inspections
• % defectives
Page | 24 • Number of corrective action plans requested in the past
• % of corrective action plans that were not closed fully
Based on the suppliers’ past performance, overall attitude, and so forth, you
will decide that some can’t be trusted (which means you should check all
their deliveries), while others can be given more rope (the most efficient
approach is often letting your best suppliers do self-inspection and be
accountable for it).
3. What procedure to follow in your incoming inspection?
When it comes to the procedure for picking samples at random, the basic
steps will probably be:
1. Get the delivery plan/notes, indicate what needs to be checked

2. Get the “not checked yet” parts in one area
3. Count quantity (if needed)
4. Pick samples randomly
5. Conduct the inspection (e.g. visual check, dimensional check, special
testing…)
6. Set aside defectives, classify them and count them
7. If the batch is accepted, have it moved into the “checked and OK” area.
If it is accepted but there is a special note for production (e.g. ‘must do
100% checks on point XYZ’), make sure it will be seen and followed. If
it is refused, trigger the appropriate response (e.g. send back to the
supplier, invite the supplier to come and do a sorting, etc.).
4. How to report the findings?
If you end up inspecting the same product type over and over, you might
want to prepare a report template that includes the checklist. And this can
be automated with dedicated software, too.
Your reporting will become part of traceability records, so don’t forget to

produce some type of record…
5. How to drive improvement in the supplier base?
This could be the topic of a 500-page book. But, where to start?

WEEK 1 ( MODULE 1)
You are collecting data. Make sure you pass these data in a way your
colleagues in procurement can use. They should have some form of a
dashboard for each supplier — at least for each key supplier.
By showing those suppliers that your company tracks important data (e.g. %
Page | 25 defectives, % late deliveries, cost reductions…), you will be more likely to get
better performance out of them.
And, when you see a very serious issue, and if the supplier is not
disproportionately large, you can probably raise a Corrective Action Request,
which might be in the form.
PROCEDURE ON PREPARING RAW MATERIALS
In many food processing operations, food products are converted from

their natural state to a state where the original food is transformed so
significantly that they are unrecognizable compared to the original form. For
example tomato is transformed to ketchup and wheat is transformed to
donuts. Because of this huge change, a processor may take the quality of
the raw material for granted. For example, he may say, I am making
ketchup so there’s no problem in using tomatoes with some insect damage,
or rotten spots here or there, or a bit of pesticide residue just over the limit.
After all, who’s going to know when everything gets squashed together? Well,
he may have been able to get away with a lax in quality raw material in the
past. However, today it’s less likely he will be. Customers have become more
sophisticated, having high demands for quality and safety of the food they
eat. Advances in technology has made it easier to detect poor quality raw
material such as the ability to rapidly and accurately detect and quantify
microorganisms, harmful chemicals and toxins. High food safety standards
such as the Food Safety Modernization Act in the US has called for greater
scrutiny of food processing operations to ensure that they are following high
food safety standards.
The quality of your raw material will directly impact the quality of your end
product. It’s the idea of “garbage in garbage out” used in computer
technology. What you put in is indeed what you get out. However, since
quality impacts cost and the amount consumers are willing to pay, then
appropriate compromise in quality may have to be found, as long as safety is
not compromised. For example, you may choose to process tomatoes that
are too small, too big or a bit soft for the fresh market, but you must never
channel tomatoes into processing because they are infested or contaminated
with harmful chemicals. So, how do we prepare raw materials for processing
to make sure we produce quality food? Three unit operations to pay close
attention to are cooling, cleaning and sorting.
Cooling

WEEK 1 ( MODULE 1)
After harvest, fruits and vegetables are not “dead”. Hundreds of chemical
reactions are taking place within the food leading to a state of senescence
(aging), including respiration. You remember respiration, right? It’s the
opposite of photosynthesis where green plants use glucose already in the
plant and oxygen in the atmosphere to produce carbon dioxide, water and
Page | 26 energy. This energy produces heat. Therefore if you pack apples in a box,
eventually they will get warm. This warmth will increase other biological
activity including growth of microorganisms, leading to faster spoilage.
That’s why fruits and vegetables must be cooled as soon as possible after
harvest to ensure their freshness. Carcass after animal slaughter must also
be chilled for the same reason. Methods of cooking may include putting the
product in a refrigerator, floating them in water, immersing in cold water or
crushed ice, air-cooling with dry air, or washing in a continuous stream of
cool water.
Processors who also grow their own raw materials limit the time that it takes
to get produce to processing by cooling directly on the farm, investing in
refrigerated trucks and/or building their processing facility in close
proximity to the farm.
Cleaning
Food, whether it be from animals or plants are produced in the physical
environment and are therefore exposed to the elements. Contaminants may
fall in either physical, chemical or biological hazards. Physical hazards may
include leaves, slicks, stones, metal, plastic, dust, sand, insect parts, and
rat droppings. Chemical hazards may include natural toxins such as
mycotoxins, and pesticides. Biological hazards may be bacteria, yeast, mold,
parasites and viruses. Much of these contaminants are removed at the
cleaning stage. Cleaning may be by dry or wet method.
Dry cleaning is common in grains and pulse processing. Cleaning may

