UNIT - III

HEALTHY PASTRY: “ SAMOSA”

Defining Product

And

Process Specification

TEAM - C

Alzahrani Ibtisam

Bande Ajinkya

Chen Lu

Psylou Marilena

Yang Yushan

Zhai Lili

Summary

The main purpose of Unit III is to develop and optimize the product with respect to process and ingredients and to have a brief idea about the required process equipments and packaging eligible according to legislation to fit the product in European market.The industrial process was designed and monitored in such a way that it assures the safety and quality of the final products. The selection of the equipments is based on the quantity of samosa production per day. For a production of 10,000 units per day, where each unit equals to 6 samosas for ready-to-eat production and 15 samosas for frozen production, the factory will produce 150,000 samosas per day. Taking into account that the base of each samosa weighs 13gr and the filling 10gr, the weight of raw materials for producing 150,000 samosas per day is 1500kg and the weight of base is 1950kg per day. The aim of consumer acceptability and preference test was to provide an indication of whether the formulated product is acceptable to the consumers, so that the preferred formulated product will be found out and process can be optimized. Two replicated experiments were carried out among 36 untrained assessors to assess in which three top attributes related to base and overall acceptability of product were examined. The results concluded that there is a significant difference only between crispiness and oiliness of samples. No significant interaction between factor X1 (frying time) and factor X2

(base combination) is identified, and X1 is considered as an important factor that affects sensory attributes when optimizing processing conditions. The group decided to chose sample I which is 25% of whole meal flour and 75% of plain flour in base and half fried for 30 seconds. The final product will be manufactured according to the process specification with use of specified quality ingredients to give a uniform product at the end of the process. The raw material could be sourced from local market or directly from the manufacturers according to amount needed. According to the calculations done the final product will be weighing average of 23gm and about 75cal energy (per samosa) and product will be sold as ready to eat (RTE) samosas and as frozen samosas. The packaging used in both cases will be transparent as far as possible to give a view of product and as far as shelf life is concerned RTE samosa have short shelf life than frozen which will be determined in further units. Food standard is a very important aspect in the food industry, given that it is directly associated with human health. It is therefore important to examine whether the industrial production of samosa conforms to the safety and quality criteria that have been set up in existing industrial standards and legislation. There are several of them that have been enforced globally, aimed at regulating the industrial production of food products. The Food Standards Agency is mandated with carrying out policies that are aimed at ensuring that food substances are safe for human consumption. This includes research funding on microbiological, radiological, and chemical safety, as well as allergy and food hygiene. It has been noted that the samosa production process was adequate and conformed to the legislation and standards of food production. However, the training process of the staff is not well developed despite its significance in the production process.In the next stage, we will continue to optimize our product in terms of the filling. We will also develop the product commercialisation, which include conducting a commercial product test, determine the factors affecting shelf-life, find proper packaging and legislation for our product, propose GMP,GHP, HACCP and quality control plans.

I. Develop process and equipment flowcharts with description of the whole production process

# Optimal Laboratory Process Flow c hart

Filling Base

sweet potato soya chunks

ready-to-eat

half fried and frozen

Washing

Cooking of filling with

spices

shaping of samosa

Cooling&serving

half fry

Dough Preparation

Rolling of dough in sheet

25% wholemeal flour + 75%white Flour

soaking

Boiling

190℃30s

stand for 15-20 min

4-5 min

10 min

diameter:5mm cubes

cutting

thickness:0.5-0.7mm diameter :about 5 inches

mixing of spices

Detailed information

shown below

fully fry

blast freezing

-30℃ 30 min

190℃1 min

heat in oven 180℃ 15 min

50℃

# Industrial Process Flow Chart

Filling Base

READY-TO-EAT FROZEN

Cooking of Soya chunksFlour (25% whole meal +

75% white flour) + spices + olive oil

Straining out water from soya chunks

Primary Packaging

Washing of Sweet potato

Dicing of sweet potato (size of dice- 0.5-1cm³)

Forming/shaping of samosa

Each samosa: 13gr base+ 10gr filling

Cooling

Shallow frying till crispy and golden brown surface

(190°C) Ready-to-eat: frying for 60sec

Frozen: frying for 30sec

Individual quick freezing

Dough Preparation

Cooking of filling (50% soya + 50% sweet potato)

Primary PackagingMetal Detector & checkweigher

Storage at 2-6°C

Storage at -18°CDispatch in secondary pack

Plastic transparent boxes

Description of the industrial process flow chart:1. Washing of the vegetables:

The first step of the industrial process for samosa production is the washing of the vegetables stage. In this stage, the onions and the sweet potatoes are put in the vegetable washing machine in order to remove soil remains, stones and any other physical hazard derived from the field.

