Polytechnic University of the Philippines

Sta. Mesa, Manila

College of Science
Department of Food Technology

Laboratory Activity

OPERATIONAL PROCESS OF MEAT, POULTRY, MILK, AND DAIRY FOOD PRODUCTS

Submitted by:

Group 3

Andaluz, Nicole C.
Celorico, Ma. Katherine P.
Maranan, John Kerby C.
Onilongo, Luis Clemente R.
Vengua, Earl Janndeil L.

BSFT 3-1D

Submitted to:

Prof Edgar I. Garcia

Fote 30155 Food Engineering

June 2024
 Abstract

In the production of food items, the procedure dictates the unit operations needed to
take and consider in order to create a product. To make the processing easier to understand,
a process flow is designed and followed. In the study, the steps to make bacon, balut, milk,
and yogurt were detailed and converted into a process flow. Each process flow highlighted
the unit operations that were done to create the products. Some of the unit operations used
in producing bacon are thermal processing, blast freezing, and sizing. Heating and
incubation were the common operations done to process duck eggs into balut while
standardization and pasteurization were done for milk and yogurt. The activity was able to
depict the processing steps and the unit operations involved through the use of a flow
diagram, providing a comprehensive overview of the procedures done for the production of
bacon, balut, milk, and yogurt.

Keywords: process flow, unit operation

 I. Introduction
Transforming raw agricultural materials into consumable foods through a series of
operations is one of the primary objectives of the food manufacturing sector. The
transformations are carried out using multiple stages and a wide variety of equipment, and
through food engineering, the effective design of each step, often known as the unit
operation, is achieved (Malekjani & Jafari, 2021; Pessoa Jr, 2003).
Unit operations change the properties of raw materials in an effort to provide
consistent, high-quality food items that are more likely to be accepted by consumers who are
becoming more particular about their preferences, or that have a longer shelf life and better
storage and transportation possibilities (Alaveranga et al., 2018). Mixing, pumping, heating,
cooling, concentrating, drying, filtration, evaporation, distillation, and extraction are a few
typical unit operations in many industrial processes. Further, all these unit operations,
notwithstanding their extensive differences and specificity, can be reduced to three types of
phenomena namely mass transfer, heat, and momentum (Augusto & Ibarz, 2016).
Evidently, food products are manufactured employing unit operations. Nonetheless,
physical processing comes in different intensities, and the amount of energy used relies on
the food's composition, the microorganism being targeted, the storage environment, the
packaging type, and the shelf life that is desired. Likewise, the high quality attained in food
products is due to both efficient control and scientific understanding of the principles in
operations used (Tadini & Gut, 2022). Therefore, understanding the underlying concept
behind each operation is essential in determining an efficient way in producing food products
that maximizes ingredient utilization, minimizes waste, and ensures optimal product quality
throughout its shelf-life.

II. Objectives
The aims of this study are to comprehensively analyze the production processes of
selected products from the Milk and Dairy, and Meat and Poultry food sectors.To achieve
this, the study is structured around two specific objectives:

A. To construct detailed flowcharts that visually represent each step of the

production process, from the raw materials through to the final packaging of
the products.
B. To Identify and categorize specific unit operations involved in these
processes.

Through these objectives, the study aims to provide a comprehensive overview of the
production methodologies employed within these key food sectors, offering insights into
operational efficiencies, technological advancements, and potential areas for innovation.

III. Calculations
 IV. Results of Discussion
In this section, the processing flow of the production of various food products from
meat, poultry, milk, and dairy are presented. The raw materials, unit operations, and the
outcome are the essential components in constructing a flowchart of a food production
process. The unit operations are actions that give change to the material present whether it
is physical or chemical (Gavhane, 2009). Unit operations also indicate the major
transformation materials undergo to produce the desired final product. Such notable
examples are blast freezing, incubation, pasteurization, and inoculation, which can be
applied in the production of milk, dairy, meat, and poultry products, respectively.
 Figure 1. Process Flow of Bacon Production

