Engineering Aspects of Food Processing
Engineering Aspects of Food Processing
Engineering Aspects of Food Processing
P.P. Lewicki
Warsaw University of Life Sciences (SGGW), Warsaw, Poland
The State College of Computer Science and Business Administration in Lomza, Poland
Keywords: Metabolic energy requirement, food production, wet cleaning, dry cleaning,
homogenization, membrane filtration, cyclones, clarifixator, coating, extrusion,
agglomeration, fluidization, battering, uperisation, pasteurization, sterilization, baking,
chilling, freezing, hydrocooling, cryoconcentration, glazing, extrusion-cooking, roasting,
frying, thermoplasticity, logistics.
Contents
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1. Introduction
2. Food industry
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3. Food processing
3.1. Mechanical Processes
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3.2. Heat Transfer Processes
3.3. Mass Transfer Processes
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3.4. Materials Handling
3.5. Hygiene of Processing
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Biographical Sketch
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Summary
The main aim of this chapter is to show the impact of chemical and process engineering
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1. Introduction
Food is any substance that can be eaten or drunk by a man to keep him alive, nourished
the body and give the pleasure. Food usually contains carbohydrates, proteins and fats
as main constituents. Vitamins, minerals and hundreds other organic and inorganic
compounds are important components of food responsible for nourishment, growth and
well-being of man.
Food composition depends on its origin and the way of processing. Food is mainly
sourced from plants and animals, but some inorganic compounds such as water and salt
are important items of human diet.
Food is a source of energy and components for growth and repair of injuries. It is
estimated that some 109 cells/min. are under constant repair and replacement in a human
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body. The requirement for energy and nutrients depends on the age and physical activity
of a person. Energy derived from food is used for biochemical reactions (chemical
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energy), for body movement (mechanical energy), and to maintain the body temperature
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(thermal energy). The energy efficiency of the human body is about 60%, but half of it
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accounts for thermal energy. The basal metabolic energy requirement ranges from 5 to
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7.5 MJ/day depending on age, sex, body mass and size. Requirement for nutrients is
recommended by WHO and local authorities. Recommended Daily Allowance (RDA) is
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the level of different nutrients that assure maintenance, growth and repair of the body
for 97.5% of the population.
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Daily energy consumption depends on availability of food, eating habits, cultural and
religious restrictions and health consciousness. It varies from less than 8 MJ/day in
areas with shortage of food to over 15 MJ/day in developed countries. Some examples
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The food energy is supplied by main food constituents. The energy value of proteins
and carbohydrates is 16.74 kJ/g and for fats, it is 33.49 kJ/g. Hence, substantial amounts
of those constituents must be consumed every day to provide body with sufficient
energy. Taking into account that most foods contain large quantities of water and
energetic efficiency of the body is 60% it shows how large mass of food is consumed
per day by a statistical man. Consumption of some foods is presented in Table 2. The
data in Table 2 shows just the consumption of basic foods, which for example for
Poland sums up to 711.2 kg/year. Adding other commodities such as confectionery,
beverages, wine, beer and luxury products, the mass of one tone or even more is
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obtained. It shows how huge amounts of food must be supplied every day.
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Country Meat Poultry Fish Milk Eggs Butter Potato Vegetables Fruits Grain
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Austria 95.1 16.9 14.7 299.8 12.9 5.2 59.7 90.4 137.2 110.8
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Denmark 93.5
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Finland 52.9 15.1 32.6 356.2 8.4 4.0 71.8 70.7 91.9 106.6
France 73.6 24.7 31.2 274.6 15.3 8.1 64.8 142.9 95.5 117.2
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Germany 70.9 13.8 14.9 255.6 12.0 6.8 72.1 90.5 113.2 112.9
Hungary 59.1 30.2 5.1 168.9 16.5 1.0 69.1 117.0 137.2 125.4
Poland 56.9 19.1 13.1 173.4 11.6 4.5 130.1 100.3 47.6 154.6
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Spain 91.6 30.4 47.4 173.8 13.1 0.8 78.6 143.3 112.7 98.9
Sweden 64.3 12.6 33.6 377.8 10.5 3.6 54.1 78.4 115.2 103.5
Food Balance Sheets, FAO 2006. Przemysl Spozywczy, 2008, 61(8), 26-31,75.