2. Dicing of the vegetables:

The vegetables used in the samosa filling should have equal size, thickness and shape in order to achieve equal heat transfer uniformity during cooking procedures. Size reduction leads to an increase in surface-to-volume ratio and a more efficient rate of heating and cooling. Size reduction also aids to the proper mixing of the ingredients in the filling. The knife blades in the dicing machine must be kept sharp so as to reduce the force required to cut the material and to minimize cell destruction. Cell destruction enables the mixing of enzymes and substrates and that leads to loss of flavor, aroma and color. Furthermore, cell destruction can be a cause for microbiological growth and off-flavor and aroma development. Vegetables are first sliced and cut into strips by rotating blades and then are cut into cubes. (Fellows 2000)

3. Cooking of soya chunks:

In this step of the process, the soya chunks which are already bought in a dehydrated form are put in a cooking kettle with boiling water in order to rehydrate and retake their previous texture and form.

4. Straining out water from soya chunks:

After the completion of soya chunks dehydration, the remnant water is poured in a colander.

5. Cooking of the filling (50% soya chunks + 50% sweet potato):

In this step of the process onions, sweet potatoes and soya chunks are cooked all together in a cooking kettle for the preparation of the filling with the addition of spices. Sweet potatoes are not already cooked before entering the cooking kettle because the team decided that there was no difference in the texture of precooked sweet potatoes and raw sweet potatoes. It is very important that all ingredients are properly mixed in order to ensure homogeneity of the filling and improve the characteristics of the final product. (Fellows 2000)

6. Dough preparation:

Dough preparation takes place at the same time with the preparation of the filling. Dough is prepared in a mixing machine, where 25% of whole meal flour and 75% of plain flour are

Dispatch in secondary packCardboard boxes

mixed with sunflower oil, water and grounded cumin. Dough is a high-viscosity material and mixing is achieving with the aid of three main actions: kneading, folding and shearing. In that way, folding and shearing forces extend protein molecules and gluten network is developed, which promotes the desirable texture of dough. Due to the nature of the dough (viscoelastic material), it is important that the mixer blades are moved throughout the vessel in order to achieve an efficient mixing. When the dough is ready is left to rest for a while in a tray. Furthermore, when the filling is cooked is also left to cool in a tray. (Fellows 2000)

7. Forming/shaping of samosas:

When the dough has rested and the filling has cooled, both materials are put in the samosa making machine, which forms the samosa. The device opens the dough in large sheets, which length and thickness can be adjusted, and then it cuts the dough in small pieces. After that, the stuffing depositor places the filling in each small sheet and as the conveyor belt transports the samosas, workers in both sides of the conveyor belt wrap the samosas.

8. Frying the samosas till crispy and golden brown surface:

Frying is used not only for altering the eating quality and texture of a food material, but also for increasing the shelf life by deactivating the enzymes, destroying the microorganisms and reducing the water activity at the food surface. In an industrial level is important to maintain high temperatures during frying in order to reduce processing time and increase production rates. However, such high temperatures cause oil deterioration and free fatty acids formation. The formation of free fatty acids can alter the organoleptic characteristics of the oil (flavor, aroma, viscosity). Samosa production requires frying in high temperature in order to achieve the desirable crispiness level. It is important that the crust is rapidly formed so as to seal moisture into the food and to reduce the rate of heat transfer to the interior. The method which is industrially used for frying samosas is shallow frying, because samosas have a large surface-area-to-volume ratio. The heat is transferred from the hot surface of the equipment, through a thin layer of oil, to the food by conduction. Shallow fried samosas present an irregular browning on their surface because the thickness of the oil layer is not constant but it depends on the surface of the food. Furthermore, steam bubbles raise the food from the hot surface of the equipment and that causes temperature variations during frying. Those temperature variations contribute to the irregular browning of shallow fried samosas. Finally, despite the fact that shallow frying has a high surface heat transfer coefficient, the heat is not uniformly transferred to the food surface. (Fellows 2000)

9. Cooling:

After shallow-frying the samosas, those batches that are destined for ready-to-eat consumption should be put in the cooling machine in order to rapidly decrease their temperature before packaging.

10. Individual quick freezing:

After shallow-frying, the batches which are destined for freezing are put in the air-blast freezing machine for 1hr. Its principle is based on quick freezing. It is important that the freezing process is fast in order to avoid thawing of the material. In the blast freezer the air is recirculated at a very high velocity. The high air velocity contributes to the reduction of the thickness of the boundary film around the food and also increases the heat transfer coefficient. Samosas are transported through an insulated tunnel on -conveyor belts. Furthermore, blast freezing is a very economical way of freezing and it can be used for different shapes and sizes of food. (Fellows 2000).

11. Primary packaging of ready-to-eat samosas:

After cooling down the ready-to-eat samosas are packaged in plastic bags which are closed with a vacuum packaging machine.

