Unit Operations in Food Processing
Unit Operations in Food Processing
Earle
This is the free web edition of a popular textbook HOW TO USE THIS BOOK:
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Introduction by page. (Follow the link at
First published in 1966 but still relevant today, Unit the foot of each page).
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Pergamon Press first published the book giving it clear layout and wide distribution at a reasonable price. A
number of colleagues helped with improvements for the second edition. More extensive acknowledgement of
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Paul Jelen encouraged putting it onto the Web, as it was still being used by their students.
Editions even for the Web do not come without cost. So particular mention for this
Web edition must be made of the New Zealand Institute of Food Science and
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As in the earlier editions, even more so in this, appearance would never have occurred without the cheerful,
unstinting, and technically invaluable help of my wife Mary. We will all be rewarded by this site being both
useful, and well and widely used.
Richard [Link]
Palmerston North, New Zealand. 2003
Dick joined Massey University in 1965, initially in food technology, and later
founding the biotechnology discipline, which had special interests in the processing
of biologicallybased materials.
He has published several books jointly with his wife (Dr) Mary Earle on product
development and reaction technology, and many technical papers and reports. He is
a Distinguished Fellow of the Institution of Professional Engineers New Zealand (IPENZ). Dick and Mary Earle
have recently established a scholarship for the support and encouragement of postgraduate research into
aspects of technology in New Zealand universities.
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to all site visitors for the free use and copying of all or part of the text for noncommercial purposes, subject to
acknowledgement of the source (which is, unless otherwise indicated):
INTRODUCTION
Unit Operations in Food Processing. Copyright © 1983, R. L. Earle. :: Published by NZIFST (Inc.)
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CONTENTS
Home
Contents
ABOUT THE BOOK
About the book The history of Unit Operations in Food Processing, and how it came to be
Introduction published on the web.
Material and energy
CHAPTER 1.
balances
INTRODUCTION
Fluidflow theory Method of studying food process engineering
Fluidflow applications Basic principles of food process engineering
Heattransfer theory Conservation of mass and energy
Overall view of an engineering process.
Heattransfer
Dimensions and units
applications Dimensions symbols
Drying Units
Evaporation Dimensional consistency
Unit consistency and unit conversion
Contactequilibrium
Dimensionless ratios specific gravity
separation processes Precision of measurement
Mechanical Summary.
separations Problems.
Size reduction CHAPTER 2.
Mixing MATERIAL AND ENERGY BALANCES
Appendices Basic principles
Index to Figures Material balances
Basis and units
Index to Examples total mass and composition
References concentrations
Bibliography Types of Process situations
Useful links continuous processes
blending
Feedback (email link) Layout
Energy balances
Heat balances enthalpy latent heat sensible heat freezing
drying canning
Other forms of energy mechanical energy electrical energy
Summary
Problems
CHAPTER 3.
FLUIDFLOW THEORY.
Introduction
Fluid statics fluid pressure absolute pressures gauge pressures
head
Fluid dynamics
Mass balance continuity equation
Energy balance
Potential energy
Kinetic energy
Pressure energy
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Friction loss
Mechanical energy
Other effects
Bernouilli's equation flow from a nozzle
Viscosity shear forces viscous forces
Newtonian and NonNewtonian Fluids power law equation
Streamline and turbulent flow dimensionless ratios
Reynolds number
Energy losses in flow
Friction in Pipes Fanning equation Hagen Poiseuille equation
Blasius equation pipe roughness Moody graph
Energy Losses in Bends and Fittings
Pressure Drop through Equipment
Equivalent Lengths of Pipe
Compressibility Effects for Gases
Calculation of Pressure Drops in Flow Systems
Summary
Problems
CHAPTER 4.
FLUIDFLOW APPLICATIONS
Introduction
Measurement of pressure in a fluid manometer tube Bourdon tube
Measurement of velocity in a fluid Pitot tube Pitotstatic tube
Venturi meter orifice meter
Pumps and fans
Positive Displacement Pumps
Jet pumps
Airlift Pumps
Propeller Pumps and Fan
Centrifugal Pumps and Fans pump characteristics fan laws
Summary
Problems
CHAPTER 6.