2. Food Industry
Food is produced by the food industry. This industry is much diversified. There are
small family run businesses almost like a craftsmen workshop, and large processing
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plants employing hundreds of workers. The size of the plant depends primarily on the
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Food industry as a whole is a large part of national economy. It employs large number
of people with different skills and education. In Poland, food industry employed in 2007
some 475 thousand people, which amounts to 1.25% of the population or 3.45% of total
employment. In Germany, food industry in 2005 employed 845 thousand people, and
the food industry of the European Union (EU-27) employed some 4.69 million people.
Processing of food consumes huge amounts of energy and water. In Poland in 2007 total
energy consumption by the food industry amounted to 8.82·1016 J and water
consumption was some 1.014·107 m3. Total energy consumption referred to population
of Poland yields some 6.36 MJ/day/person. It means that to supply a man with
appropriate food energy, food industry must input more than 45% of that value in the
form of heat and electrical energy.
Most food originating from plant and animal sources is perishable. It undergoes
senescence, biological, microbiological, chemical and physical decay. Hence, food must
be preserved in order to prevent loses. In temperate climate, agriculture is seasonal;
therefore, preservation techniques are needed in order to allow food to be available out
of the season. In developed countries more than 70% of the population live in
metropolis and big cities, while production of raw materials for food is spread all over
the country. Because of that, transportation of agricultural products and food becomes
an important issue.
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The basic aims of food industry today are as follows:
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1. To preserve food and extend the time during which a food remains wholesome, can
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be distributed and stored, also at home.
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2. To increase variety of products, which fulfill consumer expectations as far as price,
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diet, habits and other likes are concerned.
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3. To manufacture convenience products in order to reduce the time required for meal
preparation.
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All the above-enumerated goals of the food industry are subordinated to the most
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important requirement - the safety of food. Hence, all the applied preservation
techniques must assure safety of food in first place. That prerequisite enforces special
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3. Food Processing
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the raw materials into foodstuffs. The procedures and processes are conveniently called
unit operations. The idea of unit operations allow unified description of production of
different varieties of food.
From the processing point of view, raw materials can be classified as liquids and solids.
Processing of liquids differs substantially from processing of solids, because it can be
done in a hermetic system avoiding contact with surroundings. Hence, high standard of
hygiene can be easily assured. Processing of solids is more complicated, and only partly
can be isolated from the contact with surroundings. Hygienic solutions are more
complex. Some solids are a source of liquids as semi-products, and some liquids are
processed to solids. Therefore, food processing partly as liquids and partly as solids is a
common practice.
Basic unit operations used in food processing are presented on Figure 1. All the unit
operations applied in food processing can be divided into three main groups.
Mechanical processes include such unit operations as cleaning, size reduction, sorting,
grading and removing of inedible parts, mixing and mechanical separation. Heating and
cooling, evaporation, freezing all belongs to heat transfer processes. Mass transfer
occurs in such processes as drying, extraction, crystallization and distillation. Nowadays
ionizing radiation and electrical current are used to process foods. Moreover, in food
processing there are also processes of complex nature, which cannot be assigned to any
of the above groups. These are fermentation and some post-processing operations.
Raw materials
Liquid Solids
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Cleaning, removing
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inadible parts
Sorting,
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grading,
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H O separation
Disintegration
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Mixing
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Distillation
Heating Cristallization
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Forming
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Products
Many unit operations applied in food processing are well understood and theoretically
described thanks to the knowledge brought about by chemical and process engineering.
