FPPKG Lec 4 Fruit Processing AY19-20 S

TOPIC 5:
FRUIT
PROCESSING
Food Processing and Packaging AY19/20, Oct Sem

General Learning Outcomes
Students should be able to:
 Evaluate different processing parameters of fruits
and common fruit-based products
2
Specific Learning Outcomes
 Classify the various types of fruits
 Describe the upstream processing of fruits
 Outline the unit operations and processing parameters for the
canning of fruits
 Define commercial sterility
 Explain the factors that affect heat transfer in a retort process
 Calculate F0 value and its application in thermal processing
 Name the different types of fruit-based products
 Evaluate the processing technology used for the production of
different fruit-based products
- Fruit jam - Dried fruits - Fruit juices and concentrates
3
What’s a fruit?
■ In botany, a fruit is the seed-bearing structure in
flowering plants (also known as angiosperms)
formed from the ovary after flowering.
■ Are these fruits?

o Strawberry, lemons, starfruit, durian
o Cucumber, Pumpkin, egg plants, tomato
4
Classification of fruits
Fruits may be classified by:
 Botanical relationships
 Geographical relationships
 Similarities in fruit type
 Culinary use
5
 Botanical relationships
o Pome fruits (apple, pear)
o Stone fruits (apricot, cherry, nectarine, peach, plum)
o Citrus fruits (orange, lemon, mandarin, grapefruit)
o Berries (blueberries, cranberries, strawberries)
6
 Geographical relationships
o Tropical fruits (banana, durian, mango, pineapple)
o The tropics are warm, year-round, and they are also

very humid, with some areas receiving lots of rain
every year. Plants in this area have adapted to this
climate, and many tropical fruits are large, brightly
colored, and very flavorful so
that they appeal to the animals
they rely on to distribute their
seeds.
7
 Similarities in fruit type
o Berry fruits
(blueberry, boysenberry, raspberry, strawberry)
8
 Culinary use
o Salad vegetable fruits
(capsicum, cucumber, egg plant, tomato, zucchini)
9
Maturity & Ripening
 Maturity
o The stage of development of the fruit on the parent
plant
o Has acceptable eating quality at the time of harvest

or has the potential to ripen into a product of
acceptable quality
o Can be mature but unripe
o Bananas, kiwi, avocados
10
Maturity & Ripening
 Ripening
o Can occur on or off the plant
o Involves physiological transformation of the fruit
o In fruits that ripen after harvest, starch or organic

acids can be converted into sugars
o Ripeness is attained when biochemical changes

convert a mature but inedible fruit to an edible
product
11
Maturity & Ripening
 Climacteric fruits
o Have a period of rapid ripening
o Increase in respiration rate, heat evolution and often

ethylene production
o Fruit softens and develops flavour and aroma
o Can be induced to ripen by treating with ethylene
o Apple, avocado, banana, peach, mango
12
Climacteric Fruit Ripening
and Climacteric Rise
13
Maturity & Ripening
 Non-climacteric fruits
o Do not undergo rapid ripening phase
o Mature slowly while attached to parent plant
o Eating quality cannot improve after harvest
o Low rates of respiration and ethylene production
o Application of ethylene has little effect – hasten

senescence changes
o Cherry, lychee, orange, lemon, lime
14
Fruit Processing
Fruits are eaten fresh, processed into canned, dried,
frozen, baked products, or converted into juice or jam
15
Fruit Processing
 Raw materials
o Must be the right variety, sound, ripe, free from
blemishes and disease
o Final product may have poor colour, texture and

flavour if it is unsuitable for heat processing
e.g. wrong variety, unripe
o Canner contracts with the grower for supply of fruits
o Variety, maturity, size, shape, colour, quantity,

delivery schedule, etc
16
Types of Local Bananas: Varieties
Cooking and
eating.
Favoured by Eating and
Most the cooking;
common in For curries For kueh Indian quick
supermarket and chips community maturation
Cavendish Plantains Kepok Kerala Lemak manis
Children Red fresh, King of

