Lesson 1Blanchin' step design: recommended time-temperature schedules per product an' required coolin' sequenceHere wi design blanchin' steps fi carrots an' broccoli, definin' recommended time–temperature schedules, equipment options, an' di required coolin' sequence fi control enzymes, colour, texture, an' microbial load widout overcookin', fi perfect results.
Blanching objectives and enzyme inactivationHot water versus steam blancher choiceTime–temperature curves for each productBlancher loading and agitation controlImmediate cooling and cold water stagesVerification of blanching effectivenessLesson 2Packagin' an' sealin' fi two pack sizes: packagin' materials selection fi prevent freezer burn an' targets fi headspace an' sealin' integrityDis section cover packagin' an' sealin' fi two pack sizes, focusin' pon material selection fi prevent freezer burn, correct headspace targets, sealin' integrity tests, an' adjustments needed when switchin' between small an' large retail packs, keepin' it tight.
Selection of films and laminates for IQFPack size formats and line changeoversHeadspace targets and gas compositionSealing jaw temperature and dwell timeSeal integrity tests and defect criteriaCartoning, coding, and pallet labelingLesson 3Freezin' step implementation: equipment layout, entry an' exit core temperature targets, belt speeds or plate contact timesDis section focus pon implementin' di freezin' step, coverin' equipment layout fi IQF tunnels or plate freezers, entry an' exit core temperature targets, belt speeds or plate contact times, an' how fi monitor an' adjust parameters durin' production, fi no issues.
Selection of IQF tunnel or plate freezerProduct loading depth and belt distributionEntry product temperature specificationsExit core temperature and verificationBelt speed or plate contact time tuningAir velocity, fan balance, and frost controlLesson 4Post-pack checks: metal detection, weight verification, label an' date codin', an' immediate transfer to cold storageDis section detail post-pack controls before cold storage, includin' metal detection setup, weight verification tolerances, label an' date codin' rules, an' procedures fi rapid transfer to di freezer fi avoid temperature abuse an' labelin' or sealin' errors, safe an' quick.
Metal detector sensitivity and test piecesCheckweigher setup and legal tolerancesLabel content, layout, and allergen flagsDate coding formats and traceability linksReject handling and rework decisionsMaximum time to enter cold storageLesson 5Reception, sortin', an' cold chain: acceptable field temperatures, inspection criteria, an' minimal handlin' timesHere wi define best practices fi raw material reception an' sortin', includin' acceptable field temperatures, inspection an' gradin' criteria, foreign material removal, an' methods fi preserve di cold chain wid minimal handlin' times an' gentle product transfers, from field to factory.
Field temperature limits at truck arrivalSampling plans and visual inspection pointsSorting for defects and foreign materialsUse of hydrocooling or shade holdingTime limits from reception to processingDocumentation of cold chain breaksLesson 6Washin', peelin', an' cuttin' operations: machine types, sanitation, an' throughput considerations fi carrot slices an' broccoli floretsDis section explain washin', peelin', an' cuttin' lines fi carrots an' broccoli, comparin' machine types, sanitation programs, an' throughput limits, while linkin' cut size an' surface damage to downstream blanchin', freezin', an' final texture, fi clean cuts.
Washer types for carrots and broccoli floretsPeeling options and impact on yield and qualityCut size standards for slices and floretsLine balancing and throughput calculationsSanitation cycles and allergen controlForeign material removal and visual checksLesson 7Detailed stepwise flow from reception to frozen packed product wid controls at each nodeDis section map di complete process flow from reception to frozen packed product, definin' each node, associated controls, records, an' decision points, so operators can visualize dependencies an' quickly locate an' correct process deviations, easy fi follow.
High-level block flow diagram creationDetailed node descriptions and inputsCritical control points and limitsSupporting checks and monitoring recordsDeviation handling and escalation pathsFlow review for capacity and bottlenecksLesson 8Draining, dewaterin', an' pre-freeze moisture control: centrifugal, air knives, an' target moisture levelsHere wi cover drainin' an' dewaterin' methods after washin' an' blanchin', focusin' pon centrifugal systems an' air knives, how dem affect surface moisture, an' how fi set an' verify target moisture levels before freezin' fi limit clummin' an' ice buildup, dry an' ready.
Drain table design and residence timeCentrifugal dewatering setup and limitsAir knife configuration and nozzle settingsTarget surface moisture ranges by productMoisture verification tests and recordsImpact of moisture on freezing efficiencyLesson 9Cold storage an' distribution control: target storage temperature, monitorin', lot segregation, an' loadin'/unloadin' best practicesHere wi describe cold storage an' distribution controls, includin' target storage temperatures, monitorin' systems, lot segregation, pallet patterns, an' loadin' an' unloadin' practices dat prevent temperature abuse, package damage, an' loss of traceability, keepin' it all track.
Target storage temperature and tolerancesTemperature monitoring and alarm setupLot coding, segregation, and zoningPallet stacking and airflow managementLoading and unloading time limitsTruck pre-cooling and seal checks
