The Business of Processing and Canning Agricultural Produce - Sweetcorn Part 2

Summary

This video script details the comprehensive process of sweetcorn production from farm to supermarket shelves. It covers the initial weighing, husking, blanching for ease of cob removal and microbial reduction, manual cobbing, washing, and a second blanching. The corn is then frozen using a blast freezer or tunnel, packaged in retail sizes, and stored at -18 degrees for an 18-month shelf life. The script also touches on the environmental and economic benefits of utilizing waste from the process and emphasizes the importance of quality control for customer satisfaction and local industry support.

Takeaways

• 🌽 The process begins with receiving sweetcorn at the factory and recording the quantity and weight using a web bridge.
• 📦 After offloading, the sweetcorn undergoes husk removal in preparation for further processing.
• 🔥 The first blanching is performed to facilitate the cutting and cob removal, which is done manually with knives.
• 💧 The sweetcorn is then washed in clean water after cob removal.
• 🔁 A second blanching is done to reduce microbial load and deactivate enzymes, using water at 90 degrees for three minutes.
• ❄️ The sweetcorn is cooled with water and then frozen using either a blast freezer at -32 for 24 hours or a freezing tunnel at -40 for seven minutes.
• 📦 Post-freezing, the sweetcorn is stored in courtrooms at -18 degrees, with a shelf life of 18 months.
• 🛍️ Retail packaging involves packing the sweetcorn in one-kilogram and 500-gram retail packs, with each carton holding 20 pieces.
• 🚚 The final step includes transporting the sweetcorn in refrigerated vehicles to distributors.
• 🌱 The waste from the sweetcorn processing, such as husks and cobs, is given to local farmers for free, either as feed for cattle or for composting.
• 🛑 Blanching is crucial before freezing to preserve the flavor, texture, and color of the sweetcorn by slowing down enzyme activity.
• 🌟 Sweetcorn is a starchy and functional food, high in carbohydrates and beneficial nutrients, and can be used in various dishes to enhance nutrient content.

Q & A

What is the first step in the sweetcorn processing after it arrives at the factory?

The first step is to determine the weight of the sweetcorn using a web bridge where the truck passes and the weight is recorded.

Why is the first blanching of sweetcorn done?

The first blanching is done to aid in cutting or the cobbing of the sweetcorn.

What is the purpose of the second blanching process in sweetcorn processing?

The second blanching helps in microbial load reduction and deactivating enzymes.

At what temperature and for how long is the sweetcorn blanched during the second process?

The sweetcorn is blanched at 90 degrees for three minutes.

What are the two methods used for freezing sweetcorn after blanching?

The two methods used for freezing sweetcorn are the blast freezer, which operates at -32 for 24 hours, and the freezing tunnel, which operates at -40 for seven minutes.

What is the shelf life of sweetcorn once it is frozen and stored at minus 18 degrees?

The shelf life of the sweetcorn is 18 months when stored at minus 18 degrees.

How is the waste generated during sweetcorn processing used?

The waste, which includes tops of plants, husks, and cobs, can be used as feed for cattle or decomposed and used as manure on farms.

Why is blanching sweetcorn before freezing important?

Blanching sweetcorn before freezing is important because it slows down enzymes that destroy the flavor, texture, and color of the corn.

How long should small, medium, and large ears of corn be boiled during the blanching process?

Small ears of corn should be boiled for seven minutes, medium ears for nine minutes, and large ears for eleven minutes.

What is the role of the HR department in the sweetcorn processing factory?

The HR department is responsible for recruitment of workers based on the labor required in the factory and conducts orientation and training for the new recruits.

How does the sweetcorn processing factory ensure quality control?

Quality control is ensured through grading the sweetcorn at reception to check for maturity, sweetness, and any signs of overgrowth or premature harvesting.

Outlines

00:00

🌽 Sweetcorn Processing and Quality Assurance

This paragraph outlines the comprehensive process of sweetcorn production for supermarket shelves. It begins with the reception and weighing of sweetcorn deliveries using a web bridge. The sweetcorn is then husked and undergoes two blanching stages; the first to facilitate cob removal and the second for microbial load reduction and enzyme deactivation at 90 degrees for three minutes. After cooling, the sweetcorn is frozen using a blast freezer or freezing tunnel, achieving a core freeze at -32 degrees over 24 hours. The final product is stored at -18 degrees with an 18-month shelf life. The importance of cleaning and waste management is highlighted, with waste being used as feed for cattle or decomposed for farm use. The paragraph also emphasizes the necessity of blanching before freezing to preserve flavor, texture, and color.

