For more detailed instructions, see the Getting Started presentation. Manufacturing Food These icons indicate that detailed teacher’s notes or useful web addresses are available in the Notes Page. This icon indicates the slide contains activities created in Flash. These activities are not editable. For more detailed instructions, see the Getting Started presentation.

Scale of manufacturing

Can you remember?

Large-scale production planning Time The manufacturer will have deadlines to meet and the product must be produced on time, but storage of the finished product is expensive. Purchase and storage of materials Buying ingredients in bulk is cheaper, but they have to be stored and used while they are still fresh. If they are not, wastage increases. Use of equipment and resources Equipment is expensive to buy and needs to be used to its full capacity whenever possible. Workers still have to be paid if they have nothing to do, so this must not happen.

HACCP What does that stand for? Hazard Analysis and Critical Control Points Oh, right! Um, what does that mean then? It’s a way of making sure things don’t go wrong when we make our products. We have to look carefully at our processes, decide what things might go wrong and find ways to make sure they don’t. Oh, I see, that makes sense, but how do you actually do it? First we identify hazards. Those are the things that could go wrong.

Hazards What sort of things are hazards? There could be biological hazards if we didn’t keep food cool enough or left it uncovered where bacteria could get to it. We also have to avoid things getting into the food that shouldn’t be there – bits of glass from a broken jar, for instance. We call those physical hazards. Ooh, nasty! What happens if cleaning fluids get into the food? Those are chemical hazards – we have to watch out for those too.

Critical control points So what can we do about these hazards then? First of all we find the Critical Control Points. And they are? The points in our production process where we can control the hazards. Can you give me an example please? After we’ve cooked our pasta sauces, they are obviously hot. If we leave them standing in a warm place, bacteria can grow very quickly. Oh, I see, so you cool them down really quickly? That’s right, and we monitor the temperature of the food when we do it. If the results show that the food wasn’t cooled properly (perhaps the refrigeration wasn’t working well), then we have to throw the food away because it might be dangerous.

Quality assurance So HACCP is about making sure that our food is good quality? That’s right, it’s known as a quality assurance process.

HACCP words Hazard Analysis and Critical Control Points aim to spot the things that might go wrong and build in preventative measures – ways of controlling them. Hazard Type CCP Preventative measure Chicken not cooked thoroughly Biological Cooking Monitor cooking times and temperatures Hair in soup Physical Mixing Staff wear hats Nail varnish chip on bagel Packing No nail varnish allowed Metal fragments in frozen peas Scan packs with x-rays Bleach in cake mix Chemical Cleaning Rinse equipment thoroughly

Production charts A group of students are preparing samosas to serve at a evening of foods from around the world. Samosas have a filling inside a pastry case. The filling will be cooked before the samosas are filled. The samosas will be cooked and served hot. There will be meat samosas and vegetarian ones.

Production charts

Production charts

Making identical products When products are mass produced, they all need to be the same (consistent). Some ways of doing this are: weighing all ingredients and final product to make sure all portions are the correct weight using computer controlled manufacture (CAM) to keep manufacturing processes consistent buying in standard components, such as stock cubes, cake mixes and ready-made pastry, from other manufacturers using moulds and templates to control the shape of products.

Making breakfast – The story of cornflakes

Cornflakes – quality assurance The materials used are quality checked before they are used for production. The production process is carefully monitored following strict schedules, and the results are recorded and analysed. The product is tested for ‘shelf life’. Samples are tested routinely to check that the proportion of ingredients is correct using computer controlled analysis. Experienced tasters meet regularly to compare and taste the cereals being made. Consumer taste tests are also carried out at the homes of people who eat breakfast cereal regularly.

Summary One-off processing is used by craftsmen to make special products, but it is expensive. Batch processing makes larger numbers of similar products in batches. Mass production is used to make large numbers of identical products. Continuous production machines run all the time. Hazard Analysis and Critical Control Points are points in the manufacturing process where hazards can be controlled. Quality assurance is used to make sure products are made to the right standards.