HEATTRANSFER APPLICATIONS
Introduction
Heat Exchangers
Continuousflow Heat Exchangers parallel flow counter flow
cross flow heat exchanger heat transfer log mean temperature
difference
Jacketed Pans
Heating Coils Immersed in Liquids
Scraped Surface Heat Exchangers
Plate Heat Exchangers
Thermal Processing
Thermal Death Time
F values Equivalent Killing Power at Other Temperatures
z value sterilization integration time/temperature curves
Pasteurization milk pasteurization
High Temperature Short Time HTST
Refrigeration, Chilling and Freezing
Refrigeration Cycle temperature/enthalphy chart evaporator
condenser adiabatic compression coefficient of performance
ton of refrigeration
Performance Characteristics
Refrigerants ammonia refrigerant 134A
Mechanical Equipment
Refrigeration Evaporator Heat transfer coefficient fins
Chilling
Freezing Plank's equation freezing time shape factors
Cold Storage
Summary
Problems
CHAPTER 7.
DRYING
Basic Drying Theory
Three States of Water phase diagram for water
vapour pressure/temperature curve for water
Heat Requirements for Vaporization
Heat Transfer in Drying
Dryer Efficiencies
Mass Transfer in Drying mass transfer coefficient
Psychrometry absolute humidity relative humidity
dew point humid heat
Wetbulb Temperatures dry bulb temperature Lewis number
Psychrometric Charts
Measurement of Humidity hygrometers
Equilibrium Moisture Content
Air Drying drying rate curves
Calculation of Constant Drying Rates
Fallingrate Drying
Calculation of Drying Times
Conduction Drying
Drying Equipment
Tray Dryers
Tunnel Dryers
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CHAPTER 8.
EVAPORATION
The SingleEffect Evaporator
Vacuum Evaporation
Heat Transfer in Evaporators
Condensers
MultipleEffect Evaporation
Feeding of Multipleeffect Evaporators
Advantages of Multipleeffect Evaporators
Vapour Recompression
Boiling Point Elevation Raoult's Law Duhring's rule
Duhring plot latent heats of vaporization
Evaporation of HeatSensitive Materials
Evaporation Equipment
Open Pans
Horizontaltube Evaporators
Verticaltube Evaporators
Plate Evaporators
Longtube Evaporators
Forcedcirculation Evaporators
Evaporation for Heatsensitive Liquids
Summary
Problems
Back to the top
CHAPTER 9.
CONTACTEQUILIBRIUM PROCESSES
Introduction contact equilibrium separation phase distribution
equilibrium distribution coefficients
PART 1: THEORY
Concentrations mole fraction partial pressure Avogadro's Law
GasLiquid Equilibria partial vapour pressure Henry's Law
solubility of gases in liquids
SolidLiquid Equiibria solubility in liquids
solubility/temperature relationship saturated solution
supersaturated solution
EquilibriumConcentration Relationships overflow/underflow
equilibrium diagram
Operating Conditions contact stages mass balances
Calculation of Separation in ContactEquilibrium Processes
combining equilibrium and operating conditions
deodorizing/steam stripping McCabe/Thiele diagram
PART 2: APPLICATIONS
Gas Absorption number of contact stages
Rate of Gas Absorption Lewis and Whitman Theory
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CHAPTER 10.
MECHANICAL SEPARATIONS
Introduction
The velocity of particles moving in a fluid terminal velocity
drag coefficient terminal velocity magnitude.
Sedimentation Stokes' Law
Gravitational Sedimentation of Particles in a Liquid zones
velocity of rising fluid sedimentation equipment
Flotation
Sedimentation of Particles in a Gas
Settling Under Combined Forces
Cyclones optimum shape efficiency
Impingement separators
Classifiers
Centrifugal separations centrifugal force particle velocity
Liquid Separation radial variation of pressure
radius of neutral zone
Centrifuge Equipment
Filtration rates of filtration filter cake resistance
equation for flow through the filter
Constantrate Filtration
Constantpressure Filtration filtration graph
Filtercake Compressibility
Filtration Equipment
Plate and frame filter press
Rotary filters
Centrifugal filters
Air filters
Sieving rates of throughput standard sieve sizes
cumulative analyses particle size analysis
industrial sieves air classification
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Summary.