05:01

🛠️ Post-Processing Steps and Nutritional Benefits

The second paragraph delves into the post-processing steps of sweetcorn, including a final blanching to deactivate enzymes and reduce microbial load, followed by cooling and freezing at -32 degrees for 24 hours. The sweetcorn is then transferred to cold storage at -18 degrees, ensuring an 18-month shelf life. The nutritional benefits of sweetcorn as a starchy and functional food are discussed, highlighting its high carbohydrate content and the presence of multiple nutrients. Suggestions for culinary uses, such as in stews, salads, and mixed vegetables, are provided. The paragraph also touches on the creation of employment opportunities in the local community and the importance of quality control in the processing industry, including grading and checking for sweetness and maturity.

10:02

🏭 Local Manufacturing and Industry Support

The final paragraph focuses on the importance of local manufacturing and the support of local industries. It emphasizes the capability of Kenya to produce its own products, such as tomato sauce, and the competitive disadvantage faced by local companies due to imported goods. The paragraph calls for government enforcement to protect local industries and stresses the availability of local labor force, machinery, skills, and techniques. It concludes with a reminder of the importance of supporting local production and a sign-off for the show, KTN Farmers TV.

Keywords

💡Sweetcorn

Sweetcorn, also known as corn on the cob, is the primary subject of the video. It is a type of corn with a high sugar content, which is processed and sold in supermarkets. The video discusses the entire process that sweetcorn undergoes from delivery to the factory, through various stages of preparation, blanching, and freezing, to ensure it reaches consumers in a fresh and nutritious state. For instance, the script mentions the importance of blanching sweetcorn before freezing to preserve its flavor, texture, and color.

💡Blanching

Blanching is a cooking technique used in the sweetcorn processing industry to stop the action of enzymes that can degrade the quality of the sweetcorn. The process involves briefly boiling the sweetcorn and then cooling it rapidly, which is essential for preserving the sweetcorn's nutritional value and taste. The video script describes two blanching stages: the first to aid in the cobbing process and the second to reduce microbial load and deactivate enzymes, both at a temperature of 90 degrees for three minutes.

💡Cobbing

Cobbing refers to the process of removing the kernels from the cob of the sweetcorn. This is a manual process done using knives, as mentioned in the script. After the first blanching, the sweetcorn is cobbed, which is a crucial step in preparing the sweetcorn for further processing and packaging.

💡Freezing

Freezing is a preservation method highlighted in the video that extends the shelf life of sweetcorn. The sweetcorn is subjected to a blast freezer or a freezing tunnel, which operates at extremely low temperatures to quickly freeze the product. The script specifies that the blast freezer operates at -32 degrees for 24 hours, ensuring the sweetcorn is frozen to the core, which is vital for maintaining its quality during storage and transportation.

💡Microbial Load

Microbial load refers to the quantity of microorganisms present in a product, which can affect its safety and shelf life. The video emphasizes the importance of reducing microbial load through the blanching process. This is crucial for ensuring that the sweetcorn is safe for consumption and has an extended shelf life, as mentioned in the context of the second blanching at 90 degrees for three minutes.

💡Enzymes

Enzymes are biological catalysts that can cause changes in food, such as breaking down its components, which can affect the food's flavor, texture, and color. The video script explains that blanching is used to deactivate enzymes in sweetcorn, which is important for preserving its quality during storage. The final blanching process is mentioned as a way to deactivate enzymes and reduce microbial load.

💡Shelf Life

Shelf life is the period during which a product remains fresh and suitable for consumption. The video mentions that the shelf life of the frozen sweetcorn is 18 months when stored at minus 18 degrees Celsius. This indicates the importance of proper processing and storage conditions in maintaining the quality of the sweetcorn for an extended period.

💡Waste Management

Waste management is the process of collecting, transporting, and disposing of waste materials. In the context of sweetcorn processing, the script discusses how the waste generated, such as husks and cobs, is either used as feed for cattle by local farmers or decomposed to create manure for farms. This demonstrates an environmentally friendly approach to handling byproducts of the sweetcorn processing industry.