Bacon is a processed meat product commonly consumed during breakfast. As

documented by Discovery UK (2018), a series of operations are being done to convert raw
pork bellies into pre-cooked bacon (see Figure 1). First, a load of pork bellies is placed in a
big tumbler. The mechanical force applied upon meat tumbling softens the pork bellies which
makes skin easier to remove. Next, each pork belly, in the skin side down position, is placed
in a conveyor belt that takes it to an automated blade that slices the skin off the meat. The
removed skin is dropped off on a separate conveyor belt, while the skinned meat pieces are
turned back side up using a flipping device so workers in line can manually trim the
remaining skin. Meanwhile, salt was fully dissolved in a tank of water to make a brine
solution that would cure the pork. Liquid smoke and other flavorings are added to the
solution after. Following, the skinned pork bellies pass into an injector head where the
produced curing solution is repeatedly injected. Subsequently, the pork bellies are hung in a
rack using a metal hanger and put in a drench cabinet where it will be showered with liquid
smoke. This process adds flavor and color to the meat. After showering, the pork bellies are
cooked in an oven for 5 hours at a low temperature to let the flavor permeate the meat. Blast
freezing is applied for a quick chill down after cooking. Then, for a couple of days, they are
stored in a cooler to make meat firm for ease of slicing. Following, the sides of the pork
bellies are trimmed in a sizing station for it to fit in the slicing device. It then passes through a
metal detector to determine if a piece of metal hanger was left in the meat. Workers
afterwards put the pork bellies in a slicing machine to cut the meat into bacon-sized pieces.
The slices fall in a conveyor belt that takes them to a browning microwave to cook the bacon
further. Fats cooked off in the bacon are drained and as the cooked bacon exits the
microwave oven, an inspector discards substandard pieces such as broken ones. Lastly, the
bacon is stacked for packaging then packed.
 Figure 2. Process Flow of Balut Production

Figure 2 depicts the processes involved in the production of balut. According to Sison
(2017), the rice hull is first heated and then lined at the bottom of a container. Then, bags of
duck eggs were placed inside the container, which was then covered with another set of
heated hulls. To avoid the loss of heat, the box was covered by its lid. To ensure the quality
of the product, the box should be inspected every three days until the 17th day, when the
duck eggs are processed into balut.
 Figure 3. Process Flow of Milk Production

The simple production of milk is presented in Figure 3 from Tetra Pak (2021). Starting
off, quality-tested milk is subjected to separation, where the raw milk is segregated from
cream and skimmed milk by means of a centrifugal separator. The milk is then standardized
based on the ideal fat content for full-fat, semi-skimmed, and skimmed milk. And then, the
standardized milk is homogenized further to minimize the size of the bigger fat droplets. To
ensure the safety of the milk, it is pasteurized at a minimum temperature of 72°C for 15
seconds to eliminate hazardous bacteria and reduce the number of microorganisms in order
to extend its shelf life. Following pasteurization, the milk was kept cool at 4°C before being
packaged. All of these were essential to producing processed milk from the dairy farm for the
glasses of each consumer.
 Figure 4. Process Flow of Yogurt Production

The operational process of yogurt production is illustrated in Figure 4, adapted from

the study of Hossain et al. (2020), illustrating the critical unit operation steps to properly
produce a commercial yogurt product. The diagram includes the critical steps in making
yogurt, such as pasteurization, which is responsible for killing the pathogens or any spoiling
microorganisms present; inoculation and incubation, which are the addition of the probiotic
organisms and letting it proliferate and gives it the quality of a yogurt product (Yang, 2016).
The identified unit operations in yogurt production are standardization, pasteurization,
mechanical processing homogenization, cooling, inoculation, incubation, and packaging, as
these processes change the food material, whether physical or chemical.

V. Summary
This study delves into the production processes of selected food products within the
Milk and Dairy, and Meat and Poultry sectors, specifically focusing on bacon, balut, milk, and
yogurt. Through carefully constructed flowcharts, each step from raw material sourcing to
final product packaging is visualized, underlining the critical unit operations such as thermal
processing, blast freezing, sizing for bacon; heating and incubation for balut; and
standardization, pasteurization, and homogenization for milk and yogurt. The report's
comparative analysis reveals distinct processing techniques across these sectors while
emphasizing the universal importance of quality control measures to ensure product safety
and integrity. Ultimately, this study illuminates the complexity and technological
sophistication behind the production of everyday food products, offering insights into
operational efficiencies and the potential for future innovations to enhance food quality and
sustainability.

VI. Conclusion
The unit operations were identified based on the flowcharts described in the results
for the production of meat, poultry, milk, and yogurt. Bacon is produced through a series of
operations that convert raw pig bellies into bacon. Tumbling and skin removal are followed
by brining, injection, smoking, frying, and slicing, as well as metal detection and quality
testing. On the other hand, the production of balut involves a methodical process that
includes the heating of rice hulls and the incubation of duck eggs.