Plump n creamy Goreng pisang eaten flesh banana
snack
Mas Merah Rastani Berangan Raja
17
Fruit Processing
 Common upstream process steps for fruit processing
include:
o Reception and Storage
o Weighed to determine payment
o Inspected for spoilage or insect infestation at the time
of delivery
o Avoid contamination of other raw materials in the
plant
o Sampled and tested to comply with specifications
o Products often need to be stored due to temporary
oversupply
o 5-8°C chilled stores
18
Fruit Processing
Cleaning – two basic types
 Dry method / Wet method
 Methods employed depend on:
o the nature of the raw material
o the contaminants to be removed
o the desired condition of the cleaned material
19
Fruit Processing
Dry Cleaning
 Produces a dry cleaned surface
 Relatively inexpensive
 Screens – remove contaminants based on size

differences
 Aspirators – differing aerodynamic properties
 Magnets – remove metallic contaminants
20
Fruit Processing
Wet Cleaning
 Effective in removing adhering soil
 Detergents and sanitizers improve efficiency
 Treatment of effluent is expensive
 Passive soaking, agitation with propellers/paddles,

rotating drum, spray jets
21
Fruit Processing
Sorting by size
 Product size is a critical factor in the control of the
filling operation, and final product appearance
 Weight sorting
 More precise size separation
 Dimensional sorting
 Screens of various designs e.g. concentric drum

screens
22
Titan Farms new packing line can sort by color, defect, weight, and
dimension. (Photo credit: Webb’s Photography)
http://www.growingproduce.com/fruits/stone-fruit/technology-helping-to-
bring-that-fresh-picked-peach-to-consumers/
23
Cleaning and Sorting Machine
https://www.youtube.com/watch?v=vOSTje10Vss
(1 min: cleaning and classifying machine)
https://www.youtube.com/watch?v=YAUeQHghUUs
(3 mins: cleaning and packaging of apples)
24
Fruit Processing
 Peeling
o Hand peeling
o Mechanical
o Chemical
o Thermal shock (steam) peeling
o Flame peeling
https://www.youtube.com/watch?v=c_pw2dJHQRI
Peeling of pineapple, melon and papaya (7 mins) 25
Fruit Processing
 Mechanical peeling
o Cutting knives
 Fruit impaled and rotated against a knife that follows
the contour of the fruit
o Abrasion
 Surface of product ground away by rubbing against
carborundum surface
o Tends to be wasteful especially if the fruit has not

been carefully size-graded
26
Fruit Processing
 Chemical peeling
o Uses hot caustic solution to soften the skin
o Removes loosen skin with water jets or brushes
o 2-10 % lye (sodium hydroxide) for 1-2 mins at 80 °C

to boiling
o Consumes considerable quantities of water and

effluent is potentially polluting
https://www.youtube.com/watch?v=t4kbxHJ8X9E
(chemical and steam peeler,2 mins)
27
Fruit Processing
 Thermal shock (steam) peeling
o Uses steam to thermally shock the superficial layers
of the product to be peeled
o Depth dependent on the temperature and time of

exposure
o Followed by immediate and rapid cooling
o Skin removed by friction and/or water jet
o Needs large quantities of steam
28
Fruit Processing
 Flame peeling
o Product surface heated by infrared rays and by a row
of gas burners
o Brushed and rinsed to remove the charred layers
o Low peeling losses but great care needed to remove

charred skin
https://www.youtube.com/watch?v=EpOEY1rTdSo (1 min)
29
Fruit Processing
 Size reduction
o To obtain particles that can easily be packed into the
containers for canning
o To produce particles that have regular size and

shape to ensure uniform heat treatment
o To reduce preparation by consumers
30
Fruit Processing
 Blanching
o Modification of tissue structure
 Increases the flexibility of the product
 Facilitates packing into cans with minimum physical

damage
 Permits greater weight-to-volume ratio
o Removal of intercellular air and other gases

