Exam paper for second semester National Diploma in Food Technolog

De Kock, S., Dr.

Emmambux, N., Dr.

Name not available

  
 
 
 
FACULTY OF SCIENCE 
 
 
 
DEPARTMENT OF FOOD TECHNOLOGY  
 
 
 MODULE: FTN3BF3 
   FOOD TECHNOLOGY III 
   (NATIONAL DIPLOMA FOOD TECHNOLOGY) 
 
 
 
NOVEMBER EXAMINATION 
 
 
 DATE: 12 NOVEMBER 2014 SESSION:  8:30 – 11:30 
 
 
 
 
 
 
EXAMINER  Dr S de Kock 
 
 
EXTERNAL MODERATOR Dr N Emmambux 
 
 
DURATION 3 HOURS MARKS    182 (180=100%) 
 
 
NUMBER OF PAGES:  9 PAGES, INCLUDING 4 ANNEXURES 
 
 
INSTRUCTIONS:  ANSWER ALL QUESTIONS 
   CALCULATORS ARE PERMITTED (ONLY ONE PER STUDENT) 
 
 
REQUIREMENTS:  2 ANSWER SCRIPTS PER STUDENT 
 
FOOD TECHNOLOGY III FTN3BF3 NOVEMBER 2014 - 2 - 
 
 
   
 
INSTRUCTIONS TO STUDENTS: 
 
1. ANSWER ALL QUESTIONS. 
2. NUMBER YOUR ANSWERS CORRECTLY AND CLEARLY. 
3. QUESTIONS MAY BE ANSWERED IN ANY ORDER, BUT SUB-SECTIONS OF 
QUESTIONS MUST BE ANSWERED TOGETHER. 
4. MARKS WILL BE DEDUCTED FOR ILLEGIBLE WRITING. 
5. GOOD LUCK! 
 
 
QUESTION 1 
 
You have started your own food consulting business.  Explain the following phenomena 
and advise clients on what they can do to overcome the problems experienced by them 
in their different processing operations: 
 
1.1 A cheese manufacturer found that his Gouda cheese is too soft. (5) 
1.2 An ice cream manufacturer has large ice crystals in his product (hint: 
think through all processing steps from formulation to hardening). (7) 
1.3 A manufacturer of powdered egg whites to be used in the baking industry 
is complaining about browning in his product.  (6) 
1.4 A local baker at the Spar complains that his bread (which is made from 
ONLY wheat flour, water, salt and yeast) does not have a good loaf 
volume and that it has a short shelf life. (11) 
   [29] 
 
 
QUESTION 2 
 
You are employed as a quality assurance manager at a beer brewing company. 
 
2.1 Describe brewing as part of the beer manufacturing procedure (1/2 mark 
per fact).  (15) 
 
2.2 The bottles you receive for bottling of the beer arrives in batches of 
30000.  You have agreed with the supplier that you will accept a load 
provided that there is no more than 1% broken or chipped bottles.  Make 
use of the Military Standards 105D method (single normal inspection 
level) together with the attached tables and describe how you will go 
about taking samples, and when you would accept or reject a load.   (6) 
 
2.3 The beer is filled into 340 ml bottles.  As the quality assurance manager, 
you have to make sure that the fill volume is in accordance with the 
declared volume on the label.  You are prepared to take a risk of 7% of 
the units being below volume.  You have taken 5 consecutive samples 
from the line and this was repeated 5 times.  The results obtained are 
tabulated as follows: 
  
FOOD TECHNOLOGY III FTN3BF3 NOVEMBER 2014 - 3 - 
 
 
   
 
 
Sample Volume (ml) 
1 
2 
3 
4 
5 
342 
345 
335 
346 
342 
344 
338 
342 
343 
340 
340 
342 
342 
336 
342 
342 
342 
335 
345 
335 
335 
340 
342 
341 
342 
  
 
2.3.1 Use this data and the attached tables to determine if the process is in 
control and, if necessary, suggest adjustments to be made.   (15) 
2.3.2 Draw up a quality control chart that could be used at the point of filling in 
order to ensure correct product filling. (6) 
   [42] 
  
 
QUESTION 3 
 
Describe the manufacturing procedure of Swiss cheese (1/2 mark per fact).  [8] 
    