12. Primary packaging of frozen samosas:

The frozen samosas are put in the packaging machine which produces three sealing pack in order to assure a safe product.

13. Metal detector:

After the primary packaging, all batches, ready-to-eat and frozen ones pass through the metal detector in order to check if all products are free of metal remnants from the equipment surfaces. Furthermore, at the same time the weight of each package is checked.

14. Storage of ready-to-eat samosas:

The ready-to-eat samosas are stored at storing rooms under controlled conditions of temperature (2-6°C), lighting and humidity in order to maintain the quality and safety of the products. (Fellows 2000).

15. Storage of frozen samosas:

The frozen samosas are stored at storing rooms at below -18°C.

16. Dispatch of ready-to-eat samosas in secondary pack:

The primary packages of ready-to-eat samosas are put in plastic transparent boxes and then are ready for distribution.

17. Dispatch of frozen samosas in secondary pack:

The primary packages of frozen samosas are put in cardboard boxes and then are ready for distribution.

II. HEALTHY SAMOSA FACTORY LAYOUT

GENERALSTORE

RAWMATERIAL

STOREEx. Onion, flour, etc

RAWMATERIAL

HANDELING

INGREDIENTSTORE

Ex. spices, etc

CONTAINERWASH

PRIMARY PROCESSING AREA*CHOPPING ONIONS & CORIENDER*DICING SWEET POTATO

*DOUGH MAKING

COOKING AREA

COOKINGOF FILLING

SAMOSA MAIKING

PACKAGING

COOLING OR FREEZING

SECONDARY PROCESSING AREA

FRYING

PACKAGING STORE

MET

AL

DETE

CTIO N

READY TO EAT STORE

FROZEN

STORE

LOADING

CHEMICALSTORE

QUALITY CONTROL

LABORATORY

SHOWERS&

TOILETS

SHOWERS&

TOILETS

RUBBISH - MAY/MAYNOT BE FOOD WASTE FOOD WASTE

HYGENIC FACILITIES

FOOT DIP HAND WASH

III. Selecting process and ancillary equipment required to meet the define production requirement

# Equipment Flow Chart

Filling Base

READY-TO-EAT FROZEN

Cooking of Soya chunks

cooking kettle(57-1330ltrs)Flour (25% whole meal +

75% white flour) + spices + olive oil

Straining out water from soya chunks

Colander

Primary Packaging Swing Lid Open Bed Double Chamber Vacuum Packaging

Machine

Washing of Sweet potato

Spiral vegetable washing machine: capacity : 800-1500kg/hr

Dicing of sweet potato (size of dice- 0.5-1cm³)

Multifunctional Vegetable/Meat Dicing

Machine

Capacity: 1,500kg/hr

Cubic size: 8mm

Forming/shaping of samosa Spring roll Lumbia and samosa

machine-2 (model SRPF-45): 2400-2700 samosas/hr

Cooling cooling machine: capacity: 2.5tons/hr

Shallow frying till crispy and golden brown surface

Bratt Pan 150ltrs

Individual quick freezingStrimp tunnel quick freeze machine,

capacity: 2000kg/hr±10%

Dough Preparation

Spiral mixer

Capacity: 2ton/hrCooking of filling (50% soya + 50% sweet potato)

cooking kettle(57-1330ltrs)

Primary Packaging vertical packaging machine

(VTI 200 vertical wrapper (VFFS)) :70cycles/min

Metal DetectorMetal De MDC-Combo Combined metal detector & checkweigher, capacity: 50packs/min

Storage at 2-6°CStorage room Storage at -18°C

Storage room

Dispatch in secondary pack

Cardboard boxes

Dispatch in secondary pack

Plastic transparent boxes

# Description of the equipment flow chart

As far as the equipments which are used for the industrial production of samosas, they should be shelf-draining and to have a minimum number of ‘dead spaces’ where microorganisms can grow. In order to have a continuous process, belt conveyors are used, which transport the solid materials between the steps of production.

The choice of equipments will be based on the process flow chart and the quantity of the products which will be produced per day. The factory will produce 10,000 units per day. For the ready-to-eat samosas, each unit is equivalent to 6 samosas, because 6 ready-to-eat samosas will be contained in the package. For the frozen samosas, each unit is equivalent to 15 samosas, because 15 samosas will be contained in the package. The selection of the equipments was based on their capacity, after taking into consideration that the medium weight of each samosa is 23g from which 10g is the filling and 13g is the base. So, the weight of raw material needed for producing at least 150,000 samosas per day is 1500kg. And the weight of the base needed for producing at least 150,000 samosas per day is 1950kg.