 Prevents product oxidation and corrosion to internal
surface of cans
31
Fruit Processing
 Reduction of microbial and chemical contamination
o Depends on the blanching method used, time and
temperature
o Hot water blanching has greatest reductions
 Enzyme inactivation
o Preserves colour of fruits containing anthocyanin
pigments by inactivating polyphenol oxidase
32
Fruit Processing
 Blanching – adverse effects
o Loss by dissolution
 Leaching of water soluble components e.g. vitamins,
sugars, colors
o Vitamin reduction
 Thermal degradation of vitamins e.g. ascorbic acid
33
Fruit Processing
Blanching Equipment:
 Water blanchers
o Simple in design, robust and least expensive
o Water flows counter-current to the product flow and

is continuously recycled
34
Water blanching
Advantages:
 Lower capital costs
 Better energy efficiency
Disadvantages:
 Loss of water soluble components
 Higher cost of water and disposal of effluent
 Risk of contamination
35
Fruit Processing
Blanching Equipment:
 Steam blanchers
o Steam tunnels using low-pressure steam
 Relatively inexpensive and easy to manufacture but
prone to temperature variations
o Hydrostatic tunnels using higher steam pressure

 Improves steam convection, blanching rate,
decreases steam loss, higher reduction in microbial
contamination
 More expensive and complicated to operate
36
Steam blanching
Advantages:
 Smaller loss of water soluble components
 Smaller volume of waste
 Lower disposal charges
 Easy to clean and sterilize
Disadvantages:
 Limited cleaning of food
 Higher capital costs
 Uneven blanching
 Some mass loss in food
 Poor energy efficiency 37
Blanching Water Atmospheric steam Under pressure steam
Products:
Cleaning effect great reduced reduced
Leaching great reduced reduced
Heat transfer v. good good v. good
Treatment uniformity good average v. good
Microbial contamination average weak nil
Fluid:
Temperature uniformity good average good
Water consumption large slight slight
Steam consumption large average slight
Effluent great reduced slight
38
Fruit Canning
Why can fruits?
Canning extends the availability of the product

throughout the year, contains little or no additives, do
not require lowered refrigeration temperatures, and
the product is ready-to-eat
39
Fruit Canning
Forms available in canned fruits:
 Whole – plums, prunes, cherries (pitted)
 Halves – peaches, apricots, pears
(pits, stones, core removed)
 Quarters – peaches, apricots, pears
 Sections – equal pieces obtained by dividing the fruit
into more than four parts (citrus)
 Slices – smaller than sections
 Pieces – may or may not have uniform size and shape
(cubes, broken slices)
 Crushed or ground –apple sauce, purees
40
Pineapple Canning
https://www.youtube.com/watch?v=ZYQW2B_vrfs ( 4 mins)
Source: http://hongkongmarketmaine.com/hong-kong-market-items/fruits-vegetables/
41
Fruit Canning
 Packing/Filling
o Place a specified quantity into a container e.g. weight,
number, volume
o Comply with legal standards e.g. drained weight, net

weight
 Manual filling
 Volumetric filling (for liquids, purees, juices, soups)
 Gravimetric (to validate manual or volumetric fill)
42
Fruit Canning
 Packing media (cover liquids)
o Fill all voids between solid pieces of product
o Facilitate dispersion of heat throughout the container

during thermal treatment
o Facilitate uniform incorporation of various permitted

additives
o Protect product against shock and injury during

transportation and handling
43
Fruit Canning
 Packing media (cover liquids)
o Water, sugar syrups, juices commonly used for fruits
o Combination of sucrose and glucose syrups have

advantages over sucrose alone:
1. Rheological properties can be maintained without

