Apple juice production technology. Organizing the production of directly pressed apple juice - a fruity and profitable business Equipment for the production of juice from apples
In this article:
In terms of total apple harvest, Russia ranks 5th in the world, so juice production is an economically profitable business (in other words, due to the available raw materials).
The demand for the product is obvious, as more and more people prefer a fortified and natural drink. Using the example of apple juice production, we will consider in more detail the features of the functioning of a mini-factory.
List of organizational aspects for creating a mini-factory
When organizing a business for the production of natural juice, it is recommended to choose the legal form - LLC. Such a business format will facilitate easy division of responsibilities of the founders, and attracting investors will not be any particular problem. As for the choice of taxation form, at the initial stage of business activity it is preferable to choose a simplified system (15%). Further, in the case of effective and profitable development, it would be more advisable to switch to OSNO.
In the process of organizing an enterprise, you should be guided by the following OKVED activity code: 15.32 “Production of vegetable and fruit natural juices.”
If positive results are obtained, a sanitary-epidemiological certificate is issued.
Stages of production of natural apple juice
The technological flow diagram for the production of apple juice is presented in the following figure.
Juice production begins with the collection of berries; in our country this occurs from August until late autumn, exclusively by hand. It is noteworthy that apples for juice are collected not only from trees, but also from the ground. So-called carrion suitable for production. At the same time, it is prohibited to use rotten, damaged and unripe fruits. The latter variety of apples is characterized by a low concentration of sugars; they will produce little juice and it will be very sour.
Ripe fruits are poured into wooden boxes and placed into trucks with the help of a loader, which will deliver the ripe fruit to the factory.
Picked apples no longer receive moisture, but only lose it. That is why the juice in them becomes insignificant, but still less (every minute should count). Upon arrival at the plant, the raw materials are loaded into special bins (capacity up to 200 tons of apples), which are made of stainless steel.
Therefore, fruits kept in them for 24 hours will not oxidize. Next, powerful streams of water push the apples through chutes directly into the production workshop for primary cleaning.
The jets carry away leaves, branches and other debris.
Through such water trenches, fruits are delivered to the wash, because the fruits need to be washed from dust and various contaminants, including chemical ones. After all, apples are often sprayed with a variety of means of protection against harmful insects.
When the beautiful and juicy fruits are selected, they are sent to the crusher, where many hammers crush the fruit. The crushed apples are fed under a press, in which a rotating drum compresses the mixture that enters it almost to dryness.
Thus, an opaque squeezed juice is obtained. The peels and seeds are unloaded and sent to feed livestock. 
Then the resulting juice is sent into pipes to ultrafiltration.
The unit is filled with many thin membrane tubes, the structure of which can be compared to fine-pored foam rubber. The juice is forced through a membrane under pressure, so even the smallest particles of pulp get stuck in the membrane, and the purified juice passes on. The resulting clear juice is sent to vacuum evaporation unit.
This specialized equipment is equipped with a supply of juice and steam, where the liquid is heated, but not brought to a boil.
In a vacuum, the liquid from the juice evaporates along with the flavor-forming substances.
The juice, which has been deprived of water, begins to thicken. The resulting vapor begins to condense - the water is discharged to the bottom of the tank, and the “aromatic vapor” is directed upward to the condenser, where it turns into liquid.
The result is a composition that resembles the consistency of thick honey. This is concentrated apple juice. The finished flavor-forming substances are a clear liquid that has a pronounced fruity odor. Next, the concentrated apple juice is poured into barrels.
In this form it can be stored for a long time, because the less water there is in the product, the more difficult it is for bacteria to multiply in it. Such juice is safely sent to other countries.
The preliminary stage of bottling juice into bags is diluting it with once evaporated water. The concentrate is mixed because it may be subject to separation.
Also, its sample is subjected to laboratory analysis to ensure that the content of substances complies with established standards.
A high percentage of dry soluble substances indicates the need to add an increased amount of liquid. Clarified juice should not contain pulp particles, so it is diluted with a small amount of liquid and the resulting structure is examined.
Next, the safety of the juice is examined by placing small portions of the juice in a heating cabinet with a temperature of 36 C. - optimal for the development of various microorganisms. If the juice contains bacteria, yeast or mold, then they will begin to multiply in the nutrient medium and can be seen with the naked eye. After obtaining satisfactory results in the laboratory, the juice can be reconstituted, that is, water (flavor-forming substances) can be added to it.
Here it is extremely important to maintain the proportions and add the same amount of water as was removed. The proportions are as follows: 6 liters of flavor is enough for 100 liters of juice. All that remains is to pour the finished juice into bags and attach the lids to them.