Furthermore, for milk production, start with the separation of raw milk, then
standardize to reach the necessary fat content. Further homogenization and pasteurization.
Finally, precise refrigeration and packaging techniques ensure that the milk remains fresh
until consumed. Lastly, the production of yogurt includes standardization, pasteurization,
homogenization, cooling, inoculation, and incubation.

Overall, thermal processing, blast freezing, and sizing are examples of unit
operations utilized in the bacon production process. Heating and incubation were the primary
activities used to convert duck eggs into balut, whereas standardization and pasteurization
were commonly used for milk and yogurt. And these operations are necessary to manipulate
the food into the target quality characteristics.
VII. References
Alvarenga, V. O., Campagnollo, F. B., do Prado-Silva, L., Horita, C. N., Caturla, M. Y. R.,
Pereira, E. P. R., Crucello, A., & Sant’Ana, A. S. (2018). Impact of Unit Operations
From Farm to Fork on Microbial Safety and Quality of Foods. Advances in Food and
Nutrition Research, 85, 131–175. https://doi.org/10.1016/bs.afnr.2018.02.004
Discovery UK. (2018, March 1). BACON | How It’s Made [Video]. YouTube.
https://youtu.be/GAqIynamBMY?si=sPA66Q1LiiQNjvr9.
Gavhane, K. A. (2009). Unit Operations-i Fluid Flow and Mechanical Operations. published
by Nirali Prakashan, 6-7.
Hossain, M. K., Keidel, J., Hensel, O., & Diakité, M. (2020). The impact of extruded
microparticulated whey proteins in reduced-fat, plain-type stirred yogurt:
Characterization of physicochemical and sensory properties. LWT, 134, 109976.
Ibarz, A., & Augusto, P. E. D. (2016). Principles of unit operations in food processing.
Quantitative Microbiology in Food Processing, 68–83.
https://doi.org/10.1002/9781118823071.ch3
Malekjani, N. & Jafari, S. M. (2021). General mathematical and engineering principles in unit
operations of food processing. Elsevier EBooks, 403–417.
https://doi.org/10.1016/b978-0-12-818473-8.00014-1
‌Pessoa Jr, A. (2003). Unit operations in food engineering. Revista Brasileira de Ciências
Farmacêuticas, 39(4), 468–468. https://doi.org/10.1590/s1516-93322003000400017
Sison, J. (2017, October 24). How to make Balut Egg. Mama’s Guide Recipes.
https://www.mamasguiderecipes.com/2017/10/24/make-balut-egg.
Tadini, C. C., & Gut, J. A. W. (2022). The Importance of Heating Unit Operations in the Food
Industry to Obtain Safe and High-Quality Products. Frontiers in Nutrition, 9.
https://doi.org/10.3389/fnut.2022.853638
Tetra Pak. (2021, June 15). The basic steps of milk production. Youtube.
https://www.youtube.com/watch?si=tMm5hsAK1_F3CNdJ&v=7TMtA8Eh9uE&feature
=youtu.be.
Yang, J. (2016). Making Yogurt at Home.
https://www.uog.edu/_resources/files/extension/publications/Making_Yogurt_at_Hom
e.pdf
 Appendix A. Sample Team/Group Contract

GROUP NUMBER 3 SECTION BSFT 3-1D

As members of an engineering team, our mission is to perform our assignment with high
standards that bring credit to the team and our profession and that provide positive results.
Each of us will contribute a proportional share of the total effort required, helping one
another to perform the parts that make up the whole process. We agree upon the following
distribution of responsibility:

Student Name Responsibility

Andaluz, Nicole C. Introduction, Result and Discussion,

Calculations

Celorico, Ma. Katherine P Conclusion, Result and Discussion,

Calculations

Maranan, John Kerby C Objectives, Result and Discussion,

Calculations

Onilongo, Luis Clemente R. Summary, Result and Discussion,

Calculations

Vengua, Earl Janndeil L. Abstract, Result and Discussion,

Calculations

Anyone failing to complete his or her part of the assigned work by the agreed time will not be
included in the submission of the final report, thus resulting in a failing grade of that team
member. We, the undersigned, agree to perform our responsibilities in a professional and
responsible manner that supports the success of our mutual efforts.

Student Name Signature and Date

Andaluz, Nicole C.

Celorico, Ma. Katherine P

Maranan, John Kerby C

Onilongo, Luis Clemente R.

Vengua, Earl Janndeil L.