excessive sweetness
2. Physicochemical and organoleptic qualities can be
better maintained in glucose syrup
3. Favorable effect on the osmotic equilibrium between
the different constituents of the canned product
4. Prevent the flow of aromatic compounds from the fruit
to the syrup
5. Moderate the acid taste better than does sucrose
44
45
Fruit Canning
 Exhausting
o The process of removing air and entrapped gases from
the can before closing
o Creates “head space vacuum” – reduced internal

pressure after closure
o Prevents can ends from bulging during heat processing
o Reduces internal corrosion of can walls
o Prevents product oxidation
46
Fruit Canning
 Ways of creating head space vacuum:
o Fill packing media as hot as possible, >80 °C
o Preheat contents by raising the temperature using hot

water or steam
o Inject steam into the head space prior to closure
o Withdraw air from the head space in a vacuum

chamber
47
Fruit Canning
 Closing/seaming
o Cans are closed by placing the lid on the filled can and
sealing it to the body by the formation of a double seam
o Two operations:
 Can end seaming panel rolled together and interlocked
with the can body flange
 Seam is pressed to the required tightness
48
Can Seaming Operation
https://www.youtube.com/watch?v=yMgSGgiUO4A
49
Fruit Canning
 Retorting / processing
o Destruction of bacteria and spores by heat
o Heat is transferred from steam or pressurized water

into the food
50
Fruit Canning
Factors affecting rate of heat penetration:
1. Type of product – liquid or particulate foods heat faster
due to natural convection currents; solid
foods in which heat is transferred by
conduction heats slower
2. Size of the container – heat penetration to the center is

faster in small containers
3. Agitation of the container – increases the effectiveness

of natural convection currents
51
Fruit Canning
Factors affecting rate of heat penetration:
4. Temperature of the retort – higher temperature difference
between food and heating medium
causes faster heat penetration
5. Shape of the container - tall containers promote

convection currents
6. Type of container – faster in metal than through glass

or plastics
52
Fruit Canning
 Retorts
o Equipped to receive steam and water and has suitable
drain valves and vents
o Cans are loaded into cages and placed into the retort
and completely covered with the heating medium
o Batch retorts, continuous retorts, agitating cookers
Commercial sterility – heat processing that inactivates

substantially all microorganisms and spores which, if present,
would not be capable of growing in the food under defined
storage conditions
Absolute sterility is seldom achieved 53

54
Fruit Canning
https://www.youtube.com/watch?v=DDuj9ws-VLQ
https://www.youtube.com/watch?v=V2Prpr4GF_I
CANNED SARDINES (9 MINS)
55
FRUIT
CANNING:
F0
CALCULATION
D value
 When bacteria or spores are exposed to heat, they die
at an exponential rate
 This rate can be determined from a semi-log plot
 The time required to cross one log cycle is called the D

value (decimal reduction time)
Table 1. Survival of bacterial spores at different time intervals when subjected to 121°C
Tim e (m in) Spores/m l
0 800
10 190
20 27
30 6
40 1 57
1000
900
Number of surviving spores / ml
800
700
600
500
400
300
200
100
0
0 10 20 30 40 50
Time (min)
Figure 1. Survivor curve for spores
58
1000
100
Number of surviving spores / ml
10
0.1
0 10 20 30 40 50
0.01
D
Time (min)
Figure 2. Semi log plot of survivor spores versus time

59
D value
 The smaller the D value, the faster it indicates the rate
of destruction
o D = 14 mins ; D = 7 mins
o D = 14 mins; 2D = 28 mins;
3D = 42 mins; 12 D = 168 mins
o D95 ; D121 ; D135
60
Recap: Decimal Reduction Time
 The time taken for a 10-fold reduction in the number
of microorganisms at a specified temperature
100
10
D
Heating time, mins
61
62
z value
 Temperature range over which decimal reduction time
changes tenfold
za
D mins
100
10
zc
Temperature in 0C
63
z value
 Parameter to characterise the relative resistance of
microorganism to temperature
 The increase in temperature required for D to

decrease by one log cycle is called z
 z : thermal resistance
64
Example 1
A particular microorganism has a D121=14 mins and a
z value of 5 °C, what is the D value at 126 °C?
 At 121°C, it take 14 mins to decrease 1 log cycle of

the microbe (e.g. from 1000 to 100 cfu/g)