Application of momentum, heat and mass transfer theories in the design of food
processing equipment is wide and very successful. However, there are still many
processes, which are not fully understood or so complex, that their mathematical
description would not be useful in the design or exploitation of equipment. These
problems arise mostly from the structure and properties of processed material and their
Mechanical processes are intended mostly to change physical properties of raw material
and to prepare it to further processing. One of the first unit operations is cleaning, which
is done in a wet or dry way. The way the raw material is cleaned depends on its nature,
the type of soil to be removed, and further processing. In wet cleaning mechanical and
hydrodynamic forces are used, and water serves as a cleaning agent. Cleaning soft
materials easily damaged by mechanical forces, water is sprayed onto material surface
or air is pumped into water, and vigorous mixing is caused. For wet cleaning such
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methods as soaking, brushing, spraying, air bubbling and flotation are used. For each of
these methods equipment is designed mostly based on experience and observations.
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Dry cleaning is less efficient than the wet one, but it is used for materials with low
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water content. Dry cleaning is applied for example to grains, nuts, and cocoa beans. Air
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is the cleaning agent, and differences in buoyancy are used to separate material from the
contaminants. Cleaned material is fed into a stream of air and is usually separated into
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three fractions. Heavy debris fall first, then cleaned material and the light contaminants
like stalks, husks are deposited as the last. The theory of flow of diluted mixture of
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particulates in gas, as well as sedimentation principles are used to calculate the air
velocity. Aspiration cleaning is well designed and widely used in harvesting machines
and grain storage and processing facilities.
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Removal of inedible parts from the raw material is another important operation in food
processing, which needs specially designed equipment. Mostly it is a mechanical
operation but some chemicals and heat are also used. Destoning of fruits, deboning of
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meat and poultry, deheading of fish are the examples of mechanical operations, in
which force is used to push out or to cut out an inedible part of the material. Derinders
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are very specialized machines used to deskin slaughtered animals. Mechanical force is
used to separate the skin from meat, but the deskining must be initiated manually.
Defeathering of poultry and dehairing of carcasses is done mechanically but is preceded
by scalding (heat treatment). Evisceration of poultry and slaughtered animals is done
manually, while gutting of fish is done either manually or mechanically. Peeling of
fruits and vegetables is done by abrasion or using heat. Treatment with steam, hot
solution of caustic soda or flame is practiced in food processing. From the above
description, it is evident that the equipment used to remove inedible parts of the material
is very specialized, designed just for the particular material taking into account its size
and shape, physical properties and the job, which must be done. Only peeling
equipment is more versatile. Hence, mechanically resistant vegetables such as potato,
carrot, red beetroot can be peeled in abrasive machines, while soft materials as tomato,
peaches, apricots are peeled be surface heating and removing scalded peel with water
spray.
3.1.3. Disintegration
Food raw materials mostly contain large quantities of water; hence they properties differ
very much from the properties of brittle materials. Theories of Kick, Rittinger or Wang
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are not applicable, except of some special cases like lime stone disintegration in sugar
processing. Most of the disintegration equipment used in food processing is designed
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based on experience and observations.
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Appropriate design of the disintegration equipment is very important because in many
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size reduction processes some precautions must be undertaken. For example,
disintegration of potatoes for starch production or grain for flour must be done in such a
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way that the starch granules are not damaged. Disintegration of apple must assure free
flowing of juice in pores of crushed apple bed during juice expression.
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In size reducing machines compression, impact and shearing forces are mostly applied.
Disintegrating machines use all three forces, but often one prevails over the others.
Disintegrators are often equipped with screens hence; material only with appropriate
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size can leave the machine. Machines of that type reduce the size of the material but do
not create any shape. Specialized machines are used for cutting, slicing and dicing.