At first stage, two processes take place simultaneously, the preparation of the filling and the preparation of the base.Washing of the vegetables:

As far as the filling is concerned, the first step is the washing of the vegetables (potatoes and onions). The vegetable washer model which is used in the factory is the Spiral vegetable washing machine (product of the Kasmac Industries Co., Ltd.) which has a capacity of 800-1500kg/hr, a power of 3.3kw and its water consumption is 500-1000kg/hr . The washing of the vegetables is a very important step because in that way, the physical hazards (soil remnants, stones, etc) are minimized. [3] Dicing of vegetables:

In this step, the sweet potatoes are put in the dicing machine, Multifunctional Vegetable/Meat Dicing Machine (product of the Weishi Huifa Machinery Plant) with capacity of 1,500kg/hr, the cutting size of the machine is 5mm and the cubic size is 8mm. [2] Cooking of soya chunks:

Soya chunks are put in a cooking kettle with boiling water. For that purpose a cooking kettle is used (Hammilton Style “SB”) with a capacity of 57-1330ltrs. [10] Straining out water from soya chunks:

After the rehydration of soya chunks, the content of the kettle is poured in a colander (Carlisle 10628 Colander, Clear, 18" x 26" x 5"). [9]Cooking of the filling (50% soya chunks + 50% sweet potato):

The diced sweet potatoes and the boiled soya chunks are put in a kettle in order to be cooked with the addition of spices. For that purpose, a cooking kettle is used (Hammilton Style “SB”) with a capacity of 57-1330ltrs. [10]Dough preparation:

At the same time, the making of the base takes place. For that reason a dough spiral mixer is used, Bottom Discharge SP 240 E (product of Diosna), with a capacity of 2 ton/hr. The machine offers an automatic mixing process and the procedure can be programmed. It also has an automatic dough discharge. [8]Forming/shaping of samosas:

The dough and the filling are put in the Spring Roll Lumbia and samosas Machine-2, model SPRF-45, product of Anko Food Machine Co., Ltd., which has a capacity of producing 2400-2700samosas/hr. The thickness of the samosa pastry that is produced by the machine is 0.4-0.7mm and the weight of each samosa produced is 30-60g/piece. [4]Frying the samosas till crispy and golden brown surface:

The samosas can then be transported in trays and shallow fried in the Bratt Pan machine (product specification: Code 34 of the Mobdle Kitchens Ltd.), with capacity of 150ltrs. The device is composed of a heated metal surface which is covered by a thin layer of sunflower oil. The samosas which are destined for ready-to- eat form, are fried at 190°C for 1min and the samosas destined for freezing are fried at 190°C for 30sec. The temperature of the oil is very important to be high, in order to minimise the absorption of oil by the samosas. [7] Cooling:

The batches that are destined for ready-to-eat form are put on the cooling machine (model LQ-5470 of Xiamen Jianmin Food Machinery Co., Ltd.) with a power of 1.5kw and a capacity of 2.5 tons/hr. [6]Individual quick freezing:

The batches that are destined for frozen storage are put in the Strimp tunnel quick freeze machine, model SSD-2000 (product of the Zhejiang Sanshon Machinery Manufacturing Co., Ltd.), with a capacity of 2000kg/hr±10%, the input material temperature is +15ºC, the output material temperature is -18ºC and the temperature of the freezer is -36ºC±2. The freezing time is 12-100min, which can be adjusted. The principles of the equipment are based on air-blast freezing. [1] Primary packaging of ready-to-eat samosas:

After cooling down, the ready-to-eat samosas are packaged in plastic bags and the workers put the bags in the FMC J-V016 Swing Lid Open Bed Double Chamber Vacuum Packaging Machine (a product of The Food Machinery Company Ltd.), with chamber dimensions of 1040x870x200mmx2. [11]Primary packaging of frozen samosas:

After freezing, the samosas are put in the vertical packaging machine (VTI 200 vertical wrapper (VFFS)), product of the Ulma 50 which produces a three sealing pack and a medium production speed of 70cycles/min. The vertical packaging machine includes also printer and labeller. [5]Metal detector:

After packaging, all products pass through the metal detector (MDC-Combo Combined metal detector & checkweigher, product of Rehoo Industrial Limited) which has a capacity of 50 packs per minute with maximum size of package 250mm long x 300mm wide x 200mm high and a sensitivity in detecting particles from 0.1mm Fe and 1.5mm SUS to 1.8mm Fe and 2.5mm SUS, depending on the tunnel height. That step is of high importance because the samosas can be contaminated by metal pieces from the metal surfaces of the machines and the equipments. Furthermore, at the same time, that piece of equipment can monitor and measure the weight of each samosa. [12]