 
QUESTION 4 
 
Match column B with column A (e.g. 1. f) 
 
A B 
1. SFI a. Amount of glucose 
2. Lysozyme b. Nitrates 
3. Trans fatty acid c. High melting point 
4. DE d. Exudation 
5. Myofibrillar proteins e. Should be higher in a chocolate coating in 
summer 
6. Post-mortem glycolysis f. Emulsifiers in sausages 
7. Curing g. Germination 
8. Bran h. Decline in ATP 
9. Malting i. Antimicrobial properties 
10. Rigor mortis j. High mineral content 
 
   [10] 
 
 
QUESTION 5 
 
5.1 Describe the break system as part of the roller milling system that is used for the 
milling of wheat.                      (5) 
5.2 Explain how and why wheat is conditioned before milling.             (11) 
5.3 Describe the basic processing operations of breadmaking.              (10) 
FOOD TECHNOLOGY III FTN3BF3 NOVEMBER 2014 - 4 - 
 
 
   
 
5.4 Give a detailed flow diagram for the wet milling process of maize (1/2 mark per 
fact).           (6) 
   [32] 
 
 
QUESTION 6 
 
State whether the following statements are true or false and motivate your answer EVERY 
time: 
 
6.1 Cookies are produced with strong flour 
6.2 A high falling number is indicative of a low amylolytic activity in flour 
6.3 Baking powder is the same as baking soda 
6.4 Substituting some of the sucrose in a bread formulation for HFCS will enhance 
surface browning 
6.5 Sorghum beer is bitter 
6.6 The only reason for pasteurizing an ice-cream mix, is to render it free from pathogens 
6.7 The temperature of the water used to wash eggs, has to be 10°C above the temperature 
of the incoming egg 
6.8 The iodine value of an oil is an indication of its saturation 
6.9 Skim milk powder is added in the manufacturing of yoghurt 
6.10 The extraction rate of South African mills is 50%  
 
                      [15] 
      (True/false: ½ mark; reason: 1 mark) 
    
 
QUESTION 7 
 
Explain how poultry differs from cattle (cows) with regards to the following: 
 
7.1 Slaughtering of the animals         (4) 
7.2 Rigor mortis and post mortem glycolysis of the muscles    (5) 
7.3 Chemical deterioration of the meat        (3) 
                     [12] 
 
    
 
QUESTION 8 
 
8.1 Describe 4 processing steps used in the refining of oils which are designed to take out 
undesirable components in the oil.                                  (8) 
8.2 Explain how emulsifiers can be manufactured from oils.                (5) 
                       [13] 
    
 
  
FOOD TECHNOLOGY III FTN3BF3 NOVEMBER 2014 - 5 - 
 
 
   
 
QUESTION 9 
 
Due to a demand from consumers, there is a worldwide move in the food industry to more 
healthy and low fat foods. In the following food commodities, state which one of each pair is 
higher in fat and explain why (hint: think about formulations, manufacturing procedures, 
product properties etc.) 
 
9.1 Hardened ice cream and soft serve        (5) 
9.2 Mayonnaise and pourable salad dressings       (3) 
9.3 Viennas and filet steak                    (4) 
9.4 Yoghurt and frozen yoghurt         (3) 
9.5 Ricotta and cheddar cheese         (4) 
9.6 Whole egg powder and egg white powder       (2) 
                    [21] 
 
    
 
 
FOOD TECHNOLOGY III FTN3BF3 NOVEMBER 2014 - 6 - 
 
 
   
 
SAMPLE-SIZE CODE LETTERS FOR SAMPLING BY ATTRIBUTES FROM MIL-
STD-105 D 
 
Lot or Batch Size Special Inspection Levels General Inspection Levels 
S-1 S-2 S-3 S-4 I II III 
 