Experts determine the quality of juice according to the following parameters: color, taste, aroma. The finished product should be transparent and not sour, have a brown tint and an apple aroma. If the sample meets the specified requirements, the batch is sent for sale.
Business plan for setting up a technological line for the production of apple juice
1. We are setting up a production workshop - choosing a room
In a rented or purchased building, the total area of the proposed production workshop should not be less than 150 square meters. A production line is installed in a spacious room, and space is allocated for storing the initial raw material base.
It is also necessary to arrange a warehouse for finished products.
The availability of living quarters for the company’s employees should be taken care of in advance, as well as the office. In case of limited financial capabilities, it can be located directly on the territory of the enterprise.
Compliance with legally established standards is monitored at the legislative level by the relevant services. This is especially true for fire safety. In this regard, it is advisable to choose premises for a production workshop outside the city. The savings in rent and utility bills in rural areas are obvious.
2. We purchase equipment for juice production
The average cost of a production line is 2,500,000 rubles.
Costs can be significantly reduced by purchasing used equipment.
The technological line for the production of juice in liter packaging consists of:
- water treatment systems with special filters for water purification;
- washing equipment;
- tanks for mixing juice and various additives;
- homogenizer, heat exchanger and pasteurizer;
- apparatus for creating bags and bottling juice.
Often the production line is electronically controlled, which in turn allows saving on wages for factory workers.
3. We select personnel and purchase raw materials
The raw materials for the manufacture of the finished product in a volume of 35,000 liters are the following components:
- sugar - 8,000 rubles;
- fruits – 626,000 rubles;
- various additives (provided for by GOST) – 4,000 rubles;
- packaging materials – 25,000 rubles;
- cardboard boxes – 7,000 rubles.
Total: 670,000 rubles.
One juice production line has the ability to process about 4 tons of finished products (1,600 liters) per work shift. Thus, monthly production can be about 35,000 liter packages.
At the initial stage, 10 people will be quite enough to service one production line, not counting 5 management personnel. An indispensable condition is the inclusion in the staffing table of a technologist who will monitor the serviceability of the production line, as well as compliance with a number of GOST requirements, sanitary and technical rules.
The monthly payroll for employees will be 238,175 rubles:
- Basic payroll - 164,000 rubles;
- Additional payroll - 11,000 rubles;
- Payroll taxes (36.1%) – 63,175 rubles;
Basic monthly costs:
- Raw materials and additional materials – 670,000 rubles;
- Utility costs – 10,000 rubles;
- Salary of 15 employees – 238,175 rubles;
- Expenses for production needs (39% of the payroll) – 92,888 rubles;
- Rental of the building and current repair work – 65,000 rubles;
- Shop costs (50% of payroll) – 119,088 rubles;
- Losses from defects (4.5% of shop costs) – 5,359 rubles;
- Non-production expenses (5% of shop costs) -5,954 rubles;
- Depreciation of the production line – 8,000 rubles.
Total direct costs (p/p 1-5) – 1,076,063 rubles.
Total additional expenses (p/p 6-9) – 133,042 rubles.
We will calculate the main economic indicators and determine the effectiveness of the project
Planned cost (direct + indirect costs) = 1,076,063 rubles. + 133,042 rub. = 1,209,105 rubles.
Total cost of the finished product = planned cost + planned profit (20% of cost) + income tax (15% of profit) = 1,209,105 rubles. + 241,821 rub. + 36,273 rub. = 1,487,199 rubles.
Processing cost (planned cost minus costs for raw materials) = RUB 1,487,199. — 670,000 rub. = 817,199 rubles. Product cost = 817,199 rubles / 35,000 bottles = 23 rubles.
Let's determine the average market price of 1 package of juice. Let us assume absolute (100%) sales of manufactured products and the corresponding profit margin. Thus, the price, taking into account the cost, will be equal to: C roses. = 23 rubles x 2 = 46 rubles.
Calculation of profitability, profitability and production efficiency indicators in general
Income from the sale of the finished product = Retail price x Volume of production = 46 rubles. x 35,000 pack. = 1,610,000 rubles. Profit from the sale of monthly volume of juice packages = Income – Planned cost = 1,610,000 rubles. – 1,209,105 rub. = 400,895 rubles.
Monthly net profit (minus 15% income tax) = 340,760 rubles.
Product profitability = Profit from sales / Cost = 400,895 / 1,209,105 = 33%.
Profitability of production = Profit from sales / Cost of processing = 400,895 / 817,199 = 49%.
Thus, based on the above calculations, we can confidently say that the production of apple juice is an economically viable and profitable type of business activity.
On a note!
