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.