The Business of Processing and Canning Agricultural Produce - Sweetcorn Part 2
Summary
TLDRThis 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
🌽 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.
🛠️ 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.
🏭 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.
Mindmap
Keywords
💡Sweetcorn
💡Blanching
💡Cobbing
💡Freezing
💡Microbial Load
💡Enzymes
💡Shelf Life
💡Waste Management
💡Quality Control
💡Local Industry
💡Employment Opportunities
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
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