2 to 8 
9 to 15 
16 to 25 
 
26 to 50 
51 to 90 
91 to 150 
 
151 to 250 
251 to 500 
501 to 1200 
 
1201 to 3200 
3201 to 10 000 
10 001 to 35 000 
 
35 001 to 150 000 
150 001 to 500 000 
500 001 and over 
 
 
A 
A 
A 
 
A 
B 
B 
 
B 
B 
C 
 
C 
C 
C 
 
D 
D 
D 
 
A 
A 
A 
 
B 
B 
B 
 
C 
C 
C 
 
D 
D 
D 
 
E 
E 
E 
 
A 
A 
B 
 
B 
C 
C 
 
D 
D 
E 
 
E 
F 
F 
 
G 
G 
H 
 
A 
A 
B 
 
C 
C 
D 
 
E 
E 
F 
 
G 
G 
H 
 
J 
J 
K 
 
A 
A 
B 
 
C 
C 
D 
 
E 
F 
G 
 
H 
J 
K 
 
L 
M 
N 
 
A 
B 
C 
 
D 
E 
F 
 
G 
H 
J 
 
K 
L 
M 
 
N 
P 
Q 
 
B 
C 
D 
 
E 
F 
G 
 
H 
J 
K 
 
L 
M 
N 
 
P 
Q 
R 
 
Special inspection levels may be used when relatively small sample sizes are necessary and 
large sampling risks can and must be tolerated.  Unless otherwise specified, general 
inspection level II should be used;  general inspection level I may be used when less 
discrimination is needed and III when greater discrimination is needed.  In each case the 
higher the number the more discriminatory the plan. 
FOOD TECHNOLOGY III NOVEMBER 2014 7  
________________________________________________________________________ 
   
 
ACCEPTABLE QUALITY LEVELS (Normal Inspection) 
 
Sample 
Size code 
Letter 
 
Sample 
size  
0.010 
 
 
Ac  Re 
 
 
0.015 
 
 
Ac  Re 
0.025 
 
 
Ac  Re 
0.040 
 
 
Ac  Re 
0.065 
 
 
Ac  Re 
0.10 
 
 
Ac  Re 
0.15 
 
 
Ac  Re 
0.25 
 
 
Ac  Re 
0.40 
 
 
Ac  Re 
0.65 
 
 
Ac  Re 
1.0 
 
 
Ac  Re 
1.5 
 
 
Ac  Re 
2.5 
 
 
Ac  Re 
4.0 
 
 
Ac  Re 
6.5 
 
 
Ac  Re 
10 
 
 
Ac  Re 
15 
 
 
Ac  Re 
25 
 
 
Ac  Re 
40 
 
 
Ac  Re 
65 
 
 
Ac  Re 
100 
 
 
Ac  Re 
150 
 
 
Ac  Re 
250 
 
 
Ac  Re 
400 
 
 
Ac  Re 
650 
 
 
Ac  Re 
1000 
 
 
Ac  Re 
 
A 
 
B 
 
C 
 
 
D 
 
E 
 
F 
 
 
G 
 
H 
 
J 
 
 
K 
 
L 
 
M 
 
 
N 
 
P 
 
Q 
 
 
R 
 
 
 
 
2 
 
3 
 
5 
 
 
8 
 
13 
 
20 
 
 
32 
 
50 
 
80 
 
 
125 
 
200 
 
315 
 
 
500 
 
800 
 
1250 
 
 
2000 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
0       1 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
0       1 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
0       1 
 
 
 
 
 
 
1       2 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
0       1 
 
 
 
 
 
 
1       2 
 
 
2       3 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
0       1 
 
 
 
 
 
 
1       2 
 
2      3 
 
 
3       4 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
0       1 
 
 
 
 
 
 
1       2 
 
2       3 
 
3       4 
 
 
5       6 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
0       1 
 
 
 
 
 
 
1       2 
 
 
2       3 
 
3       4 
 
5      6 
 
 
7       8 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
0       1 
 
 
 
 
 
 
1       2 
 
2       3 
 
 
3       4 
 
5       6 
 
7       8 
 
 
10   11  
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
0      1 
 
 
 
 
 
 
1       2 
 
2       3 
 
3       4 
 
 
5       6 
 
7       8 
 
10   11 
 
 
14   15 
 
 
 
 
 
 
 
 
 
 
 
 
0       1 
 
 
 
 
 
 
1       2 
 
 
2       3 
 
3       4 
 
5       6 
 
 
7      8 
 
10   11 
 
14   15 
 
 
21   22 
 
 
 
 
 
 
 
 
 
 
0       1 
 
 
 
 
 
 
1       2 
 
2       3 
 
 
3       4 
 
5       6 
 
7      8 
 
 
10   11 
 
14   15 
 
21   22 
 
 
 