It is also possible not to produce concentrated juice, but to purchase it. Our country has established supplies from China, Brazil, Iran, Turkey and other countries. It would be preferable for a mini-factory to cooperate with intermediaries rather than work directly with a large manufacturer.
In this case, there is no need to purchase a number of expensive installations; you can limit yourself to only tanks for mixing additives, devices for removing bags and packaging the finished product.
Possible ways to market apple juice
It is more expedient to supply the first batch of apple juices to grocery stores, kiosks, retail outlets and small supermarkets. A deliberate reduction in the cost of a product over a short period of time will interest consumers and allow them to appreciate the taste of the new product.
Running promotions or special offers will have a similar effect.
It is extremely undesirable for young companies to devote all their efforts to entering large federal networks, since there is every chance that they will not be able to withstand the competition of experienced market participants. The corresponding costs can become an unaffordable budget item. Therefore, it is necessary to enter the market gradually, taking the following active steps to strengthen your authority every month:
- advertising in the media, Internet and television;
- carrying out an independent examination with mandatory publication of its results; - packaging the product in a high-quality and bright tetrapack;
- active use of outdoor advertising, etc.
Focusing your efforts on a specific region will allow you to quickly get used to it and gain market position.
Then you can gradually expand the range of products, specializing in the production of tomato and orange juices, multivitamins, etc. Recently, more and more consumers prefer glass containers because they want to visually perceive the product they are purchasing. There is also the opportunity to launch the production of premium juices (so-called branded juices), when exclusively selected raw materials are used in the production process.
Juices are the most valuable component of fruits, berries and vegetables. They contain many water-soluble biologically active and easily digestible substances. Most juices have a pronounced healing effect.
Juice is a liquid product obtained from high-quality ripe fresh or kept fresh by cooling fruits and (or) vegetables, intended for direct consumption or for industrial processing.
The range of juices is extremely wide.
Depending on the production method, juices can be directly pressed or reconstituted; depending on the production method - clarified, unclarified and pulpy juices (nectars); depending on the composition - from one type of raw material, two or more (blended); natural without additives and with additives (sugar or sweeteners, vitamins, minerals, acids, etc.). In addition, concentrated juices with a high content of soluble solids are produced.
Technology for the production of natural juices. The technological process for the production of natural juices includes the following operations: preparation (washing, in some cases cleaning) and crushing of fruit and vegetable raw materials (its features), juice extraction (on a drainer and presses), its purification (straining) and clarification, filtering, packaging, pasteurization.
Crushing prepared fruit and vegetable raw materials. It should ensure the destruction of pulp cells by at least 75%. Quinces, apples, pears, rhubarb are crushed using knife, grating or disc crushers. Apples are crushed into particles of 2...6 mm in size, depending on the density of the fruit tissue and the pressing equipment used. The denser the fabric, the smaller the fruit particles should be.
Stone fruits (cherries, cherries, plums) are crushed using universal crushers. Crushing is adjusted so that the seeds do not crush. The presence of destroyed seeds in the pulp is allowed no more than 15% of its mass.
Currants, gooseberries, and lingonberries are crushed using roller or disk crushers. Ripe strawberries, raspberries and blueberries do not need to be crushed.
To increase the yield of juice during pressing, the pulp is preheated, treated with enzyme preparations or electric current.
When the pulp is heated to 70...76 °C, denaturation of proteins occurs and its juice-giving ability increases.
Treatment of the pulp with enzyme preparations leads to the hydrolysis of proteins, pectin compounds and starch, which also helps to increase the juice yield. A suspension of the enzyme preparation is added to the pulp of pome fruits immediately after crushing, and into the pulp of stone fruits after adding water (10...15% of the pulp mass) and heated to 40...45 °C. The pulp and the preparation are mixed and kept for 40...60 minutes, depending on the type of raw material being processed, and transferred for pressing.
Pressing pulp. To extract juice, the pulp of fruits and berries is fed to presses of various systems.
To press apple pulp on a batch press to increase the juice yield and make pressing easier, it is recommended to install drainers in front of the presses. The time for juice separation in the drain and pressing should not exceed 20 minutes to avoid significant oxidation and darkening of the pulp and juice. The juice yield in the drain is up to 30%. With increasing pressure and a higher yield of juice, it becomes enriched with suspensions and its clarification will be difficult.
To increase the juice yield when using screw presses, it is recommended to additionally press the apples after the screw press using a hydraulic, batch or basket press. The sediment from the separator of coarse impurities is combined with the marc and pressed together with them.
The pulp sediment can be used as an additive (no more than 20%) to applesauce when cooking jam or returned to the pulp for re-pressing.