IV. Product formulation and optimization

This section of the report discusses the experiments conducted whilst optimizing the product formulation for the groups’ samosa product. In order to achieve the optimized processing conditions and formulation for products, two main methods are considered, which are conducting a screening experiment and using a response surface design. The former is used to optimize a product formulation. Through examining a list of factors, more than two, then to determine which one of these have a greater effect on the products. This method is useful when we do not know beforehand which factors are most effects on our selected response. However, the filling of product seems to be constant, therefore the crispiness and golden surface of base is mainly considered. According to this element, we decided two factors, which are frying time and the base combination. Both affect the crispness and golden surface of base. Thus the step of screening experiment conducted can be skipped. We continue to do a response surface experiment. There are two factors with three levels in a response surface experiment.Factor A: frying time Factor B: base combinationa .Fully fried (FF): 60 seconds a. 25% wholemeal flour (W):75% plain flour (P)b. Three-quarter fried (¾ F): 45 seconds b. 50% wholemeal flour(W): 50% plain flour(P)c .Half fried (HF): 30 seconds c. 75% wholemeal flour(W): 25% plain flour(P)

(1)FF +25% W:75% (2) FF+50%W:50% (3)FF+75%W:25%P (4) ¾ F +25% W:75%P (5)¾F+50%W:50%P (6)¾F+75%W:25%P

(7)HF +25% W:75%P (8)HF+50%W:50%P (9)HF+75%W:25%P

Due to different level of each factor affect product attributes, so the best level would be obtained based on this experiment which is to determine the optimized processing condition for products. The ANOVA results and the graphics generated from ‘R’ are discussed over the next few pages. Results

Q1 Response - Golden surface

Graph1. The response of golden surface for FO module

The straight lines of the above graphic tell us that there is no interaction between the two factors, frying time and base combination when assessing the golden surface. The above graphic also tells us that as you increase the frying time, you also get an increase in golden surface(as expected).

The ANOVA results for the golden surface response suggest that the two factors that are all not significant with a p value > 0.05.

From the graph we can see that 1.0 on the x-axis is frying time and 1.0 on the y-axis is base combination, we can obtain the optimization processing conditions for product crispiness, where -1.0 = 30 seconds and 1.0 = 60 seconds of frying time, then -1.0 = 25% wholemeal flour and 75% plain flour and 1.0= 75% wholemeal flour and 25% plain flour of base combination. So based on these results we can assume that applying longer frying time with higher wholemeal flour would provide the optimum crispiness with regards to consumer acceptability. But the interval between each straight line is only 0.05, indicating not big change in preference of golden surface. Q2 Response - Crispiness

Graph 2. The response of crispiness for SO moduleThe ANOVA results for the crispiness response suggest that the only factor

that is significant is the frying time with a p value < 0.05. And there is no interaction between two factors.

The above graphic also tells us that as we decrease the frying time, we also get an increase in crispiness (as expected). .

From the graph we can see that -1.0 on the scale for frying time and -1.0 on the scale for base combination, we can obtain the optimization processing conditions for product crispiness, where -1.0 = 30 seconds and 1.0 = 60 seconds of frying time, then -1.0 = 25% wholemeal flour and 75% plain flour and 1.0= 75% wholemeal flour and 25% plain flour of base combination. The votes go higher with reducing frying time and wholemeal flour content. However, frying time does have a limit of at least 20-30 seconds frying in order to make sure samosa is fried properly. So based on these results we can assume that samosas containing less wholemeal flour, and frying for at least 20 seconds would provide the optimum crispiness with regards to consumer acceptability.

Q3 Response - Oiliness

Graph3. The response of oiliness for SO module

The ANOVA results for the oiliness response suggest that the only factor that is significant is the frying time with a p value < 0.05. And there is no interaction between two factors.

From the graph we can see that -1.0 on the scale for frying time and -1.0 and 1.0 on the scale for base combination, we can obtain the optimization processing conditions for product oiliness, where -1.0 = 30 seconds and 1.0 = 60 seconds of frying time, then -1.0 = 25% wholemeal flour and 75% plain flour and 1.0= 75% wholemeal flour and 25% plain flour of base combination. Similarly to crispiness, based on these results we can assume that base combination with less wholemeanl flour under at least 20 seconds frying processing condition would provide the optimum preferred oiliness with regards to consumer acceptability.

Q4 Response - Overall acceptability

Graph 4. The response of overall acceptability for SO moduleThe ANOVA results for the oiliness response suggest that the only factor that

is significant is the frying time with a p value < 0.05. And there is no interaction between two factors.

From the graph we can see that -1.0 on the scale for frying time and -1.0 on the scale for base combination, we can obtain the optimization processing conditions for product overall acceptability, where -1.0 = 30 seconds and 1.0 = 60 seconds of frying time, then -1.0 = 25% wholemeal flour and 75% plain flour and 1.0= 75% wholemeal flour and 25% plain flour of base combination. Same situation as crispness and oiliness, optimal product and processing condition would be occurred when less wholemenal flour and less frying time are applied in the experiment.