With a z value of 5 °C = every 5 °C increase in

temperature, we can reduce D by 1 log
D121= 14 mins D126= 1.4 mins

65
Example 2
A particular microorganism has a D121=14 mins and a
z value of 5 °C, what is the D value at 131 °C?

With a z value of 5 °C = every 5 °C increase in

temperature, we can reduce D by 1 log
D121= 14 mins D126= 1.4 mins D131= 0.14 mins
66
How to do it?
z= (T2 – T1) Given:
T2 = 126
log DT1 – log DT2 T1 = 121
z =5
z = (126 – 121) / log 14 – log DT2 DT2 = ?
DT1 = 14 mins
5 = 5 / log (14/DT2)
log (14/DT2) = 1
14/DT2 = 10
DT2 = 1.4 mins
67
Try this?
z = (T2 – T1) / log DT1 – log DT2
Given:
T2 = 131 ; T1 = 121 ; z = 10; DT2 = ? ; DT1 = 0.2 mins
z = ( 131 – 121 ) / log 0.2 – log DT2

10 = 10 /log (1.4/DT2)
log (0.2/DT2 )= 1
0.2/DT2 = 10
DT2 = 0.02 mins
68
Thermal Death Time, F
 The total time required to accomplish a stated
reduction in a population of vegetative cells or spores
 This time can be expressed as a multiple of D values
 A 99.99% reduction in microbial population would be

equivalent to four log-cycle reduction or F = 4D
 4 log cycle: % Reduction = Initial load – final load x 100 %

o 10 000 = 104 Initial load
o 1 000 = 103
% Reduction = 10 000 – 1 x 100 %
o 100 = 102 10 000
o 10 = 101 = 9 999 x 100 % = 99.99 %
o 1 = 100 10 000
69
Try this?
1 000 = 103
100 = 102
10 = 101
F = 2D. How many percent reduction is that?
(1 000 – 10)/1 000 X 100 % = 99 %
70
 Typical thermal death time in thermal processing of
shelf-stable foods is F = 12D with the D value for
Clostridium botulinum
o D121 = 0.2 mins
o z = 10 °C
71
 Thermal destruction of microorganisms takes place
logarithmically
 Therefore, a sterile product cannot be produced with

certainty
 The probability of survival can be predicted

o time and temperature of heating
o heat resistance of microorganism
72
 Spoilage probability
1 N0
 F D
r 10
r – total number of containers processed
N0 – initial population of spoilage microorganisms in each container
73
Example 3
Estimate the spoilage probability of a 2.4 mins process at
121 °C when D121 = 0.2 mins and the initial microbial
population is 105 per container.
5 5
1 N0 10 10 7
 F D  2.4 0.2  12  10
r 10 10 10
7
 r = 10
i.e.. spoilage of one container in 10,000,000 containers can

be expected
74
How to do it?
■ F = 12D = 2.4 mins @121 °C
 F = ? @140 °C
FR – known thermal death time
FR T  T R  z
 10 TR – known reference temperature
F
2 .4 140  121  10
 10  10 19 10
F
F = 1.8 seconds (0.03 mins)
75
• Find F at 131 0C
2.4 131121 10
 10  1010 10
F
F = 2.4/10 = 0.24 mins or 14.4 seconds
• Find F at 141 0C
2.4 141121 10
 10  10 20 10
F
F = 2.4/100 = 0.024 mins or 1.44 seconds
76
Try this?
■ F = 12D = 2.4 mins @121 °C
 F = ? @111 °C
FR T  T R  z
 10
F
2 .4 111  121  10  10 10
 10  10
F
F = 24 mins
77
 For reference purposes, a commonly used thermal
death time is written as F0
 Represents the time for a given reduction in

population of a microbial spore with a z value of
10 °C at 121 °C
Z 10
T F 121
78
What is Fo value?
 It is defined as the number of equivalent minutes of
heat processing at temperature 121.1 °C delivered to
a container or unit of product.
79
 Two processes that involve different times and
different temperatures can be converted to their
equivalent F0 for comparison:
FR T 121
10T TR  z F0  FT 10 z
F
T = temperature at which a process is performed