The yield of juice depends on the quality of the raw materials, the preparation of the pulp, the method of pressing and is, %: from grapes 70...80, apples 55...80, cranberries 70...80, cherries 60...70, red currants 70...80, black currants 55...70.
Straining the juice. The juice flowing out from under the press is filtered through a stainless steel sieve with holes with a diameter of 0.75 mm or a nylon sieve to remove pieces of pulp, seeds and other impurities that got into the juice during pressing.
Further operations with juice depend on what types of juice are produced: clarified or unclarified.
Juice clarification. Clarified juices are prepared from barberries, lingonberries, pears, cranberries, rowan berries, red currants, grapes, apples, etc.
You can clarify the juice immediately after its production or later by preparing semi-finished products, canning them and then clarifying them.
Juices are clarified using the following methods: fining, enzyme preparations, gelatin with enzyme preparations or bentonite with gelatin and enzyme preparations, or silicon dioxide with gelatin and enzyme preparations, or heating.
Filtration. After clarification, the juice is sent for filtration. Filtration on filter presses is carried out at a pressure of 39.2... 157 kPa.
Juice packaging. For packaging juice, bottles or jars with a capacity of 0.2...3 dm 3 are used. The juice heated to 75...78 °C is packaged and sent for pasteurization or sterilization.
Pasteurization of juice. Natural juice, with sugar, blended is pasteurized in jars with a capacity of 0.65 ... 1.0 dm according to the formula 10-20-20 minutes at a temperature of 85 ° C and a pressure of 118 kPa.
It is allowed to preserve juices using the hot filling method. In this case, before packing into a heated container, the juice is heated to a temperature of 96...98°C.
Reconstituted juices from concentrated juices are produced in this order.
The concentrate is weighed on an electronic scale and, according to the recipe, added to the water in the long-term pasteurization bath. In it, concentrated juice is mixed with water. In order to remove the microflora present in the concentrate, pasteurization is carried out. Then, in a rotary-pulsation installation operating on the principle of cavitation or a homogenizer, the mass is homogenized to obtain a homogeneous mixture without lumps and inclusions.
Prepare the container. Then the prepared bottles are sent to the bottling plant, and then to the vacuum capping line.
After bottling, bottles with juice reconstituted from concentrate are inspected on a special screen, where unwanted inclusions in the liquid in the bottle are identified and some of the products are rejected. The bottles are then labeled. The mass fraction of soluble solids in directly pressed juices and reconstituted juices is given in Table 8.3.
Bottles that have passed inspection control are sent to group packaging - into a thermal tunnel, where they are wrapped in stretch film, and they are sent to a warehouse for temporary storage or sale.
Progressive waste-free technology for producing apple juice is the use of microwave energy with a frequency of 2400+50 MHz for 2...3.5 minutes. When processing whole washed apple fruits, the temperature throughout the entire volume of the fruit reaches 80...90 °C, which ensures inactivation of enzymes and prevents oxidation of the resulting juice. The new technological scheme for processing apples includes the following operations: washing, inspection, rinsing the fruit in the shower, microwave treatment, draining the juice through a drainer, pressing (microwave drying of apple pomace), filtering, microwave pasteurization of the juice, packaging the juice into prepared and Microwave-treated bottles, capping, storage. It allows you to obtain not only juice with a natural taste, aroma and color, but also reduce the time of its production and dispose of waste (drying the pomace). According to the scheme considered, tomato, plum, apricot, etc. juices are produced. The cavitation effect when processing whole fruits in a microwave installation makes it possible to eliminate their crushing.
The shelf life of juices depends on the container in which they are placed: in glass containers (light) - 2 years; in glass containers (dark) - 1 year; in metal containers - 1 year; in aluminum tubes - 1 year; in consumer packaging made of combined materials based on aluminum foil and paper (cardboard) aseptic and hot-filled drinks - 1 year.
For liquid products of aseptic preservation, combined materials based on foil, paper, cardboard and polymer, for example, polyethylene/paper/polyethylene/aluminum foil/polyethylene, are widely used.
In consumer containers made of combined film materials, juices are stored for 9 months, and in bottles made of polymer materials - 1 year.
Apple juice is the juice that is squeezed from fresh apples. The presence of natural sugar in apples gives it a sweet taste. Currently, most apple juice is produced industrially through pasteurization and aseptic packaging.
Apples are the most popular pome fruit used for canning. These canned foods are very diverse: compotes, juices, jams, nectars, etc. Modern nutrition in the country and the world is now focused on the production of natural canned food with a low calorie content and attractive packaging.
Apple juice production technology.