involve a variety of mechanisms. For example, passing the grain e.g. wheat
through a stream of air to lift off light unwanted particles such a leaves and
dust. Size separation devises such as sieves are used to separate
contaminants that are larger or smaller than wheat. Gravity tables are
employed to separate materials by density such as stones. Imaging
machines are used to identify and separate contaminants by color, and
magnets are used to trap and remove metals.
Wet cleaning methods are more suitable for food that will not absorb water
such as fruits and fresh vegetables. It is a more effective method than dry
cleaning for removing dust and pesticides. However, if water is not removed
from the surface properly, this may lead to spoilage. The need for clean
water and treatment of effluent at the end of the process may increase
operational cost. Common methods wet cleaning include soaking, spraying
and flotation of produce in troughs (called fluming).
Sorting

WEEK 1 ( MODULE 1)
Sorting during the material preparation process involves placing produce
into categories based on specifications or standards to be met. For example,
foods may be processed based on differences in physical properties such as
color, texture, size, shape and weight. For example, pumpkins for the fresh
market should preferably be of uniform shape, weight and size for packing.
Page | 27 Those that have an irregular shape or are too big or too small can be
diverted for cooking and pulping for use in value added products such as
pies and or dehydrated and added to soups. Separation may also be done
based on chemical composition such as brix (sugar content). Juice
processors for example will want fruits that have high sweetness with an
acceptable balance in acidity. In flour milling, flour is sorted into different
streams and packaged based on bran and protein content.
Principles of The food processing & preservation

Fermentation could be described as a process in which
microorganisms change the sensory (flavor, odor, etc.) and functional
properties of a food to produce an end product that is desirable to the
consumer.
Fermentation, along with salting, cooking, smoking, and sun drying,

is one of the earliest ancient traditions developed by cultures all around the
world to extend the possible storage time of foods.
• Before the initiation of preservation technology, humans frequently had to
choose between starvation and eating spoilt foods and then suffer the
possible consequences of this.
• For thousands of years, raw animal and plant ingredients have been
fermented. Fermented fruits were probably among the first fermented foods
eaten.
• The methods for fermentations were developed by trial and error and from
the experiences of many generations
Factors Produced by the Metabolic Activity of

Microorganisms That Can Contribute to the Increased
Stability and Safety of Fermented Foods
• Low Ph
• Organic acids, e.g., lactic acid, acetic acid, and formic acid

WEEK 1 ( MODULE 1)
• Low redox potential
• Nutrient depletion
• Accumulation of inhibitors, e.g., toxins, bacteriocins, antibiotics,
lactococcins, nisin, natamycin, hydrogen peroxide
• Ethanol
Page | 28 • Diacetyl
• Carbon dioxide
Microbial Contamination of Foods
• Foods are derived from other living organisms and during their
development and preparation they are continuously exposed to microbial
contamination.
• The resultant contaminating microflora can have different effects on the
food. • These include negative effects such as spoilage, where the food
becomes unfit for human consumption or health risks when infectious or
toxigenic microorganisms are present. • Negligible effects on the food occur
when the microflora does not cause disease or any detectable changes in the
food.
• However, benefits can also be reaped from the action of the
microorganisms when their activity brings about improvements in the
appeal of the food. In developed countries, the improved appeal is the major
reason for microbial fermentations of foods continuing today.
Examples of Microbial Metabolic End Products Used in

Fermented Foods
Metabolic End Product Example of Uses

Carbon dioxide leavening bread
Ethanol Alcoholic beverages
Acetic acid Vinegar
Lactic acid Fermented vegetables
Flavor compound - Diacetyl Dairy products
Flavor compound – Acetaldehyde Yogurt
Potential Benefits of Fermented Foods
Increased Lowered
Safety Toxicity
Health benefits Cooking time
Retail value Production costs
Nutritional value Equipment needs
Digestibility Levels of anti-nutritional factors