 
 
 
 
 
 
 
 
0       1 
 
 
 
 
 
 
1       2 
 
2       3 
 
3       4 
 
 
5       6 
 
7       8 
 
10   11 
 
 
14   15 
 
21   22 
 
 
 
 
 
 
 
 
0       1 
 
 
 
 
 
 
1       2 
 
 
2       3 
 
3      4 
 
5       6 
 
 
7       8 
 
10   11 
 
14   15 
 
 
21   22 
 
 
 
0       1 
 
 
 
 
 
 
1       2 
 
2       3 
 
 
3       4 
 
5       6 
 
7       8 
 
 
10   11 
 
14   15 
 
21   22 
 
 
 
 
 
0       1 
 
 
 
 
 
 
1       2 
 
2       3 
 
3       4 
 
 
5       6 
 
7       8 
 
10   11 
 
 
14   15 
 
21   22 
 
 
 
 
 
 
 
1       2 
 
 
2       3 
 
3       4 
 
5       6 
 
 
7       8 
 
10   11 
 
14   15 
 
 
21   22 
 
 
 
 
 
1       2 
 
2       3 
 
 
3       4 
 
5      6 
 
7       8 
 
 
10   11 
 
14   15 
 
21   22 
 
 
 
 
1       2 
 
2       3 
 
3       4 
 
 
5       6 
 
7      8 
 
10   11 
 
 
14   15 
 
21   22 
 
 
 
2       3 
 
3       4 
 
5       6 
 
 
7       8 
 
10   11 
 
14   15 
 
 
21  22 
 
3      4 
 
5       6 
 
7       8 
 
 
10   11 
 
14   15 
 
21   22 
 
 
 
 
5       6 
 
7       8 
 
10   11 
 
 
14   15 
 
21   22 
 
 
7       8 
 
10   11 
 
14   15 
 
 
21   22 
 
30   31 
 
10   11 
 
14   15 
 
21   22 
 
 
30   31 
 
44   45 
 
 
14   15 
 
21   22 
 
30   31 
 
 
44   45 
 
 
 
21   22 
 
30   31 
 
44   45 
 
30   31 
 
44   45 
 
 
 = Use first sampling plan below arrow.  If sample size equals, or exceeds, lot or batch size, do 100 percent inspection. 
 
 = Use first sampling plan above arrow. 
 
   Ac = Acceptable number. 
 
   Re = Rejection number.  
FOOD TECHNOLOGY III NOVEMBER 
2014 8
  
________________________________________________________________________ 
   
 
FACTORS FOR THE CALCULATION OF SIGMA CONTROL CHARTS FOR X, 
R CHARTS 
 
 
 
No of 
determinations in 
samples  
 
n 
Charts for 
averages 
Distribution charts Factors for 
standard 
deviation 
 
d2 
Factors for control 
limits 
Factors for control limits 
A2 D3 D4 
 
2 
3 
4 
5 
6 
7 
8 
9 
10 
 
 
1.880 
1.023 
0.729 
0.577 
0.483 
0.419 
0.373 
0.337 
0.308 
 
0 
0 
0 
0 
0 
0.076 
0.136 
0.184 
0.223 
 
3.268 
2.574 
2.282 
2.114 
2.004 
1.924 
1.864 
1,816 
1.777 
 
1.128 
1.693 
2.059 
2.326 
2.534 
2.704 
2.847 
2.970 
3.078 
 
FOOD TECHNOLOGY III NOVEMBER 
2014 9
  
________________________________________________________________________ 
   
 
THE AREA UNDER THE NORMAL CURVE 
 
k is the multiplier for the standard deviation which will cover that part of the area under 
the curve, on both sides of the average, as indicated in the tabulated values. 
 