Problems.
CHAPTER 11.
SIZE REDUCTION
Introduction
Grinding and cutting.
Energy Used in Grinding Kick's Law Rittinger's Law
Bond's Law Work Index
New Surface Formed by Grinding shape factors
Grinding equipment.
Crushers
Hammer mills
Fixedhead mills
Plate mills
Roller mills
Miscellaneous milling equipment
Cutters
Emulsification disperse/continuous phases stability
emulsifying agents
Preparation of Emulsions shearing homogenization
Summary.
Problems.
CHAPTER 12.
MIXING
Introduction
Characteristics of mixtures.
Measurement of mixing sample size sample compositions
Particle mixing random mixture thorough mixture
mixing index
Mixing of Widely Different Quantities mixing in stages
Rates of Mixing mixing times
Energy Input in Mixing
Liquid mixing propeller mixers Power number Froude number
Mixing equipment
Liquid Mixers
Powder and Particle Mixers
Dough and Paste Mixers
Summary.
Problems.
APPENDICES
1. Symbols, units and dimensions
2. Units and conversion factors
3. Some properties of gases
4. Some properties of liquids
5. Some properties of solids
6. Some properties of air and water
7. Thermal data for some food products
8. Steam table saturated steam
9. (a) Psychrometric charts normal temperatures
9. (b) Psychrometric charts high temperatures
10. Standard sieves
11. (a) Pressure/enthalpy chart for refrigerant R134a
11. (b) Pressure/enthalpy chart for refrigerant Ammonia
INDEX TO FIGURES
INDEX TO EXAMPLES
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REFERENCES
BIBLIOGRAPHY
USEFUL LINKS
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APPENDICES
Home
Contents
About the book 1. Symbols, units and dimensions
Introduction 2. Units and conversion factors
3. Some properties of gases
Material and energy
4. Some properties of liquids
balances 5. Some properties of solids
Fluidflow theory 6. Some properties of air and water
Fluidflow applications 7. Thermal data for some food products
8. Steam table saturated steam
Heattransfer theory
9. (a) Psychrometric charts normal temperatures
Heattransfer 9. (b) Psychrometric charts high temperatures
applications 10. Standard sieves
Drying 11. (a) Pressure/enthalpy chart for refrigerant R134a
11. (b) Pressure/enthalpy chart for refrigerant Ammonia
Evaporation
Contactequilibrium
separation processes
Mechanical N.B. Alternative versions of some of the more complex charts are provided
these are Macromedia FlashPaper files (.swf), which allow zooming and offer a
separations more convenient format for printing.
Size reduction To view these you need the Flash Player your computer probably already has
Mixing this, but if not, it is available for free download from Macromedia:
Appendices Get the free Flash Player
Index to Figures
Index to Examples
References
Bibliography
Useful links
Feedback (email link)
Unit Operations in Food Processing. Copyright © 1983, R. L. Earle. :: Published by NZIFST (Inc.)
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APPENDICES
APPENDIX 1
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H enthalpy, kJ kg1; [F] [L] [M]1, Hs, enthalpy saturated vapour, Ha, Hb, Hc,enthalpy in
refrigeration system
Henry's Law constant, atm mole fraction1, kPa mole fraction1; [F] [L]2
k constant
constant of proportionality
friction loss factor; dimensionless
thermal conductivity J m1 s 1 °C1 ; [F] [L]1 [t]1 [T]1
k 'g masstransfer coefficient
k g gas masstransfer coefficient, k 'g masstransfer coefficient based on humidity difference, k l
liquid mass transfer coefficient (units and dimensions from context)
K constant, K', K'', etc.