WEEK 1 ( MODULE 1)
Suitability for subsequent processing
Sensory properties
Ease of storage and transportation
Shelf life
Page | 29
Microorganisms Used in Food Fermentations
A variety of groups of microorganisms are frequently used in fermented

foods.
Microbial Group Product

• Lactic acid bacteria (LAB) Lactic acid
• Acetic acid bacteria Acetic acid
• Yeasts Alcohol and Co2
• Molds Enzymes
Hazard Analysis and Critical Control Point (HACCP)
The National Advisory Committee on Microbiological Criteria for Foods

(Committee) reconvened a Hazard Analysis and Critical Control Point
(HACCP) Working Group in 1995. The primary goal was to review the
Committee's November 1992 HACCP document, comparing it to current
HACCP guidance prepared by the Codex Committee on Food Hygiene. Based
upon its review, the Committee made the HACCP principles more concise;
revised and added definitions; included sections on prerequisite programs,
education and training, and implementation and maintenance of the HACCP
plan; revised and provided a more detailed explanation of the application of
HACCP principles; and provided an additional decision tree for identifying
critical control points (CCPs).
The Committee again endorses HACCP as an effective and rational means of

assuring food safety from harvest to consumption. Preventing problems from
occurring is the paramount goal underlying any HACCP system. Seven basic
principles are employed in the development of HACCP plans that meet the
stated goal. These principles include hazard analysis, CCP identification,
establishing critical limits, monitoring procedures, corrective actions,
verification procedures, and record-keeping and documentation. Under such
systems, if a deviation occurs indicating that control has been lost, the
deviation is detected and appropriate steps are taken to reestablish control
in a timely manner to assure that potentially hazardous products do not
reach the consumer.

WEEK 1 ( MODULE 1)
In the application of HACCP, the use of microbiological testing is seldom an
effective means of monitoring CCPs because of the time required to obtain
results. In most instances, monitoring of CCPs can best be accomplished
through the use of physical and chemical tests, and through visual
observations. Microbiological criteria do, however, play a role in verifying
Page | 30 that the overall HACCP system is working.
The Committee believes that the HACCP principles should be standardized

to provide uniformity in training and applying the HACCP system by
industry and government. In accordance with the National Academy of
Sciences recommendation, the HACCP system must be developed by each
food establishment and tailored to its individual product, processing and
distribution conditions.
In keeping with the Committee's charge to provide recommendations to its

sponsoring agencies regarding microbiological food safety issues, this
document focuses on this area. The Committee recognizes that in order to
assure food safety, properly designed HACCP systems must also consider
chemical and physical hazards in addition to other biological hazards.
For a successful HACCP program to be properly implemented, management

must be committed to a HACCP approach. A commitment by management
will indicate an awareness of the benefits and costs of HACCP and include
education and training of employees. Benefits, in addition to enhanced
assurance of food safety, are better use of resources and timely response to
problems.
The Committee designed this document to guide the food industry and
advise its sponsoring agencies in the implementation of HACCP systems.
DEFINITIONS
CCP Decision Tree: A sequence of questions to assist in determining whether

a control point is a CCP.
Control: (a) To manage the conditions of an operation to maintain

compliance with established criteria. (b) The state where correct procedures
are being followed and criteria are being met.
Control Measure: Any action or activity that can be used to prevent,

eliminate or reduce a significant hazard.
Control Point: Any step at which biological, chemical, or physical factors can
be controlled.
Corrective Action: Procedures followed when a deviation occurs.
Criterion: A requirement on which a judgment or decision can be based.