K .00 .01 .02 .03 .04 .05 .06 .07 .08 .09 
 
0.0 
0.1 
0.2 
0.3 
0.4 
 
0.5 
0.6 
0.7 
0.8 
0.9 
 
1.0 
1.1 
1.2 
1.3 
1.4 
 
1.5 
1.6 
1.7 
1.8 
1.9 
 
2.0 
2.1 
2.2 
2.3 
2.4 
 
2.5 
2.6 
2.7 
2.8 
2.9 
 
3.0 
3.5 
4.0 
4.5 
5.0 
 
 
.0000 
.0398 
.0793 
.1179 
.1555 
 
.1914 
.2258 
.2580 
.2882 
.3159 
 
.3413 
.3643 
.3849 
.4032 
.4192 
 
.4331 
.4452 
.4554 
.4641 
.4713 
 
.4773 
.4821 
.4862 
.4893 
.4919 
 
.4938 
.4953 
.4965 
.4974 
.4981 
 
.4987 
.4998 
.4999 
.4999 
.4999 
 
.0040 
.0438 
.0832 
.1217 
.1591 
 
.1950 
.2291 
.2612 
.2910 
.3186 
 
.3438 
.3666 
.3869 
.4050 
.4207 
 
.4345 
.4464 
.4564 
.4649 
.4719 
 
.4778 
.4826 
.4865 
.4895 
.4920 
 
.4940 
.4955 
.4966 
.4975 
.4982 
 
.0080 
.0478 
.0871 
.1255 
.1628 
 
.1985 
.2324 
.2642 
.2939 
.3213 
 
.3461 
.3686 
.3888 
.4066 
.4223 
 
.4357 
.4474 
.4573 
.4656 
.4726 
 
.4783 
.4831 
.4868 
.4898 
.4922 
 
.4941 
.4957 
.4967 
.4977 
.4983 
 
.0120 
.0517 
.0910 
.1294 
.1665 
 
.2019 
.2357 
.2674 
.2967 
.3238 
 
.3486 
.3708 
.3907 
.4082 
.4236 
 
.4370 
.4485 
.4582 
.4664 
.4733 
 
.4788 
.4834 
.4871 
.4902 
.4925 
 
.4944 
.4957 
.4968 
.4977 
.4983 
 
.0160 
.0557 
.0948 
.1331 
.1700 
 
.2054 
.2389 
.2704 
.2996 
.3264 
 
.3508 
.3729 
.3925 
.4099 
.4251 
 
.4382 
.4496 
.4591 
.4671 
.4738 
 
.4793 
.4838 
.4873 
.4904 
.4927 
 
.4945 
.4959 
.4969 
.4977 
.4984 
 
 
.0199 
.0596 
.0987 
.1368 
.1736 
 
.2088 
.2422 
.2734 
.3023 
.3289 
 
.3531 
.3749 
.3944 
.4115 
.4265 
 
.4394 
.4505 
.4599 
.4678 
.4744 
 
.4798 
.4842 
.4878 
.4906 
.4929 
 
.4946 
.4960 
.4970 
.4978 
.4984 
 
.0239 
.0636 
.1026 
.1406 
.1772 
 
.2123 
.2454 
.2764 
.3051 
.3315 
 
.3554 
.3770 
.3962 
.4131 
.4279 
 
.4406 
.4515 
.4609 
.4686 
.4751 
 
.4803 
.4846 
.4881 
.4909 
.4931 
 
.4948 
.4961 
.4971 
.4979 
.4985 
 
.0280 
.0675 
.1064 
.1443 
.1808 
 
.2157 
.2486 
.2794 
.3079 
.3340 
 
.3577 
.3791 
.3980 
.4147 
.4292 
 
.4418 
.4525 
.4616 
.4693 
.4756 
 
.4808 
.4850 
.4884 
.4911 
.4932 
 
.4949 
.4962 
.4972 
.4980 
.4985 
 
.0319 
.0714 
.1103 
.1480 
.1844 
 
.2190 
.2518 
.2823 
.3106 
.3365 
 
.3599 
.3810 
.3997 
.4162 
.4306 
 
.4430 
.4535 
.4625 
.4700 
.4762 
 
.4812 
.4854 
.4888 
.4913 
.4934 
 
.4915 
.4963 
.4973 
.4980 
.4986 
 
.0359 
.0754 
.1141 
.1517 
.1879 
 
.2224 
.2549 
.2852 
.3133 
.3389 
 
.3612 
.3830 
.4015 
.4177 
.4319 
 
.4441 
.4545 
.4633 
.4706 
.4767 
 
.4817 
.4857 
.4890 
.4916 
.4936 
 
.4952 
.4964 
.4974 
.4981 
.4986 
 
The tabulated values multiplied by 100 will give percentage. 
 


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