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Food materials are mostly visco-elastic, some show plasticity, and only some dry
products can be treated as brittle. Because of that, use of energy for size reduction is
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small. Most of energy is used to overcome inertia and friction forces in disintegrating
machines. Milling of wheat requires about 1 kJ/kg, chopping fresh meat, depending on
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the size, needs from 1 to 20 kJ/kg, and chopping of frozen meat needs 35 or 70 kJ/kg
when pieces are 3 or 2 mm, respectively. Slicing of sugar beet requires energy from 0.9
to1.6 kJ/m2, and for potatoes, the needed energy is about 0.6-0.7 kJ/m2. The output of
the disintegrating machines depends on the kind of disintegrated material, the degree of
disintegration and further processing steps. It varies from hundreds of kilograms per
hour to some 60 t/h.
causes of fat globules disintegration. The emulsion is forced through the narrow slit
with high velocity. Pressure applied on the homogenizing valve is 40-60 MPa.
Application of pressures exceeding 100-150 MPa leads to disintegration of microbial
cells, and homogenization adds some pasteurization effect. In colloidal mills,
suspension is forced into clearance between stationary and rotating disc, which rotates
at 3000-15000 rev/min. Shearing forces cut pieces of suspension and retards
sedimentation. Colloid mills are also used in production of paste-like products (peanut
butter, meat paste).
Disintegration of the stream of liquid into small droplets is applied in spray drying.
Formation of liquid droplets suspended in a gas is done in a centrifugal atomizer or in a
pressure nozzle. The way the cloud of liquid droplets is formed depends primarily on
the kind of sprayed material and the output of the dryer. Milk is mostly sprayed by
centrifugal atomizers, while tea or coffee extracts are sprayed with nozzles. The
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important property of the spraying equipment is the size distribution of droplets. The
narrow is the size distribution of droplets the efficient is the drying, and better is the
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quality of the dried product.
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In food processing stream of gas is also divided into bubbles suspended in liquid in
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order to produce sparkling soft beverages, foamed products or to cause and facilitate
mixing. For mixing purposes barbotage is used, while in foamed products processing
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vigorous mixing is applied.
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Some raw materials and disintegrated material often needs sorting. Sorting is done by
weight, size, shape, and color. The need for sorting arises from few reasons.
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Sorting is done mostly taking advantage of gravity force. Screens with fixed or variable
aperture as flat or drum machines are commonly used. In the case of flat screens,
vibration is applied to move the material, while in the drum design inclination and
rotation cause movement of the material from inlet to outlet. Large objects are sorted in
cable, rope, belt or roller sorters. In these machines, the material moves in between two
cables, belts or rolls. The aperture between them increases continuously and material
with prescribed size is collected along the sorter. Sorting may damage the material,
especially that with soft texture. Hence, in some sorters material is collected in
containers filled with water. Sorting and washing can be combined in one operation.
Sorting by size or shape sometimes is done manually using special calibrators. This is
done for material, which must be calibrated by two dimensions. Example is cucumber
and gherkin processing. Both are sorted by diameter and length. It can be done
mechanically but the damage to the material is extensive.
Color sorting is done either manually or by image analysis. Manual sorting is applied to
large objects like fruits and vegetables, and is done by comparison with color standards.
Image analysis is also applied to sort large objects by color. The sorted material is
mostly packed and sold. Material subjected to freezing or drying may also undergo
color sorting. Hence, this sorting is aimed to fulfill expectations of the consumer. In
some instances color sorting is aimed to assure quality of the final product. For example,
in sesame seeds husk is bitter and must be removed to assure high quality of halva.
Another example is separation of bruised apple or fungi infected potatoes. Material,
which not matched the standard, is removed by the jest of air actuated by computer.
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The above-described methods of sorting divide the material into fractions on the
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physical basis. However, separation of the material into fractions with different quality
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is also required. It is done by grading. In many instances, size and weight of the material
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are related to the quality and sorting is sufficient as a method of grading. There are
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some material features, which cannot be assayed by size, shape or weight. Freshness of
eggs, ripeness of fruits, crumb structure in bread, baking properties of flour are
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examples of quality features, which cannot be divided into classes by sorting. Grading
in most cases must be done by a laboratory tests. In some cases, physical properties can
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be used for machine grading. It was already mentioned that small green peas is sweeter
than the large one. Density of peas is related to its tenderness. Hence, grading can be
done using brines of varying density. Grading is a process difficult to realize in the on-
line fashion.