💡Quality Control

Quality control is the process of ensuring that the sweetcorn meets the required standards before it is processed and sold. The video script mentions that farmers are given specifications for the raw material, and the sweetcorn is graded upon arrival at the factory to check for maturity and sweetness. This is crucial for maintaining the quality of the final product and ensuring customer satisfaction.

💡Local Industry

Local industry refers to businesses that operate within a specific region, providing employment and contributing to the local economy. The video script highlights the importance of supporting local industries, such as sweetcorn processing, to create jobs and reduce reliance on imported goods. It emphasizes the need for government enforcement to protect and promote local manufacturing capabilities.

💡Employment Opportunities

Employment opportunities refer to the availability of jobs or positions within a certain field or industry. The video script discusses how the sweetcorn processing factory has created jobs for the surrounding community, with an HR department responsible for recruitment and training. This illustrates the social and economic impact of the industry on the local area.

Highlights

The process of sweetcorn from delivery to supermarket shelves involves several stages including weighing, husking, blanching, cobbing, and freezing.

A web bridge is used to record the initial weight of the sweetcorn delivery truck.

Husk removal is the first step in sweetcorn preparation, followed by the first blanching to aid in cobbing.

Cobbing is done manually using knives after the first blanching process.

Second blanching at 90 degrees for three minutes helps in microbial load reduction and enzyme deactivation.

Blast freezers and freezing tunnels are used for sweetcorn freezing at -40 degrees for seven minutes and -32 degrees for 24 hours, respectively.

Sweetcorn is packed in retail packs of one kilo and 500 grams, then transported in cartons to distributors.

Cleaning of sweetcorn is crucial and involves washing with clean water, with the dirty water saved and residue considered waste.

Waste from sweetcorn processing, including husks and cobs, can be used as cattle feed or decomposed for use as manure.

Blanching sweetcorn before freezing slows down enzymes that destroy its flavor, texture, and color.

Different sizes of sweetcorn require varying blanching times: small ears for 7 minutes, medium for 9, and large for 11 minutes.

Sweetcorn is a starchy and functional food, high in carbohydrates and beneficial nutrients.

Sweetcorn can be combined with other foods like carrots, potatoes, and peas to enhance nutrient content.

The company creates employment opportunities and provides training for workers in the sweetcorn processing industry.

Quality control is essential in sweetcorn processing, with checks for maturity, sweetness, and proper blanching temperatures.

Local industries should be supported by enforcing regulations on imports to protect domestic production.

The company's focus on quality ensures customer satisfaction and maintains a positive brand image.

Transcripts

[Music]

let us take a look at the process

with which the sweetcorn has to go

through before it gets to the shelves

in our supermarkets once we receive the

sweetcorn in the factory we have to

determine the weight of the quantity

delivered

we have a web bridge outside there where

the truck passes

the the first weight is recorded then it

proceeds through the reception

here we offroad and then it goes back

after offloading and then we we get

there

the quantity delivered after that we do

preparation

what they are doing here is the hurting

removing of

a husk from the now the sweetcorn

after this we have to do blanching

why we are doing the first blanching is

to help to aid in cutting or the cobbing

of the sweetcorn

after this after the cobbing the

sweetcorn

which is done manually by the use of the

knives

after the cobbing whatever the suitcase

which has been

covered because the cobbed they are

collected

and they are washed in very clean water

after this after cleaning now we have to

do again second blanching

this second blanching it helps in also

microbial load

reduction and also to deactivate the

enzymes

we do blanch at 90 degrees

for three minutes after blanching

now we cool with water after cooling

now the product is also subjected to

there

it is shifted to the freezers

we have a blast freezer or we can use

the freezing tunnel

the freezing tunnels operates at -40

for seven minutes the blast freezer

it has a capacity of 20 tons

and it operates at -32 for

24 hours after 24 hours

the product is already frozen to the

core

after this the product is shifted to the

courtrooms

which operates at minus 18.

