Functional Value-Added Fruit and Vegetable Processing, Product Development, and Marketing for Small Farms Solveig Hanson Postville, IA 2006 SARE National Conference
Farming and Processing Processing is important! Food in forms consumers can & will use Licensed processing facility Built 2002-2003 Light processing during growing season Full season potential
Off Season Processing Fill local foods availability gap Fill farmers cash flow gap
Goal Develop value-added products from our vegetables and fruits Market those products locally Create a product-development methodology to share with other small-scale producers
Developing Products Preliminary market analysis Survey of shareholders Conversations with local institutions - school, restaurants, college Produce available
Developing Products Simple storage Freezing: tomatoes, strawberries, raspberries, peppers, onions Brining: cucumbers Not recommended Cool storage or refrigeration: apples, winter squash, pumpkin
Sample Brining Worksheet Brining Worksheet Batch #: Brine Recipe: Cuc weight: Cuc description: 5% Brine 3/4 C salt per gallon water from Pickles & Relishes p. 86-70 modified: adding 1/4C salt as per Ball Blue Book Brining Steps Day Number Date Instructions Done Observations 1 Make 5% brine (3/4C salt to 1 gal water) 1 Cool brine 2 Pour brine over cucs. Weight w/ plate. Cover& store in cool place 3 Add 1/4 C salt for each 5# cucs. Add salt on top of plate. 4 Remove scum. 5 Remove scum. 6 Remove scum. 7 Remove scum. 8 Remove scum. 9 Add 1/4 C salt for each 5# cucs. Add salt on top of plate. 10 Remove scum.
Developing Products Recipe testing Small batches Recorded changes on Recipe Sheets
Sample Recipe Worksheet Gherkin Pickle Recipe Trial Worksheet Date: 12/16/04-12/17/04 Source: Ball Blue Book p. 45 Ingredients: 1-1/2 recipe: 8# small cucumbers (1-1/2 to 2-1/2") 12# small cucumbers 8 C sugar, divided 12 C sugar, divided 6 C vinegar, divided 9 C vinegar, divided 1/2 tsp turmeric 3/4 tsp turmeric 2 tsp celery seed 3 tsp celery seed 2 tsp mixed whole pickling spice 3 tsp mixed whole pickling spice 2 sticks cinnamon 3 sticks cinnamon 1/2 tsp whole allspice 3/4 tsp whole allspice Modifications: omitted salt b/c using desalted cucumbers, omitted 1st 2 days of soaking cucs in salted water; used slightly larger cucs making 1-1/2 recipe Raw Product Batch: 3 Jar Sterilization Process: Boiling Water Canning Method:
Sample Recipe Worksheet Steps and Timing Step Done Time Comments 1Day 1: drain desalting cucs and prick with fyes 1:20 Day 1: Combine 4-1/2 C sugar, 4-1/2 C vinegar, and turmeric in saucepot. Tie whole spices in a spice bag; add spice bag 2 to syrup; bring to a boil yes 1:20-2:00 made double the 1-1/2 recipe - didn't quite cover, but will after first rebatch tonight 3 4 Day 1: Pour hot syrup over cucumbers; let stand 6-8 hours. yes 1:20-2:00 Day 1: Drain cucumbers, reserving syrup. Add 3 C sugar and 3 C vinegar to syrup; bring to a boil; pour over cucumbers. Let stand overnight. yes 20:15-21:00 again doubled syrup - 6 C sugar and 6 C vinegar 5 Day 2: Drain cucumbers, reserving syrup. Add 3C sugar and 1-1/2 C vinegar to reserved syrup; bring to a boil; pour over cucumbers. Let stand 6-8 hours yes 8:30-9:00 single recipe for syrup - 3C sugar and 1-1/2 C vinegar; had weighted plate on cucs overnight; smooshed some - tasting good, though 6 7 8 Day 2: Remove spice bag. Drain cucumbers, reserving syrup. Add 1-1/2 C sugar to syrup; bring to a boil. yes added 1-1/2 C sugar; didn't double 3:00 recipe Day 2: Pack pickles into hot jars, leaving 1/4" headspace. yes 3:45-4:15 Day 2: Ladle hot liquid over cucumbers, leaving 1/4" headspace. yes 3:45-4:15
Developing Products Sampling and Taste Testing Pickles at Community Tasting Fair Squash at VegetaBall
Producing Value-Added Foods Final recipe Approval by Process Authority if necessary Recipe Checklist for Scheduled Process Make Sheet Easy way to track steps and document changes Corresponds to lot numbers
Sample Recipe Checklist Low Sugar Raspberry Jam Date: Batch Number: Step Done Notes 1. Bring boiling-water canner, 1/2 full of water, to simmer. 2. Wash jars in hot, soapy water; rinse. Pour boiling water over lids in saucepan off heat. Let stand in water until ready to use. 3. Drain frozen raspberries. Pulse berries in food processor; do not puree. Use 2 parts fruit to 1 part juice. 4. Measure 3-3/4 C of fruit & juice into saucepan. 5. Measure 3 C sugar into bowl. 6. Measure 1/4 C sugar from measured amount into 4 Tbsp pectin. 7. Stir pectin-sugar mixture into fruit. 8. Bring mixture to full rolling boil - a boil that doesn't stop bubbling when stirred - on high heat, stirring constantly.
