Introduction to Food Process Engineering

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About Course

Every food plant runs on heat, flow, pressure and clean steel. This course teaches the engineering that keeps product safe and lines running.

A pasteuriser only works if the heat exchanger, pump and holding tube are sized and run correctly. A cold room only holds temperature if the refrigeration plant is right. Operators, technicians, maintenance staff and new engineers who understand the engineering behind the process spot problems earlier and fix them properly.

Introduction to Food Process Engineering is a 16-hour online course for students, technicians, operators, maintenance staff and new engineers in food manufacturing. It needs school algebra and nothing more, and every calculation is worked through step by step with examples from dairy, brewing, beverages, meat and bakery plants.

What the course covers

Six modules: units, dimensions and process calculations; mass and energy balances; heat transfer and heat exchangers; fluid flow, pumps and pipework; utilities including steam, water, compressed air and refrigeration; and hygienic equipment and plant layout.

Each module closes with a practical activity, a knowledge check and a game: choose the right pump for the duty, find the pinhole in a pasteuriser plate, and trace refrigerant round the cycle. Every lesson has a Listen to this lesson option. All activities, knowledge checks and games are compulsory and open in order.

The course ends with a capstone project and a proctored final assessment: 40 questions drawn at random, so every attempt is different. 60 minutes, 70 percent to pass, 3 attempts.

Your certificate

Pass the final assessment and you receive an ASC Food Safety Certificate of Achievement for Introduction to Food Process Engineering. It shows your name, the course, the completion date and a unique verification ID with a QR code, so an employer or auditor can check it online at ascfoodsafetytraining.com. You can download it from your dashboard as soon as you pass.

The course was developed by ASC Food Safety’s multidisciplinary team of industry professionals, led by Mthokozisi Nkosi, with contributions from specialists in brewing, dairy processing, meat processing and nutrition. It follows international references: Codex Alimentarius, ISO 22000 and WHO and FAO guidance.

What Will You Learn?

  • Convert plant data into consistent SI units, check equations for dimensional consistency and use food property data and steam tables correctly.
  • Solve mass balances for blending, milk standardisation, evaporation and drying, including wet- and dry-basis moisture problems.
  • Calculate sensible and latent heat loads and steam demand using energy balances and steam tables.
  • Explain conduction, convection and radiation, estimate an overall heat transfer coefficient and the LMTD, and select plate, tubular or scraped-surface heat exchangers.
  • Use the Reynolds number to predict flow behaviour, relate flow to holding time and pressure drop, and choose between centrifugal and positive-displacement pumps.
  • Describe how steam, water, compressed air and refrigeration systems work, and specify the quality and safety controls they need.
  • Apply hygienic design, CIP, zoning and maintenance principles to reduce food safety risks in equipment and plant layout.

Course Content

Module 1: Units, Dimensions and Process Calculations
Learn the language of engineering: SI units, conversions and dimensional checks, the key physical properties of foods, and how to read property tables without falling into common traps.

  • Lesson 1: Learning Outcomes
  • Lesson 2: Speaking SI: Units, Conversions and Dimensions
  • Lesson 3: The Properties That Shape Every Process
  • Lesson 4: Moisture Bases and Property Tables
  • Lesson 5: Commissioning Day: Checking the Quick Sums
  • Module 1 knowledge check
  • Game: Unit Speed-Dating

Module 2: Mass and Energy Balances
Account for every kilogram and every kilojoule: conservation of mass in blending, standardisation, evaporation and drying, then energy balances with sensible and latent heat using steam tables.

Module 3: Heat Transfer and Heat Exchangers
Discover how heat moves by conduction, convection and radiation, how resistances combine into an overall heat transfer coefficient, and how plate, tubular and scraped-surface heat exchangers, regeneration and cleaning work in practice.

Module 4: Fluid Flow, Pumps and Pipework
Understand how liquid foods flow, from Newtonian milk to shear-thinning ketchup, predict laminar and turbulent flow with the Reynolds number, and choose the right pumps, hygienic valves and flow meters.

Module 5: Utilities: Steam, Water, Air and Refrigeration
Tour the services that keep a food plant running: boilers and steam quality, culinary steam, process water, compressed air purity classes, and the vapour-compression refrigeration cycle, with the safety controls each one needs.

Module 6: Hygienic Equipment and Plant Layout
Design out contamination: hygienic design principles, stainless steel grades, surface finish, drainability and dead legs, cleaning in place, and plant zoning, flows and maintenance practices that protect food safety.

Course assessment and Feedback
The final assessment for the Introduction to Food Process Engineering.

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