According to this regulation there are:
-directly squeezed apple juice (juices obtained from fresh or preserved fresh apples using mechanical processing);
-freshly squeezed apple juice (obtained by direct extraction, not canned, made in the presence of the consumer from fresh or preserved fresh apples);
-concentrated apple juice (made by physically removing water from the juice to increase the amount of soluble solids by two or more times);
- diffusion apple juice (obtained by extracting extractive substances from fresh or dried apples with water, from which it is impossible to obtain juice by mechanical processing). Apple juice obtained in this way is first concentrated and then reduced.
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Similarly, with the process of manufacturing various types of canned food, the delivery, acceptance and storage of components for the production of apple juice is carried out. The raw materials are thoroughly washed and then inspected to remove fruits that have been damaged by pests, as well as those that are rotten or have other defects. In the production of apple juice, the main method of influencing plant tissue is mechanical crushing (grinding). But chopping very finely can make the tissue a solid mass that lacks the channels needed to allow the juices to flow out.
Juice is extracted from apple pulp by pressing, centrifugation, diffusion and other methods. Pressing is the main method of obtaining juice from fruits. The juice is extracted by applying pressure to the pulp.
Destruction of plant tissue by pressure, crushing of the biomembrane of the cell structure is not a function of pressing. Its main function is to squeeze out juice that was obtained from cells damaged during pre-treatment. Pressing is not used to extract juice from cells, but is used to extract juice (the liquid phase of the pulp), which flows out of destroyed cells before pressing. Pre-treatment of raw materials mainly affects the high yield of juice from the fruit.
To achieve a more pleasant taste, juices are blended (mixed). They can mix juices of two different types, juices of one type of apple, or juices of apples containing different amounts of sugar and acid.
Organization of apple juice production.
It should be noted that for small businesses, the production of canned food is currently a fairly convenient area. Due to very simple technology, low cost (i.e. it does not require significant capital investments and large areas for production), easy organization of production (little technological equipment is required), technically easy production equipment (it can be made in simple conditions) a large number of representatives small businesses are involved in this area.
The production of quality goods is the main criterion for successful growth and development of a business, for this I recommend that you read the article about . No need to add flavoring additives. Instead, you can mix the juices of different fruits, mix them in different ways, make multi-fruits, or even mix the juices at the request of the buyer and get a unique taste.
The price of mini lines for the production of apple juice by direct extraction starts from 1,000,000 rubles.
It should be noted that the mixes contain more vitamins and nutrients, as they complement each other. It follows that juice mixtures are more beneficial.
The problem with doing business in this industry is that to produce large volumes of juice, you need a huge amount of fruit. For example, to make 250 ml of juice you will need 1 kg of apples, and even more berries - from 1 kg - 50 ml of juice.
You can try to develop the idea of developing a small business for the production of natural juices into making juice from vegetables or. Vegetables contain vitamins that are not found anywhere, neither in fruits nor in berries, and are no less useful.
Production of directly pressed juice from our own apples. |
Fruits arriving for processing are washed in a fan washing machine (pome fruits - in a drum and fan washing machine), then rinsed in the shower and inspected on a conveyor belt, from where they are fed into the crusher by an elevator. The crushed mass from the crusher enters a screw or microwave blancher to soften the pulp and transfer coloring substances from the skin to the juice. Stone fruits can be heated in their entirety, without crushing, but cherries must be destemmed.
Cherries, dogwoods and plums are heated to 85 -90 °C, peaches, apricots and berries - to 70 - 75 °C, crushed quince and apples - to 90 - 95 °C. Rose hips are not heated.
After heat treatment, the hot fruit mass is sent for mashing. Stone fruits, if they have been heated in their entirety without removing the seeds, are first rubbed on a rubbing machine with a sieve hole diameter of 5 mm, then on a double wiper with a sieve hole diameter of 1.5-1.2 and 0.4 mm. The finely ground mass is mixed with sugar syrup in a ratio of 70: 30 to 50: 50. After mixing, the juice is homogenized, deaerated, heated to 70 - 80 ° C and sent for packaging, capping and sterilization.
Some juices with pulp for baby food are produced natural, without added sugar or syrup.