WEEK 1 ( MODULE 1)
Critical Control Point: A step at which control can be applied and is
essential to prevent or eliminate a food safety hazard or reduce it to an
acceptable level.
Critical Limit: A maximum and/or minimum value to which a biological,

Page | 31 chemical or physical parameter must be controlled at a CCP to prevent,
eliminate or reduce to an acceptable level the occurrence of a food safety
hazard.
Deviation: Failure to meet a critical limit.
HACCP: A systematic approach to the identification, evaluation, and control

of food safety hazards.
HACCP Plan: The written document which is based upon the principles of
HACCP and which delineates the procedures to be followed.
HACCP System: The result of the implementation of the HACCP Plan.
HACCP Team: The group of people who are responsible for developing,
implementing and maintaining the HACCP system.
Hazard: A biological, chemical, or physical agent that is reasonably likely to

cause illness or injury in the absence of its control.
Hazard Analysis: The process of collecting and evaluating information on

hazards associated with the food under consideration to decide which are
significant and must be addressed in the HACCP plan.
Monitor: To conduct a planned sequence of observations or measurements

to assess whether a CCP is under control and to produce an accurate record
for future use in verification.
Prerequisite Programs: Procedures, including Good Manufacturing Practices,

that address operational conditions providing the foundation for the HACCP
system.Severity: The seriousness of the effect(s) of a hazard.
Step: A point, procedure, operation or stage in the food system from primary
production to final consumption.
Validation: That element of verification focused on collecting and evaluating

scientific and technical information to determine if the HACCP plan, when
properly implemented, will effectively control the hazards.Verification: Those
activities, other than monitoring, that determine the validity of the HACCP
plan and that the system is operating according to the plan.
HACCP PRINCIPLES

WEEK 1 ( MODULE 1)
HACCP is a systematic approach to the identification, evaluation, and
control of food safety hazards based on the following seven principles:
Principle 1: Conduct a hazard analysis.
Page | 32 Principle 2: Determine the critical control points (CCPs).
Principle 3: Establish critical limits.
Principle 4: Establish monitoring procedures.
Principle 5: Establish corrective actions.
Principle 6: Establish verification procedures.
Principle 7: Establish record-keeping and documentation procedures.
Safe Food Handling

1. Do not talk while preparing or cooking to make food free from saliva.
2. Always use clean utensils and maintain the cleanliness of the kitchen so
that the food maybe free from flies and other insects.
3. Use trash can w/ cover
4. Comfort rooms near the kitchen must always be tightly closed that odor
may not be absorbed by the food being prepared.
5. Use potholders, clean towels for sanitation purposes.
Personal Hygiene
Clean hands.
Personal cleanliness/daily bathing or showering with soap.
Wearing proper work attire, including a clean uniform.
Avoiding unsanitary habits and actions, such as scratching, touching
parts of our body, etc.
Good health.
Reporting immediately to the doctor when feeling ill. The prevention of
food-borne illness
After using the restroom, a handkerchief or a tissue.

WEEK 1 ( MODULE 1)
Before coming to work and after a break, especially after eating or
drinking. After handling something dirty (pans, china, trays, equipment,
towel, etc.). After smoking.
After handling raw food, particularly meat, poultry or seafood.
Page | 33
After touching your hair, nose or other parts of your body.
After using any cleaning materials, including chemicals.
ALWAYS WASH YOUR HANDS
Cleaning
• Removal of visible dirt, soil, debris (including rust) and food matter from
crockery, cutlery, glasses, equipment or utensil
• Removal of odour Sanitizing
• Killing of microbes using either hot water or chemicals
CLEANING AND SANITIZING

What is to be cleaned?
When can it be cleaned?
What equipment is needed for cleaning?
Alternatives?
Everything cannot be cleaned at same time
Map out cleaning plan in Food Safety Plan Cleaning procedures
General cleaning requirements

• Follow manufacturer’s instructions in relation to using chemicals on the
equipment
• Follow manufacturer’s instructions when cleaning their equipment
• Pay attention to the job
• Don’t cause any damage to anything being cleaned
Kitchen items to be cleaned

• Crockery
• Glassware
• Cutlery • Utensils
• Pots, pans and other dishes
• Containers • Chopping boards
• Knives
WEEK 1 ( MODULE 1)
• Stove
• Oven, etc.
Page | 34
OCCUPATIONAL SAFETY AND HEALTH STANDARDS
The Occupational Safety and Health Standards was formulated in

1978 in compliance with the constitutional mandate to safeguard the
worker’s social and economic well-being as well as his physical safety and
health. Adopted through the tested democratic machinery of tripartism, the
1978 Standards is considered as a landmark in Philippine labor and social
legislation.
With joint efforts from the Bureau of Working Conditions, the International
Labour Organization (ILO) Manila Office and the tripartite sectors, the
revisions to the OSH Standards were approved in August 1989. With the
latest improvements in the Standards, all establishments covered will now
be provided with a better tool for promoting and maintaining a safe and
conducive working environment.
Self-Check 1.2-2
Test I. Direction: Definition of terms.
1. Cooling
2. Sorting
3. Cleaning
4. HACCP
5. CCP