Sample Recipe Checklist Scrumptious Squash Record Ingredients: 9x13 pan 8 C mashed squash (4#) 1 C brown sugar 1 C margarine 1 C chopped walnuts 1/3 C flour 1 tsp salt mixed w/ squash 3C mixed topping per pan Ingredients: 8x8 pan 4 C mashed squash (2#) 1/2 C brown sugar 1/2 C margarine 1/2 C chopped walnuts 3 Tbsp flour 1/2 tsp salt mixed w/ squash 1.5 C mixed topping per pan Step Done Comments 1 Mix salt with squash 2 Mix sugar, walnuts & flour 3 Cut cold margarine into mixture 4 Spread squash in pan 5 Sprinkle topping evenly over squash 6 Place pan in labeled bag 7 Seal bag 8 Freeze
So What Have We Made? For Sale: Scrumptious Squash Casserole Mashed Squash and Pumpkin Puree Apple Pie Filling with Pie Kits In Progress: Strawberry and Raspberry Jams Salsa Tomato pasta sauce Abandoned: Brined pickles
Producing Safely & Legally Defining type of food Canned - Heat Processed Low acid Green beans, corn, peas ph greater than 4.6 Acid or acidified Tomatoes, salsa, pickles ph less than 4.6 Low water activity Jam, syrup Frozen or refrigerated
Frozen or Refrigerated Foods Work in Licensed Processing Facility Use sanitary procedures Track processes via Make Sheets Track lot numbers Label correctly
Canned: Low Water Activity Foods Same criteria as frozen/refrigerated, plus: Check with Process Authority about canning methods and recipe approval Check about type of jar and lid
Canned: Acid and Acidified Foods Better Process Control School 3 day training in thermal processing Testing over microbiology, regulations, container handling, sanitation, recordkeeping, etc Geared for larger plants, accessible to smaller entities Certified person must be on-site for processing acid & acidified foods
Canned: Acid and Acidified Foods Must record ph of finished product with ph meter Process Authority must approve recipe and process Must use one-piece plastisol-lined lid
Canned: Acid and Acidified Foods Records needed: Examination of raw materials Recipe record (Make Sheet) Time/temperature of processing Any deviations from normal process Initial temperature at container closure Container closure records ph after processing Lot numbers Distribution of finished product
Labeling On Principal Display Panel: Name of food Amount of product On Information Panel: Name & address of manufacturer, packer or distributor (You!) Ingredient list Nutrition labeling if applicable
Helpful People Department of Inspections & Appeals IA State Extension Food Processing Specialist General processing regulations and sanitation Process Authority - WI or NE Recipe approval Determination of critical control points & recordkeeping
Remaining Goals Submit processes for salsa and pasta sauce to Process Authority Produce jam for sale - and salsa & pasta sauce, too, upon approval Produce squash casseroles and pie filling again this year Further develop markets for these products
Remaining Goals Compile packet of sample recordkeeping sheets, pertinent regulations, and authorities to contact for more information Develop report for submission to journals and publication on our website
Thank You! Solveig Hanson 776 Old Stage Rd. Postville, IA 52162 563-864-3847 farm 563-380-9848 cell growers@sunflowerfields.org www.grownlocally.com www.sunflowerfields.org