Technological diagram for the production of juices with pulp from cherries, plums, apricots, apples and other fruits
Technological line for the production of juices with pulp:
/ - washing machine; 2 - inspection conveyor; 3 - elevator; 4 - crusher; 5 - machine for removing stalks; b - screw heater; 7 - wiping machine; 8 - screw press; 9- pumps; 10 - syrup boiler; 11 - mixers; 12 - separator; 13 - collection; 14 - homogenizer; 15 - tubular heater; 16- vacuum pump; 17- deaerator; 18- pasteurizer; 19 - collection of finished product
The fruits are washed in a double fan washing machine 1, pass through a stalk removal machine 5 and an inspection conveyor 2. From here, the pome fruits are fed into the crusher 4 by the elevator 3 and from there into the screw heater b, the stone fruits are fed directly into the heater. From the heater, the stone fruits enter the 7 grinding machine, where they are cleared of seeds, and the stone fruits are fed into the 8 screw press, where the juice and part of the pulp are squeezed out. The pitted mass is rubbed a second time on a rubbing machine with a smaller diameter of the sieve openings. The finely pureed fruit mass enters the mixer 11, where syrup from the syrup boiler 10 is added to it. The resulting mixture is passed through a separator 12, in which larger particles of pulp are separated, and reserved in a collection 13. From the collection, the juice passes into a plunger-type homogenizer 14, heated to 45 °C in a tubular heater 75 and deaerated in a deaerator 17, then heated to 75 °C in a pasteurizer 18 and supplied for packaging.
Fortified juices with pulp.
Juices with pulp for baby food are produced in one type or blended with the addition of vitamin C or vitamin C and B-carotene.
When making juices with vitamin C, crystalline ascorbic acid in the amount required by the recipe is mixed with sugar or a small (3-5 kg) amount of the product, mixed thoroughly and added to the mixer, where all the components of the juice are mixed. For 1 ton of finished product add 500 g of ascorbic acid.
Peach, apricot, plum, and plum-apple juices are produced with vitamin C.
To enrich juices with B-carotene, carrot juice concentrate “Carotene-70” is used, which is dosed and added to the product simultaneously with vitamin C. For 1 ton of juice, 3.5 kg of carrot concentrate is added.
Juices with pulp and sugar are produced with vitamin C and carotene: apricot, peach, apple.
Cocktails
A new type of fortified juices with pulp are cocktails, which are a mixture of fruit and berry purees with whey and the addition of ascorbic acid.
For the production of cocktails, cherries, plums, apples, strawberries are used separately or in a mixture of apples with cherries, plums and strawberries.
Puree from fruits and berries is obtained in the same way as in the production of canned puree.
Whey is used with an acidity of no more than 75°; it is prepared in a similar way to the production of desserts.
The sugar is sifted. Crystalline ascorbic acid in an amount of 0.05% is added directly to the product when mixing or mixed with sugar. The whey content in cocktails is 25-35% of the net weight, which increases the nutritional value of juices and their content of minerals and amino acids.
All cocktail components are mixed in accordance with the recipe and then homogenized. Further operations are carried out as in the production of fruit juices with pulp.
The pH value of cocktails should be no more than 4. If the pH value is exceeded, it is adjusted by adding citric acid.
Fruit juices without pulp.
Juices without pulp for baby food are prepared natural, without any additives, and with one type of sugar or mixed (blended) from two types of fruits. Juices without pulp are obtained from pome and stone fruits (cherries, plums, cherries), cultivated and wild.
For the production of juices without pulp, complex lines of equipment are used that provide the necessary preparation of raw materials, extraction and processing of juice.
The first operation is washing, which is carried out in two washing machines installed in series. Washed fruits are inspected, removing fruits affected by pests and diseases. After washing, the fruits are crushed in disk or grating crushers: pome fruits (apples, quinces, pears) into particles 2-6 mm in size, rose hips 1-2 mm.
Stone fruits and berries are processed using roller crushers. Crushers must be adjusted in such a way that crushing of the seeds does not occur. The content of crushed seeds in the pulp is no more than 15%; a small amount of them improves the taste and smell of the juice. When crushed, plums should only be flattened without losing their integrity. Ripe raspberries, strawberries and blueberries do not need to be crushed.
For some fruits and berries, crushing alone is not enough to obtain juice. To facilitate the release of juice, additional processing is necessary, which includes heating or electric shock; enzyme preparations are not used.
Plums are heated with the addition of 10% water to 70 - 72 ° C until cracks appear on the skin; blackberries, lingonberries, chokeberries - up to 65 - 75 ° C with the addition of 12 - 15% water to the mass of raw materials.
The pulp of almost all fruits and berries with dense skin can be exposed to the action of electric current in special devices - electroplasmolyzers.
The processed pulp is fed for pressing, for which hydraulic batch presses are used, either periodic or continuous - screw or belt.
Screw presses produce juice with a high content of suspended matter, so they are used for squeezing juice from a limited range of raw materials - grapes, pomegranates and some other berries and fruits. Belt presses give good results when pressing apples.
When producing clarified apple juice, the strained juice is clarified. When preparing juices for baby food, clarification can be carried out by gluing using 1% solutions of gelatin or tannin and gelatin.
To remove part of the protein substances and other thermolabile colloids, unclarified juice is subjected to instant heating to a protein coagulation temperature of 85 - 90 ° C, then quickly cooled to 30 - 35 ° C and separated.