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Expression of liquid fraction from plant material is used in fruit and oil processing. The
process is usually preceded by size reduction and heat treatment. The cells must be
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of disintegrated seeds is, in some cases, applied. In processing of some fruit juices
heating and enzymatic treatment are used to avoid jellification of concentrated product.
In wine making grape expression is preceded by maceration, during which native
enzymes hydrolyze pectins. It results in higher yield and better color and taste of juice.
Expression is done in batch presses such as tank press or hydraulic ram press or in
continuous presses. In tank press, fruit pulp is fed into horizontal cylinder in which a
plastic bag is axially mounted. Air is pumped into the bag, which expands and exerts
pressure onto pulp. The tank can be rotated to loosen the pulp and facilitate removal of
press residue. In hydraulic ram press fruit pulp placed in cloth bags is stacked one over
another. The bags are separated by plastic ribbed plates to facilitate liquid flow. The
pressure gradually increases due to lowering of pressure plate. The juice is collected at
the base of the press. This type of presses is used for fruit juice expression.
Continuous presses are designed as belt presses, screw presses and roller presses. In belt
presses aperture between two belts decreases along and disintegrated material is
squeezed. In screw presses in a horizontal cylinder, helical screw is rotated. The pitch of
the screw flights gradually decreases towards the discharge and exerts higher and higher
pressure on the pulp. Screw presses are used to express oil from oil seeds. The roller
press is built of two cylinders in between which the pulp is fed. To facilitate liquid flow
the cylinders are grooved. The press residue is removed with doctor blades.
Batch presses allow better expression of liquid from the disintegrated material, because
of higher pressures applied. In continuous presses, the press residue still contains
substantial quantities of liquid and further processing is required. In case of oil seeds
extraction is applied.
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Biographical Sketch
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Piotr P. Lewicki is a 1961graduate of Warsaw University of Life Sciences, Faculty of Food Technology.
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The degree of Doctor of Science he received in 1969 from Massachusetts Institute of Technology,
Cambridge, Mass., USA. Studying at MIT Piotr P. Lewicki took his major in food science and minor in
chemical engineering. In 1975 he defended habilitation thesis and in 1976 he was nominated associate
professor in food engineering. .In 1982 Piotr P. Lewicki was nominated full professor of food
engineering.
In the years 1962 - 2008 he was employed by the Warsaw University of Life Sciences in Warsaw. In
1978 Piotr P. Lewicki was appointed the head of the Department of Food Engineering in the Faculty of
Food Technology. At that time he was also deputy Dean for student affairs in the Faculty. In the years
1981-1984 he was Dean of the Faculty and during the years 1987-1990 he was appointed a deputy-rector
(vice-president) of the University. In 2008 Piotr P. Lewicki has taken the position of the director of the
Institute of Food Technology in the State College of Computer Science and Business Administration in
Łomża.
Piotr P. Lewicki was a visiting professor of food engineering in the University of Minnesota, St. Paul,
USA (1976-1977), in Bundesforschrungsanstalt für Ernährung in Karlsruhe, Germany (1991) and in
Universidad Nacional de San Agustin de Arequipa in Peru (2001, 2003).
Piotr P. Lewicki is an editor and co-author of instruction manuals for students and two textbooks on food
engineering (four editions) and design of food processing plant (two editions). He has done translation of
few professional books from English to Polish. In total he published over 250 publications in Polish and
international scientific journals.
Piotr P. Lewicki is a member of the Committee of Food Science of the Polish Academy of Sciences, the
Societas Sientiarum ac Litterarum Varsoviensis (Warsaw Scientific Society), Food Working Party of the
European Association of Chemical Engineers and The International Academy of Food science and
Technology. He is on the editorial board of Journal of Food Engineering (Esevier), International Journal
of Food Properties (Marcel Dekker) and Polish Journal of Food and Nutritional Sciences (Polish
Academy of Sciences).
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