From the results, it is shown that the optimization combination of base is 25% wholemeal flour and 75% plain flour. And the optimization frying time condition is half fried (30 seconds).

V. Product acceptability and preference

Consumer acceptability and preference tests are able to provide an indication of whether the formulated product is acceptable to the consumers, so that the preferred formulated product will be found out and process can be optimized.

The sensory test was conducted using Compusense five. 36 untrained assessors (2 replicated experiments) were involved in the preference and

acceptability test to assess 9 products with different frying time and flour combinations by using 9-hedonic scale. These 9 samples were named from A to I and coded automatically in three random digital numbers by computer:

Product name Frying time and base combination

A-475 FF, 75(w):25(p)B-735 FF, 50(w):50(p)C-788 FF, 25(w):75(p)D-763 ¾ F, 75(w):25(p)E-657 ¾ F, 50(w):50(p)F-393 ¾ F, 25(w):75(p)G-915 HF, 75(w):25(p)H-164 HF, 50(w):50(p)I-674 HF, 25(w):75(p)

Note: The numbers shown in the table are the percentage of each type of flour in whole flour.

The questionnaire designed in computer is shown below. The higher the scores are, the more preference get from consumers.

Dislike extremely Dislike very much Dislike moderately Dislike slightly Neither like or dislike Like slightly Like moderately Like very much Like extremely

Q1. How do you think the golden surface of the sample?

Q2.How do you think the crispiness of the product?

Q3.How do you think the oiliness of the product?

The amount of oil used was related to low fat content and texture. Thus it is important to determine if we use appropriate oil according to scores.

This was to see if product has a good surface colour according to scores.

This was used to determine if the base crispiness of product was good for consumer.

Q8. How do you think the overall acceptability of product?

During preparing frozen samosa samples, fully fried samples were baked for 10 minutes, ¾ fried samosas were baked for 12 minutes, and as to half fried for 15 minutes under around 1800C in the oven. Samosas served were cut in half and also were ensured that they were big enough to one bite for assessors. Furthermore, product waste and sample preparation time were both reduced, and samples were able to be kept warm when served to assessors. These 9 products were presented separately and each participant was asked to have a 20-30 seconds break after every 3 samosas had been tasted in order to get available results for analysis. In the test, only three top attributes related to base that were golden surface, crispiness and oiliness, and overall acceptability of each product were rated according to 9-hedonic scale by participant as base was the most important concern in samosa production when filling had been already fixed.

Serving temperature of samples was considered as a factor that affects crispiness in the test. Products would become soggy and soft with cooling down; as a result, the first sample presented may have relatively higher score of crispiness than the others. However, according to the results of each assessor from computer, crispiness of the first sample not always got higher rating and had even lower scores than the last sample in certain cases, indicating that temperature change of samosas before and after serving did not give a big effect on crispiness. Results of single-factor within-subjects ANOVA (shown in Appendix A) give an initial idea of the difference of each attribute in each formulated base. The results show that there is no significant difference in terms of golden surface and overall acceptability. As to crispiness, significant difference in degree of preference is identified in the paired comparisons of C-H, E-H, and G-H. The mean rating of sample C, E, G and H are 5.75, 5.67, 6.17, and 6.11 respectively, which all are around like slightly region. Therefore, sample G had the significant highest preferred crispiness. Similarly with crispiness, both of sample G and I significant got higher preference than sample B, D and F. In conclusion, sample G met most of the assessors’ preference.

In the 3K factorial, factor X1 is frying time and factor X2 is base combination. Based on the results from 3K factorial ANOVA (shown in Appendix B), the F0 model of golden surface indicates that no significant effect of X1 or X2 on golden surface, and no interaction between X1 and X2 are determined. According to SO model, it is interesting to find out that only X1 affects oiliness, crispiness and overall acceptability significantly, and no significant interaction between two factors are identified. These results indicate that frying time is an important factor influenced on sensory attributes. From the 3D graphs of attributes except golden surface as shown in the task 4, the preference goes higher with reducing frying time and lowing wholemeal flour, which may be a reason that sample I got the highest scores of these attributes. However, no significant difference in sample G and I based on the results from single-factor within-subjects ANOVA, therefore the base combination (25% wholemeal flour+75% plain flour) and processing conditions (half fried) of sample I should be the final choice.

The aim was to see if the improvement product attains a higher preference, thus we can certain the optimization processing conditions.

VI. Product formulation and process specification

The raw materials used and their specification is as follows-

Sr.

No.