once we receive the order we have again

to do now parking

in the retail packs we have retail parts

of one kilo

and 500 grams pack again

in cartons each carton holding 20 10

pieces

for one kilo and for 500 grams it

holds 20 pieces then we transfer

we transport our products in a referred

vehicle

to our distributor cleaning is an

important part of the processing of

sweetcorn

it is done through drinking with water

the dirty water is then saved

and the residue is considered as waste

the waste contains tops of plants husks

carbs and called ears the amount of each

in the waste will depend on the

processing equipment corn variety

and maturity growing conditions for the

sweetcorn

and equipment operators

farmers can use this waste as a feed to

their cattle

while others can choose to decompose it

and

use it as manual on their farms

this is waste of after cleaning the

sweetcorn

they already cleaned the sweetcorn to be

taken for blanching

and also this this waste we do dispose

and we give it to the farmers within

this

area local free we don't sell

sell it to the farmers also the sweet

corn the waste coming from the

garden piece the waste coming generated

from the

sweetcorn the husk and the cups

we also give it to the farmers from this

area

corn on the cob needs to be blanched

before freezing

because blanching slows down enzymes

that destroy the flavor

texture and color of the corn blanching

corn before freezing

helps to remove that from the corn and

brighten its color

corn on the cob is frozen in the same

manner as

corn of the cob however the blanching

process takes a few minutes

longer focon on the curb small ears of

corn should be boiled for seven

minutes medium years for 9 minutes and

large ears of corn should be boiled for

11 minutes

corn should be cooled for the same

amount of time that it is boiled

[Music]

so after cleaning the sweetcorn kennels

we have to do now the blanching the

final blanching

this final blanching will help in

deactivating the enzymes

and also reduction of microbial load

after blanching we do cooling now we are

starting lowering now the temperatures

down

we do cool with water after cooling with

water

we transfer now the already cooled

sweetcorn kennels to them

blast freezer or freezing tunnel

where in case you are using the glass

freezer

we have to store them there for 24 hours

at

-32 after this period the product is

already

frozen it is again now shifted to the

courtrooms

which operates at minus 18.

the shelf life of the product is 18

months

under minus 18. this is the first

blanchard

we are using this blanchard to do the

blanching

of sweetcorn before the cobbing the

temperatures for blanching

first blanching is for hot water

treatment for a short time

so the temperature here is at 90 degrees

for three minutes once the sweetcorns

are blanched

okay they are subjected to the cobbing

after the cobbing and washing they are

taken to the second blancha

here is the second blancha

also the temperatures for blanching is

90 degrees for three minutes

after this the sweetcorn kennels

are cooled with water after cooling

then they are shifted to their

courtrooms sweetcorn is starchy

vegetable

that doubles up as a functional food

starchy means it is high in carbohydrate

content functional means it contains

multiple nutrients that can bring

benefits to

our bodies when it comes to the diet

sweetcorn works well

as a side dish in soups and salads by

combining it with

other foods it can boost the nutrient

content even more

mr masharia elaborates on the advantages

of sweetcorn

and the different ways you can prepare

it

the level of sitcom sweetness in this

sweetcorn is very high

it is sweet yeah again once you eat this

sitcom

you can't feel like that that problem of

stomach

summer caps it that is it is not like

the other white

it's not like the other cup the white

cob this one you can even mix with

carrots

you can mix with potatoes you can mix

with garden peas

and you can also mix with french beans

to make mixed vegetables

so you can use it also as a stew

for maybe serving chapati for serving

rice so it's different from the other

corn

giorkanic has created a lot of

employment opportunities

for the surrounding community we recruit

our workers

we have the hr department who which does

the recruitment

according to the labor required in the

factory once they're

but once the the the workers are

recruited

we do an array we do an orientation to

them

now regarding the machine the pp's

and then gradually we do training

gradually we do training

maybe because it does manual work in in

one week's time

already they know what we are they are

supposed to do

quality is key on processing of any

product

without quality customer satisfaction

cannot be achieved and brand outlook can

be negatively affected

which in turn may bring down the company

mr macharia explains to us how they

ensure that everything they process

is good for the market when we are

contracting these farmers we are giving

them

our specs raw material specs so

the farmers are aware of what we need in

the factory

so when the sweden are delivered we have

also to do grading

to check the level of defense are they

overgrown

are they too young what

they are premature we check that and

also

we are checking also the sweetness the

bricks

these are the quality controls that we

do

at reception

[Music]

when we have importers bringing in

things from outside

easily into the country when we in kenya

can manufacture these products

then we need to secure our local

industries you know we have a lot of

companies that

start a tomato sauce factory and we

can't compete because the people

bringing this from outside and importing

it

when we can do it ourselves here locally

we have we have the labor force we have

the machinery we have the skills and

techniques we have good education uh

nitra is really supporting as well

and this is where the government needs

to enforce

in terms of importing that's it for

today's show

we hope you've enjoyed and keep watching

ktn farmers tv

[Music]

you