WEEK 1 ( MODULE 1)
Test II. Direction: Identification with explination.
1. 7 principles of HACCP
Page | 35 2. 3 Bucket system
L.O.3 Perform Alcoholic Fermentation of Fruits/Vegetables
Information sheet 1.2-3

WEEK 1 ( MODULE 1)
Page | 36
An easy way to remember the difference between the two despite

their overlap is that pickling involves putting food into an acidic brine to
produce a sour flavor, whereas fermenting gives food a sour flavor without
any added acid. Pickling is often the least healthy choice in terms of these
two foods.
Pickling & Fermentation
Add some zip to your meals with

pickled foods! Pickling combines spices, sugar and vinegar with fruits and
vegetables to create a unique sweet-sour flavor yet retain a crisp, firm
texture. Firming agents are optional.
Brined or Fermented Pickles - This curing process involves soaking the

food in a brine for several weeks. Curing changes the color, flavor, and
texture of the food. Fermentation produces lactic acid to help preserve the
food. Some foods are brined, but not cured. These will have vinegar added to
them for preservation.
Fresh Pack or Quick Process Pickles - This method involves a boiling hot
pickling mixture of vinegar, spices, and seasonings. The food may be brined
prior to adding the pickling liquid. The end result is an easy to prepare
pickle with a tart flavor. Allow them to stand several weeks after heat
processing to improve the flavor.
Fruit Pickles - Whole or sliced fruits are simmered in a spicy, sweet-sour

syrup made with vinegar or lemon juice prior to canning.

WEEK 1 ( MODULE 1)
Relishes - Chopped fruits and vegetables are cooked in a spicy vinegar
solution to the desired consistency prior to canning.
Chayote pickles
Page | 37 Ingredients:
1 ½ kls. Chayote cut into strips

2 pcs. Regular carrot cut into strips
20 pcs. Shallots/sibuyas tagalog
1 box raisen
1 pc. Sweet red pepper
1 pc. Sweet green pepper
1 small piece ginger
1 sachet pineapple tidbits
PROCEDURE:
1. Wash, peel and cut the vegetables into thin strips.

2. Add salt and wash the vegetable individually set aside for 10 mins.
3. Rinse and squeeze to remove juice, mixed all vegetable in mixing bowl.
4. Prepare the pickling solution.
2 cups vinegar
2 cups refined sugar
1 tsp salt
Ginger
Pepper corn
5. Boil solution for 5 minutes strain and pour by batches over the vegetable.
6.Pack in jars. Remove air bubbles by inserting the knife around the side of
the bottle.
7.fill up by more pickle solution and cover lightly.
8.Wipe and label.
View video on COC 2: Process Food by Fermentation and Pickling 1.2-1
Job Sheet 1.2-1

Title:
PROCESS FOOD BY SALTING,CURING AND SMOKING

WEEK 1 ( MODULE 1)
Performance Objective:
At the end the student will be able to make a finished
product of Chayote Pickling
Page | 38
Supplies/Materials :
CBLM (Information Sheet 1.2-3)
Chayote Pickling tools, equipment, materials and ingredients provided
Steps/Procedure:
Instruction:
1. Read Information sheet 1.2-3

2. View video presentation on Process food by fermentation
and pickling ( chayote pickles)
3. Given materials for ( chayote pickles) use it for the
demonstration.
3. Make a video presentation about Process food by
fermentation and pickling ( chayote pickles)
4. Submit the chayote pickles finished product and the
recorded video job sheet 1.2-1 to your facilitator.
Assessment Method:
Demonstration through video recording and presenting the finished
product
CORE COMPETENCIES and LEARNING OUTCOMES
CAN I…? YES NO

PROCESSES FOOD BY FERMENTATION AND PICKLING
L.O.1. Prepare equipment, tools, materials and utensils (FP)
L.O.2. List of raw materials for Fermentation & Pickling

WEEK 1 ( MODULE 1)
CORE COMPETENCIES and LEARNING OUTCOMES
CAN I…? YES NO

L.O.3. Fermentation and Pickling
Page | 39 L.O.4. Processing method for Fermentation and Pickling
L.O.5. Packaging Processed Product
COMPETENT :________________
NOT YET COMPETENT :________________
PERFORMANCE CRITERIA
1.1 Equipment, tools and utensils for fermentation and pickling

are selected according to requirements
1.2 Equipment, tools and utensils are checked and calibrated in
accordance with manufacturer’s specifications
1.3 Equipment/ utensils for the above food processing methods
are readied and sanitized according to manufacturer’s