The clarified juice is filtered and sent for heating and packaging. Unclarified juice is heated after separation.
When making juices with sugar or blended, mixing the juices and adding sugar is carried out before heating.
The juice, packaged in small containers with subsequent sterilization, is heated to 75 - 80 ° C and packaged in prepared bottles or jars. When producing juice with vitamin C, ascorbic acid is added to the hot juice, mixed for 5-10 minutes and immediately transferred for packaging.
The filled container is sealed and sent for sterilization (pasteurization), which is carried out at 85, 90 or 100 °C depending on the acidity of the juice and the capacity of the container, the duration of sterilization is from 10 to 20 minutes.
Juices can be packaged in large containers with a capacity of 2, 3 and 10 dm3 using the so-called hot filling method without subsequent sterilization. During hot filling, the juice is heated to 95 - 97 °C with automatic temperature control and immediately poured into prepared hot jars, which are sealed with boiled lids. The sealed jars are laid on their sides for 20 minutes to sterilize the upper empty space of the container, after which they are blown with cold air to reduce the harmful effects of heat on the quality of the juice.
Scheme of a mechanized line for the production of clarified juices from apples and other fruits
Technological scheme for the production of clarified fruit juices:
1 - container tipper; 2, 3 - fan washing machines; 4 - machine for removing stalks; 5 - inspection conveyor; 6 - elevator; 7 - crusher; 8 - drainer; 9 - dispenser; 10 - hydraulic press with pump; 11 - collector with filter; 12 - collection-measurement; 13, 20 - mobile pump; 14 - shell-and-tube heater; 15 - temperature holding unit; 16 - collection mixer; 17, 19 - vessels; 18- pasteurizer; 21, 23, 24 - screw pumps; 22- filter press
Raw materials from containers are unloaded into a washing machine. Washing is carried out in two sequentially installed fan washing machines. If raw material with stems is processed, it goes through a destemming machine. The fruits are then inspected on the conveyor and fed by elevator to the crusher. The juice released from the fruit during crushing is isolated from the pulp in a drainer and discharged into a collecting container with a filter. Partially dehydrated pulp is loaded through a dispenser into a hydraulic press. The squeezed juice is pumped into a collection container with a filter. Passing into the container through the filter, the juice is freed from suspensions. From a container with a filter, the juice is pumped into measuring containers for mixing the juice with sugar or other juices to produce blended juices. The mixture obtained in accordance with the recipe is heated in a shell-and-tube heater, maintained at this temperature for the required time in the soaker, then fed through an intermediate collector for filtration into a filter press. The filtered juice is heated to pasteurization temperature and immediately packaged into prepared bottles.
Line for the production of clarified apple juice with a capacity of 3 t/h for raw materials.
Fruits received for processing are poured into concrete tanks, from where they are sent to the workshop by hydraulic conveyor through underground channels. Here, using a screw separator 2 located in a concrete bath (pit), the fruits are separated from the water and, using an elevator 3 with a shower device, they are raised to the machine for final washing 4. The water coming from the screw separator contains large contaminants ( pebbles, branches, leaves, etc.) fall into the loading funnel of an inclined screw conveyor with a perforated bottom that retains and removes contaminants. The purified water flows into the bath (pit), from where, using a submersible pump 1, it is supplied back to the concrete baths with fruits for reuse.
The washed fruits are inspected 5, removing fruits unsuitable for processing, and lifted by an elevator 6 to the receiving collection 7,
Line for the production of clarified apple juice
1, 9, 17, 24 - pumps; 2- screw separator; 3.6 - elevators; 4- washing machine; 5 - inspection conveyor; 7, 13, 15, 18, 22 - collections; 8 - crusher; 10-press; 11 - pasteurizer-cooler; 12- pasteurizer; 14, 16 - filters; 19 - collection; 20 - cooler; 21 - pipe static mixer; 23 - pectolytic drug dispenser
rinsing the fruits with a stream of clean water. Apples from the collection in the required quantity (depending on the productivity of the press) are fed to crusher 8. The crushed fruit mass is immediately sent by pump 9 to pressing 10.
The resulting juice is cleaned from possible large particles in a pressing unit and, after pasteurization and cooling 11, is sent to one of the containers for depectinization. The pomace from pressing is crushed on a mixer with the possible addition of water and sent to fermentation containers.
The juice, after pasteurization and cooling (45 - 50 °C), is first sent to the intermediate collection 22, from where it is sucked into the depectinization tank by the dosing pump 24. Along the way, a pectolytic preparation 23 is introduced into the pipeline while it is mixed using a pipe static mixer 21.