Ingredient(12 samosas)

Specification Amount

1 Minced soya chunks “East End” 100gm2 Diced sweet

potatoesSize=0.5cm-0.7cm

cubes100gm

3 Roghan josh ready spice

Medium spicy 27-30gm

4 Chopped onions Size=not bigger than 0.5cm

Half bowl (about 50gm)

5 Yoghurt Plain yoghurt Table spoon (12gm)6 Chilli powder Red Indian chilli powder Half table spoon (5gm)7 Ginger garlic paste “Mothers recipe”

readymade Half table spoon (7-

10gm)8 Sunflower oil “Flora” sunflower oil 4-5 table spoons (20-

22gm)9 Fresh coriander

leaves (chopped)Fresh leaves with less

amount of stem15gm

10 Mint sauce “Best-in” mint sauce Hint of taste (2-3gm)11 Cumin seeds “East End” Half table spoon (4-

5gm)12 Mustard seeds “East End” 1gm13 Salt “Tesco” low sodium

salt2-3 pinch (1-2gm)

14 Whole meal flour Pillsbury whole meal flour

50gm

15 Plain flour “Morrisons” plain flour 150gm16 Ground cumin in

base“East End” Half table spoon (5gm)

17 Oil in base “Flora” sunflower oil Table spoon (5gm)18 Salt in base “Tesco” low sodium

salt1-2 pinch (1-2gm)

Key- “_ _ _”= Brand/manufacturer nameThe raw materials like sweet potato, green chilli, fresh coriander leaves and

onions will be sourced from local market as these are cheaper whereas other ingredients can be sourced from one or more supermarkets or could be directly sourced from the manufacturer if company in ready to invest in raw material purchase. The quality of the ingredients required will be specific and a quality check can be step could be carried when the material arrives at the factory to ensure it so the final product will be having uniform quality.

The raw materials will be subjected to processing in hygienic environment in the factory and process is planned in such a way that there is least contact of the product n workers while the equipments are maintained in good hygienic condition ultimately increasing the shelf life of the final product. The components of product i.e. first base will be prepared with 25% whole meal flour and 75% plain flour in a dough mixer with addition of spices, salt & oil and second component filling is cooked according to the designed procedure with 50% soya chunks and 50% sweet potato cubes with addition of spices and is stuffed in samosa by samosa making machine. The samosas are then subjected to frying. The samosas intended to be sold as ready to eat (RET) will be full fried (for 1minute at 190°C) while samosas intended to be sold as frozen are to be half fried (for 30 seconds at 190°C). The full fried samosas will be cooled whereas the half fried once will be subjected to freezing and both will be packed in their respective packets. At the end of the process the each samosa will weigh average 23gm of which base contributing 12.50-13.50gm and filling contributing 9.50 to 10.50gm with which we can calculate the nutritional value.

Nutritional content per samosa (23gm)In cal or gm

Total Energy 78.76calCarbohydrates 11.36gm

Proteins 4.73gmFats 1.6gmSalt 0.2gm

The team is planning to launch the RTE samosas in pack of 6 samosas and frozen samosas in pack of 15 weighing 130gm and 330gm each packet respectively. The packaging used for the RTE samosas will be a tray type or a transparent tub type pack but having a transparent air tight lid in both cases on which label could be placed or on one of the tray/tub wall. The reason to select a rigid pack is to avoid ware and tear of samosa. A thin PET tray can be used for this purpose which avoids gas exchange through packet which is responsible for making samosas soggy/less crispy. The frozen samosas will be packed in a transparent plastic bag type pack having label from one side and other side empty to give a glance at samosas.

The RTE samosas will be having considerably short shelf life then the frozen once which could be determined by experiments in further units.

VII. European and international regulations for the production process

There are several standards and regulations that have been globally enforced, aimed at regulating the industrial production of food products. The Food

Standards Agency is mandated with carrying out policies that are aimed at ensuring that food substances are safe for human consumption. This includes funding of research on microbiological, radiological, and chemical safety, as well as allergy and food hygiene. Furthermore, the Codex Alimentarius was developed as a series of related texts and food standards, aimed at providing high level consumer protection and fair practice in the international trade of agricultural products and food. Samosa has been known to be an unhealthy food and therefore it is important to follow strict standards during the production process in order to create a healthy samosa (Food Standards Agency, 2011). This paper will discuss whether the provided process of industrial samosa production conforms to the safety and quality criteria stipulated in the existing industrial standards and legislation.

The food safety and quality criteria requires the production of any food substance to conform to set guidelines in order to ensure that it is fit for human consumption: not contaminated in any way and is of the nature, quality, and substance that is healthy to the consumers. In a nutshell, the production of food substance should ensure that it is handled properly at every stage of the production process. The handling of the food substance should guarantee that any contamination is avoided. Furthermore, the food should be kept in the conditions that prevent the growth of bacteria. In the context of the samosa production that this paper focuses on, it is imperative to consider if the whole production process conforms to the safety and regulation criteria (Queensland, n.d).