K' masstransfer coefficient through membrane, kg m2 h1; [M] [L]2 [t]1; for ultrafiltration m s 1, for
reverse osmosis kg m2 h1 kPa1
KK Kick's constant m3 kg1 ; [L]3 [M]1
KR Rittinger's constant m4 kg1; [L]4 [M]1
Ks rate constant for crystal surface reactions m s 1; [L] [t]1
Kd mass transfer coefficient to the interface, m s 1; [L] [t]1
Kg overall gas mass transfer coefficient
Kl overall liquid mass transfer coefficient
L flow rate of heavy phase kg h1 ; [M] [t]1
half thickness of slab for Fourier and Biot numbers m; [L]
length m; [L]
ratio of liquid to solid in thickener underflow;
Lc thickness of filter cake, equivalent thickness of filter cloth and precoat m; [L]
(Le) Lewis number (hc/k'gc p) or (hc/k gc s) dimensionless
m mass kg; [M]
number, general
(M) mixing index, dimensionless
M molecular weight; dimensionless
molal concentration (kg) moles m3 ; [M] [L]3
n number, general
N number of particles in sample;
rotational frequency, revolutions/minute or s ; [t]1
(Nu) Nusselt number (hcD/k); dimensionless
p partial pressure Pa; [F] [L]2
pa partial pressure of vapour in air, ps saturation partial pressure
factor in mixing and in grinding, dimensionless; factor in particle geometry in grinding, fractional
content in mixing; dimensionless
P constant in freezing formula; dimensionless;
power N m s l, J s1; [F] [L] [t]1
pressure Pa; [F] [L]2
Ps pressure on surface Pa; [F] [L]2
Power number (P/D5N); dimensionless
(Po)
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absorbtivity; dimensionless
coefficient of thermal expansion m m1 °C1; [T]1
1, 2 length ratios in freezing formula; dimensionless
thickness of layer for diffusion m; [L]
difference
tm logarithmic mean temperature difference °C; [T]
emissivity; dimensionless
roughness factor; dimensionless
efficiency of coupling of freezing medium to frozen foodstuff
airdrying efficiency, % , dimensionless
latent heat kJ kg1; [F] [L] [M]1
shape factor for particles, dimensionless
viscosity kg s 1 m1; Pa s, N s m2; [M] [t]1 [L]1 ; [F] [t] [L]2
ratio of circumference to diameter of circle , 3.1416
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8/30/2015 Unit Operations in Food Processing R. L. Earle Appendix 2 Units and Conversion Factors
APPENDICES
APPENDIX 2
Force
1 Newton = 1 kg m s 2
1 lb ft s 2 = 1.49 kg m s2
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8/30/2015 Unit Operations in Food Processing R. L. Earle Appendix 2 Units and Conversion Factors
Unit Operations in Food Processing. Copyright © 1983, R. L. Earle. :: Published by NZIFST (Inc.)
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8/30/2015 Unit Operations in Food Processing R. L. Earle Appendix 3 Some Properties of Gases
APPENDICES
APPENDIX 3
Unit Operations in Food Processing. Copyright © 1983, R. L. Earle. :: Published by NZIFST (Inc.)
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APPENDICES
APPENDIX 4
Thermal
Specific heat Density Viscosity Temperature
conductivity
(J m1 s 1 °C1) (kJ kg1 °C1) (kg m3) (N s m2) (°C)
Water (see
0
Appendix 6)
Sucrose 20% soln. 0.54 3.8 1070 1.92 x 103 20
0.59 x 103 80
60% soln. 6.2 x 103 20
5.4 x 103 80
3.7 x 103 20
Sodium chloride
22% soln.
0.54 3.4 1240 2.7 x 103 20
Unit Operations in Food Processing. Copyright © 1983, R. L. Earle. :: Published by NZIFST (Inc.)
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8/30/2015 Unit Operations in Food Processing R. L. Earle Appendix 5 Some Properties of Solids
APPENDICES
APPENDIX 5
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Unit Operations in Food Processing. Copyright © 1983, R. L. Earle. :: Published by NZIFST (Inc.)
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8/30/2015 Unit Operations in Food Processing R. L. Earle Appendix 6 Some Properties of of Air and of Water
APPENDICES
APPENDIX 6
Extracted from An Introduction to Heat Transfer, Fishenden, M. and Saunders, 0. A., by permission of the
Clarendon Press, Oxford.
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Unit Operations in Food Processing. Copyright © 1983, R. L. Earle. :: Published by NZIFST (Inc.)