The processes of depectinization and clarification occur depending on the type of preparation used.
If the preparation for clarification requires cooling of the juice, then after depectinization it is pumped through a cooler 20 into containers for clarification 19 and the preparation is added manually. If cooling is not required, the juice is not pumped in this case, and the clarification preparation is introduced into a container for depectinization. Upon completion of depectinization and clarification, the sediment formed at the bottom of the container is pumped into a collection for receiving sediment 18, from where it is sent by pump 1 7 to filter 16.
The juice obtained in this way is pumped using a pump into a collection tank 19, where the juice obtained from filtering the sediment is added. The juice mixture is filtered again 14 to obtain a fully clarified juice ready for bottling. This juice is collected in the receiving collector 13, and then sent to the bottling line, where it is pre-deaerated and pasteurized.
The juice is bottled at 80°C, followed by additional pasteurization and cooling in a tunnel pasteurizer-cooler.
Technical characteristics of the line for the production of clarified apple juice
- Line capacity for raw materials, t/h - 3
- Total installed power, kW -106.85
- Total water consumption, m3/h - 12
- Total steam consumption, t/h - 500
- Number of production workers per shift - 12
Line for processing stone fruits into clarified juices with a capacity of 3 t/h for raw materials.
Fruits received for processing are first loaded into a washing machine, then inspected and crushed. The crushed mass is heated, rubbed and cooled to the depectinization temperature.
The juice is released through a vacuum filter. The resulting juice, if necessary, is once again depectinized and clarified in tanks provided for these purposes, or immediately sent for secondary filtration.
Line for processing stone fruits into clarified juices):
/ - washing machine; 2 - inspection conveyor; 3 - crusher; 4 - heater; 5 - wiping machine; 6 - cooler; 7 - vacuum filter; 8, 9 - containers for depectinization and clarification; 10 - filter
Technical characteristics of the line for processing stone fruits into clarified juices
- Line capacity for raw materials, t/h 3
- Power, kW - 40.8
- Water consumption, m3/h - 4.0
- Steam consumption, t/h - 500
- Number of workers per shift - 12
Bottling of juice into bottles is provided on the same line as for juice from pome fruits.
The pre-prepared juice is sent to the bottling shop, where it is deaerated, pasteurized and bottled.
Russia ranks 5th in terms of apple harvest in the world, while the raw materials for the production of natural apple juice are accessible and cheap. Apple juice production is considered an economically viable and profitable business.
Organization of apple juice production
A business producing natural apple juice must be registered as an LLC or legal form. This format will make it possible to differentiate the responsibilities of the founders and attract investors. It is recommended to choose a simplified taxation system.
A product certification procedure is carried out to obtain the appropriate document. It is necessary to analyze the hygienic characteristics of packaged products. If the results are positive, a conclusion from the SES on the quality of the juice is issued.
Stages and technology of apple juice production
The production of apple juice begins with a manual harvesting process from August to late autumn. Apples for juice can be collected from trees and from the ground. The fruits are placed in wooden boxes, which are transported to the factory by trucks. After which the raw materials are loaded into stainless steel bins.
Next, streams of water push the fruits through chutes into the production workshop, where they undergo primary cleaning. Jets of water remove excess debris. Then the apples go to the sink and are washed with cold water to remove dust and chemical contaminants.
The next stage of production is sorting. The apples are manually culled. Selected fruits are sent to the crusher. The crushed raw materials fall under the press. The rotating drum compresses the mixture and produces an opaque pressed juice. It is sent to special pipes for ultrafiltration.
The unit consists of thin tubes made according to the membrane principle. The juice is passed under pressure through a membrane and enters a vacuum evaporation unit, leaving pulp particles behind. Under vacuum, the liquid evaporates with aroma-forming substances. The juice thickens, and the vapor condenses and turns into liquid.
Making concentrated apple juice
The concentrated juice is poured into barrels, in which it can be stored for a long time. The preliminary stage of bottling juice into bags is diluting the concentrate with evaporated water. After which it is mixed to avoid separation.
A sample of juice is subjected to laboratory analysis, which is carried out to ensure compliance with established standards. A high percentage of soluble solids in juice indicates the need to add additional liquid to the drink to obtain the ideal structure.
Then the safety of the drink is examined by placing small portions of the juice in a special thermal cabinet at a temperature of 36ºC. After receiving positive results, the drink is restored by adding flavoring substances.
Then the finished natural juice is poured into bags, and lids are attached to them. Next, the technical control department tastes the juice, determining the quality of the product according to the following parameters: taste, color and aroma. If the sample fully meets the requirements, the batch of juice is sent for sale.
Video - how apple juice is produced