The first important step in ensuring safety and quality in production is the washing of the vegetables, which includes onions and potatoes. Moreover, the whole process of samosa production relies on correct temperatures. The right temperatures ensure that any pathogen that could be in the food is destroyed and that it is cooked to the required standard. The production process of the samosa has also conformed to quality and safety criteria by ensuring the products remain covered and heated by the cooking kettle to avoid any contamination (Food Standards Agency, 2011).

In this regard, the preparation process has shown that the good understanding of safety and quality standards. The process has also shown that the products are prepared in such a way that avoids any contact with potentially contaminated raw foods and equipments. The cooling process has also been done in a way that avoids contamination since the products are cooled while in the cooking kettle. The duration of the cooling is not provided but the recommended period is within one and a half hours (Will & Guether, 2007).

The samosa should be fried until it becomes crispy and the surface a golden brown. This is a clear indication that the food product has been well-cooked and

the process followed. In addition, the 72 liters of oil used is adequate, given the amount of samosa fried food products. The use of cooking oil in the production process is very significant, particularly in ensuring that the food product is free from too much calories which will make it unhealthy for human consumption. The cooling and individual quick freezing process has also utilized the use of machines and equipments to ensure that the right temperatures are applied. The packaging process has also conformed to the safety and quality criteria since the process has utilized the needed machines and equipment to ensure that the samosa products are not contaminated (Will & Guether, 2007).

In general, the industrial production process of samosa has followed safety and quality criteria. The whole process of storage, preparation, cooking, cooling and packaging is well carried out and will ensure that the final product is healthy for human consumption. But despite the adequate procedures, the process has not fully explained whether the involved food production staff had adequate training to correctly handle the food products. It is a requirement that the staff for the food production process is well trained in order to avoid any kind of contamination and ensure that the product is fit for human consumption (Will & Guether, 2007).

This paper has discussed whether the provided process of the industrial production of samosa conforms to the safety and quality criteria set by existing industrial standards and legislation. It has been noted that the process was adequate and conforms to the standards of food production. But the training process of the staff is not well-discussed despite its significance. It is important that staff training be given adequate consideration in order to ensure full compliance with the established standards and legislation.

VIII. ACTION PLAN FOR STADGE 4

The main tasks for the 4th stage will be:

1. Conduct a commercial product test using a test market.

2. Determine intrinsic and extrinsic factors affecting shelf-life and propose methods to control and monitor shelf-life.

3. Propose adequate packaging that meet food quality and safety requirement.

4. Demonstrate that the product and its production process is in compliance with national and EU labeling legislation and food safety requirements.

5. Propose a prerequisite programme for Good Manufacturing Practice (GMP) and Good Hygiene Practice (GHP).

6. Conduct a Hazard Analysis Critical Control Points (HACCP) analysis of production process.

7. Propose a plan for the quality control of raw materials and the final products, as well as possible solutions for on-line or in-process monitoring, that includes measurement techniques and statistical process control methods.

Milestone: Basically, milestones are set up for each big task or important meeting of stage 4.The following represent key project milestones, with estimated completion dates:

Milestone Estimated Completion Date

Evaluation of the commercial product test 10/07/2011

Evaluation of the packaging and food safety requirements 20 /07/2011

Evaluation of the GMP&GHP 24/07/2011

Evaluation of the HACCP plan 28/07/2011

Stage presentation 05/08/2011

List of deliverables with an agreed time line for completion

Tasks Deliverables1. Conduct a commercial product test using a test market.

Data analysis of commercial product test.(13/07/2011)

2. Determine intrinsic and extrinsic factors affecting shelf-life and propose methods to control and monitor shelf-life.

Shelf-life determination as a part of a quality control plan. (15/07/2011)

3.Propose adequate packaging that meet food quality and safety requirement.

A proposal for primary, secondary and tertiary packaging(17/07/2011)

4. Demonstrate that the product and its production process is in compliance with national and EU labeling legislation and food safety requirements.

Determination of the degree of compliance of our production process with ISO 22000 standards and EU legislation.(20/07/2011)

5. propose a prerequisite programme for Good Manufacturing Practice(GMP) and Good Hygiene Practice (GHP).

A 10-page GMP and GHP manual (22/07/2011)

6. Conduct a Hazard Analysis Critical Control Points (HACCP) analysis of production process.

A HACCP plan of production process.(27/07/2011)

7. Propose a plan for the quality control of raw materials and the final products, as well as possible solutions for on-line or in-process monitoring, that includes measurement techniques and statistical process control methods.

A quality control plan including measurement schedules and a basic statistical process control (SPC) programme. (29/07/2011)

8.Report writing and action plan for Unit 5.

A 20 page product commercialization report.(03/08/2011)

Gantt chart for Action plan

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