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8/30/2015 Unit Operations in Food Processing R. L. Earle Appendix 7 Thermal Data for Some Food Products
APPENDICES
APPENDIX 7
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Specific heats, latent heats of freezing and thermal conductivities of foodstuffs can be estimated if the
percentage of water in the foodstuff is known. If this percentage is p then:
(a) Specific heat = 4.19p/100 + 0.84(100 p)/100 kJ kg1 °C1 above freezing
= 2.1 p/100 + 0.84(100 p)/100 kJ kg1 °C1 below freezing.
(b) Latent heat = 335p/100 kJ kg1
(c) Thermal conductivity = 0.55p/100 + 0.26(100 p)/l00 J m1 s 1 °C1 above freezing
= 2.4p/100 + 0.26(100 p)/l00 J m1 s 1 °C1 below freezing.
These equations represent a considerable oversimplification so they, and also the tabulated data, should be
used with caution, particularly in the region between 0°C and 18°C. Freezing of foodstuffs occurs over a range
of temperatures and not at any fixed point. For complete data the only really satisfactory source is a
thermodynamic chart such as those prepared by Riedel (for example, in DKV Arbeitsblatt 811, 1957 C. F.
Muller, Karlsruhe) for lean beef, and also for egg yolk, potato and fish.
Unit Operations in Food Processing. Copyright © 1983, R. L. Earle. :: Published by NZIFST (Inc.)
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8/30/2015 Unit Operations in Food Processing R. L. Earle Appendix 8 Steam Table Saturated Steam
APPENDICES
APPENDIX 8
Enthalpy
Temperature Pressure(Absolute) Latent heat Specific volume
(sat. vap.)
(°C) (kPa) (kJ kg1) (kJ kg1) (m3 kg1)
Temperature Table
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Pressure Table
* Reproduced with permission from J. H. Keenan et al., Steam Tables lnternational Edition in Metric Units,
John Wiley, New York, 1969.
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Unit Operations in Food Processing. Copyright © 1983, R. L. Earle. :: Published by NZIFST (Inc.)
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APPENDICES
APPENDIX 10
STANDARD SIEVES
Unit Operations in Food Processing. Copyright © 1983, R. L. Earle. :: Published by NZIFST (Inc.)
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REFERENCES
Home
Contents
About the book ASHRAE Guide and Data Books, American Society of Heating, Refrigerating
Introduction and Air Conditioning Engineers, New York.
BIRD, R. B., STEWART, W. E. and LIGHTFOOT, E. N. (1960) Transport
Material and energy
Phenomena, Wiley, New York.
balances BOND, F. C. (1952) Min. Engng. 4, 484; Chem. Engng. 59, 169.
Fluidflow theory CHARM, S. E. (1971) The Fundamentals of Food Engineering, 2nd Edition,
Fluidflow applications AVI, Westport.
CLELAND, A. C. and EARLE, R. L. (1982) Int. J. Refrig. 5,134.
Heattransfer theory
COULSON, J. M. and RICHARDSON, J. F. (1977, 1978) Chemical
Heattransfer Engineering, Vol.1, 3rd Edition. Vol.2, 3rd Edition, Pergamon, Oxford.
applications DK V Arbeitsblatt 202 (1950), C. F. Muller, Karlsruhe.
Drying EDE, A. J. (1949) Mod. Refrig. 52, 52.
ESTY, J. R. and MEYER, K. F. (1922) J. Infec. Dis. 31, 650.
Evaporation FISHENDEN, M.D. and SAUNDERS, 0. A. (1950) An Introduction to Heat
Contactequilibrium Transfer, Oxford University Press.
separation processes GROSSE, J. W. and DUFFIELD, G. M. (1954) Chem. and Ind. 1464.
Mechanical HENDERSON, S. M. and PERRY, R. L. (1976) Agricultural Process
Engineering, 3rd Edition, Wiley, New York.
separations International Critical Tables (1930), McGrawHill, New York.
Size reduction JASON, A. C. (1958) in Fundamental Aspects of the Dehydration of
Mixing Foodstuffs, Society of Chemical Industry, London.
McADAMS, W. H. (1954) Heat Transmission, 3rd Edition, McGrawHill, New
Appendices
York.