FT = time the temperature is applied , in minutes
80
Process Calculation
 A process with different times and different
temperatures can be converted to their equivalent F0
and can be added up to determine the lethal effect or
lethality of the process
 Lethality is the integrated impact of time and

temperature on the microbial population, expressed as
time at the reference temperature
T 121 z
F0  FT 10
F0  tT .10 T121 z
Lethal rate 81
82
Process Calculation
 Lethal rate – the proportion of the thermal death time
at temperature T to the thermal death time at a
reference temperature TR
 A plot of lethal rate versus time of process is a lethal

rate curve
 The area under the lethal rate curve is defined as the

lethality
83
Table 2. Thermal processing data obtained in a retort
Time (min) Temp Lethal Rate

10 43.3 1.7x10^-8
15 82.2 1.3x10^-4
20 101.7 0.011
25 111.1 0.1
30 116.1 0.32
35 118.3 0.53
40 120.0 0.77
45 120.6 0.88
50 112.8 0.15
55 91.1 0.001
84
F - SPOIL Version 2.5 (September 25, 2013)
CALCULATION OF F-VALUE, MICROBIAL SPOILAGE RATE, AND NUTRIENT

RETENTION FROM TIME-TEMPERATURE DATA, BY ADDITION OF LETHALITIES
Protected; no password HAS University of Applies Sciences; NL j.w.mrouweler@freeler.nl
For 4 worked examples of the use of this spreadsheet, and for its validation: see from row 205 onward.
yellow cell = input values blue cell = calculation results; equations
NB: If the product in the can is a SOLID, please calculate the spoilage rate twice:
** first use the total initial number of micro-organisms in the can; the resulting number of spoiled cans b1 will be too high;
** next use the initial number of micro-organisms in 1 gram; the resulting number of spoiled cans b2 will be too low.
The correct number of spoiled cans, so the CORRECT SPOILAGE RATE b of the SOLID product then will be: b2 < b < b1.
F: interval = 5 min. Constant interval between temperature measurements [in min.]
Tref = 121 oC Reference temperature for F-value [in oC]
z= 10 oC z-value for F-value [in oC]
Micro- D-value of m.o. = 0.2 min. D-value of micro-organism of concern [in min.]
organism Tref of m.o. = 121 oC Reference temperature for D of micro-organism [in oC]
of z of m.o. = 10 oC z-value for D-value of micro-organism [in oC]
concern: Initial number a = 100000 total per can Initial total number of micro-organisms of concern in can
Input: Calculation results:

Time Core Lethality F-value (F for Spoilage rate b
temperature T factor micro- after heating
(= min. at Tref. of organism) [= number of
[min.] [oC] 121 oC) [min.] surviving m.o. per can]