WEEK 1 ( MODULE 1)
specifications
1.1 Raw materials are sorted and graded according to approved
criteria and enterprise requirements
2.4 Sorted and graded fresh fruits and vegetables are weighed,
washed, peeled, cut and sliced according to required sizes
Page | 40 and shapes
2.5 Fish and other marine products are cleaned, eviscerated, cut
and washed according to specifications.
3.1 Prepared fruit is mixed with water according to

specifications
3.2 Mixture is allowed to boil and juice is extracted in
accordance with specifications and enterprise requirements
3.3 Extracted juice is cooled and mixed with other ingredients
like sugar and yeast in accordance with specifications
3.4 Juice is fermented for 1-2 weeks as required
3.5 Fermented juice is strained, filtered and heated according to
specifications
Good luck!!!

WEEK 1 ( MODULE 1)

COC 2 Fermentation and Pickling

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

COC 2 Fermentation and Pickling

Uploaded by

Copyright:

Available Formats

CORE COMPETENCIES

UNIT OF COMPETENCY : Process Food by Fermentation and Pickling

MODULE TITLE : Processing Food by Fermentation and Pickling

UNIT CODE : AGR741301

L.O.1 Prepare Equipment, Tools and Utensils

INFORMATION SHEET 1.1-1

ginamit laganan kan

Long handled ladles (SS)

ginagamit nin lutuan nin mga

Pairing knives ginagamit na

GLOBAL i.t. Studies Inc. Prepared by:

Ginagamit sa pang ubak o pang giris sa darakulang

Peelers ginagamit nin pang

Ginagamit pansukol kan mga solidong ingredients

Measuring cups for liquid (plastic)

GLOBAL i.t. Studies Inc. Prepared by:

ginagamit sa mga mislahan o

Heavy duty plastic chopping board( HDPE)

GLOBAL i.t. Studies Inc. Prepared by:

ginagamit bilang tadtataran

Wire baskets ginagmit bilang basket pag dakul na

GLOBAL i.t. Studies Inc. Prepared by:

Casseroles stainless steel

Food tongs ginagamit pangkua nin kakanun

GLOBAL i.t. Studies Inc. Prepared by:

SS spatula ginagamit sa pang

ginagamit para maging laganan kan mga ginagamit

Colanders, stainless steel

GLOBAL i.t. Studies Inc. Prepared by:

Washing vat ginagamit

GLOBAL i.t. Studies Inc. Prepared by:

GLOBAL i.t. Studies Inc. Prepared by:

Stoves ginagamit nin

Trolley ginagamit laganan

Cap sealer pan sarado nin

Pressure cooker pan luto sa mga medyo kaipuhan

GLOBAL i.t. Studies Inc. Prepared by:

refractometer (0-70o brix)

GLOBAL i.t. Studies Inc. Prepared by:

Gas tank liquid or gas flammable materials na

GLOBAL i.t. Studies Inc. Prepared by:

Digital weighing scales 1 – 2 kg cap with 2 decimal

Tools, Equipment , Materials

GLOBAL i.t. Studies Inc. Prepared by:

PROCEDURAL ENFORCEMENT GUIDELINE of 7’s from 5’s of

War on Waste (WOW) programme.

GLOBAL i.t. Studies Inc. Prepared by:

3. Cleanliness (Sweeping) – keeping the workplace swept & thoroughly clean.

4. Routine Clean-up (Standardizing) – standardize clean-up & organization

5. Discipline Habit (Self Discipline) – make a habit of maintaining

6. Safety (Risk Elimination) – attention to safety throughout the other steps.

GLOBAL i.t. Studies Inc. Prepared by:

Food contact surfaces and large utensils/machines

GLOBAL i.t. Studies Inc. Prepared by:

GLOBAL i.t. Studies Inc. Prepared by:

Cleaning, Washing and Sanitizing

GLOBAL i.t. Studies Inc. Prepared by:

2. What are the 3 bucket system in cleaning ? explain.

3. How do you store equipment’s and tools?

L.O.2 Prepare Raw Materials

GLOBAL i.t. Studies Inc. Prepared by:

Information sheet 1.1-2

GLOBAL i.t. Studies Inc. Prepared by:

1. A way to focus on the most important criteria