Index to Figures McCABE, W. L.,SMITH, J. [Link] HARRIOTT, P.(1975) Unit Operations of
Index to Examples Chemical Engineering, 3rd Edition, McGrawHill, New York.
References
Bibliography
Useful links
Feedback (email link)
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BIBLIOGRAPHY
Unit Operations in Food Processing. Copyright © 1983, R. L. Earle. :: Published by NZIFST (Inc.)
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BIBLIOGRAPHY
Home
Contents
About the book General Data
Introduction
Material and energy Handbook of Chemistry and Physics, Chemical Rubber Publishing,
Sandusky,(updated frequently).
balances International Critical Tables (1932) McGrawHill, New York.
Fluidflow theory KEENAN, J. H., KEYES, F. G., HILL, P. G. and MOORE, J. G. (1969)
Fluidflow applications Steam Tables, Wiley, New York.
PERRY, R. H., GREEN, D.W. and MOLONY, J.D. (1997) Chemical
Heattransfer theory
Engineers' Handbook, 7th Edition, McGrawHill, New York.
Heattransfer
applications
Drying Fluid Flow
Evaporation
STREETER, V.L., WILEY, E.B. and BEDFORD, K.W. (1998) Fluid
Contactequilibrium Mechanics, 9th Edition, McGrawHill, New York.
separation processes STEFFE, J.F. (1996) Rheological Methods in Food Process Engineering, 2nd
Mechanical Edition, Freeman, East Lansing: and on
[Link]/divisions/food_eng/pub/[Link] (2000)
separations
Size reduction
Mixing Heat Transfer
Appendices
Index to Figures EDE, A. J. (1967) An Introduction to Heat Transfer, Pergamon, Oxford.
FISHENDEN, M.D. and SAUNDERS, 0. A. (1950) An Introduction to Heat
Index to Examples Transfer, Oxford University Press, Oxford.
References KERN, D. Q. (1950) Process Heat Transfer, McGrawHill, New York.
Bibliography McADAMS, W. H. (1954) Heat Transmission, 3rd Edition, McGrawHill, New
York.
Useful links
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Sterilization by Heat
STUMBO, C. R. (1973) Thermobacteriology in Food Processing, 3rd Edition, Academic, New York.
Refrigeration
ASHRAE Guide and Data Books, American Society of Heating, Refrigerating, and Air Conditioning
Engineers, New York.
ANDERSEN, S. A. (1959) Automatic Refrigeration, McLaren, Glasgow.
JORDAN, R. C. and PRIESTER, G. B. (1956) Refrigeration and Air Conditioning, Prentice Hall, Englewood
Cliffs.
Dehydration
Fundamental Aspects of the Dehydration of Foodstuffs (1958) Society of Chemical Industry, London.
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8/30/2015 Unit Operations in Food Processing R. L. Earle
Food Engineering
BRENNAN, J. G., BUTTERS, J. R., COWELL, N. D. and LILLY, A. E. (1990) Food Engineering Operations,
3rd Edition, Applied Science, London.
CHARM, S. E. (1971) The Fundamentals of Food Engineering, 2nd Edition, AVI, Westport.
EARLE, R.L. and EARLE, M.D. (2003) Fundamentals of Food Reaction Technology,
Leatherhead Food International and RSC, Leatherhead.
FELLOWS, P. (2000) Food Processing Technology, Principles and Practice. 2nd Edition, Woodhead,
Cambridge.
HARPER, J. C. (1976) Elements of Food Engineering, AVI, Westport.
HELDMAN, D. R. (1975) Food Process Engineering, AVI, Westport.
HELDMAN, D. R. and LUND, D. E. (1992) Handbook of Food Engineering, Marcel Dekker, New York
LENIGER, H. A. and BEVERLOO, W. A. (1975) Food Process Engineering, Reidel, Dordrecht.
LONCIN, M. and MERSON, R. L. (1979) Food Engineering; Principles and Selected Applications, Academic,
New York.
SINGH, R. P. and HELDMAN, D. R. (2001) Introduction to Food Engineering, 3rd. Edition, Academic,
London.
TOLEDO, R.T. (1991) Fundamentals of Food Process Engineering, 2nd Edition, van Nostrand, Reinhold,
New York
USEFUL LINKS
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