0 30 7.9433E-10 3.97164E-09 3.97164E-09 1.0000E+05
5 40 7.9433E-09 4.36881E-08 4.36881E-08 1.0000E+05
10 43 1.5849E-08 1.22933E-07 1.22933E-07 1.0000E+05
15 82 1.2589E-04 0.000629586 0.000629586 9.9278E+04
20 101 1.0000E-02 0.050629586 0.050629586 5.5828E+04
25 111 1.0000E-01 0.550629586 0.550629586 1.7654E+02
30 116 3.1623E-01 2.131768416 2.131768416 2.1936E-06
35 118 5.0119E-01 4.637704584 4.637704584 6.4785E-19
40 120 7.9433E-01 8.609345757 8.609345757 8.9799E-39
45 120.6 9.1201E-01 13.16939995 13.16939995 1.4223E-61
50 112 1.2589E-01 13.79886266 13.79886266 1.0132E-64
55 91 1.0000E-03 13.80386266 13.80386266 9.5650E-65
85
1
0.9
Unit Area
0.8
0.7
0.6
Lethal Rate
0.5
0.4
0.3
0.2
0.1
0
10 15 20 25 30 35 40 45 50 55
Time (min)
Figure 3. Plot of lethal rate versus time obtained during retort processing
86
Process Calculation
 To verify that a thermal process has achieved the
required F0
 To estimate the actual process time required to

achieve a target F0
87
Fruit-based Products
Other processed fruit-based products include:
 Fruit preserves e.g. jams, glazed fruits
 Dried fruits
 Fruit juices and concentrates
88
Fruit Preserve and Jams
U.S. Federal Standards
 A preserve is minimally 45 parts prepared fruit with 55
parts of sugar and is concentrated to 65 % or higher
solids
 Jellies are similar to preserves, with 45 parts of

clarified fruit juice and 55 parts of sugar resulting in a
minimum of 65 % solids
 Both can utilize a maximum of 25 % corn syrup for

sweetness, pectin and acid to obtain a gel texture
 21 CFR 150.160
89
Singapore Food Regulations
90
 Manufacture of Jams
o Four main ingredients, namely:
 Fruit: Fresh, concentrated, frozen and/or canned
 Pectin
 Nutritive carbohydrate sweeteners, Sugars
 Acids
o Other Optional ingredients

 Spice
 Buffering agents
 Preservatives
 Antifoaming agents
91
Prepared Prepared Sugar: Glucose Syrup Other
Fruit Pectin Sucrose Ingredients
Mixing
Boiling
Holding
Filling
Holding and
Dispatch
92
Preprocessing – Upstream fruit processing that include
harvesting, sorting/washing/cleaning,
peeling and slicing/cutting
Main stages in jam manufacture are:

 Blending of ingredients
o For consistency of product quality
o Critical ingredients like citric acid (pH adjustment) and volatile

flavouring may be added at later stage to prevent profile lost
 Evaporation of the mixed puree to desired total solid content
 Heat treatment to pasteurize products
 Can be done by simple atmospheric batch evaporation 93

New Processing Methods
1. Plate evaporation process
2. Vacuum batch process

http://www.fruitandvegetable.ucdavis.edu/files/217076.pdf
3. High pressure processing
94
Plate Evaporation Process
Processing Fruits Science & Technology by Barrett, Page 119 95

 Suitable for jam that do not have large particulates in
suspension
 Produces high quality product and good process

economy
 1st stage – involve mixing of all ingredients
 The premix then undergoes Paraflow plate heat

exchanger where the mix is heated by condensate and
steam
96
 2nd trimming stage of de-sulphiting may be required if
sulphited fruit pulp are used
 The hot mix is then fed into the plate evaporator which
is held under vacuum
o Involves rising and falling film-type evaporator where
the temperature of evaporation is about
60 to 65 ºC
 For some soft fruit, especially strawberries, preservation is
done with a mix of 6 % SO2 solution and calcium bisulphite
solution (containing also 6 % SO2).
97
 Concentrated jam and resulting vapour is then
discharged through a rectangle port to a snail shell
separator where the jam is separated from the vapour
 The concentrated jam is passed through a scraped

surface cooler
 Cooled jam is then transported to the buffer storage

prior to filling/packaging
98
Vacuum Batch Process
Processing Fruits Science & Technology by Barrett, Page 120 99

 Use for production of high-quality jams that contain fruit
pieces and/or whole fruits
 Various ingredients are weighed into a premix vessel

which is jacketed for preheating of the mix and
dissolution of the sugar
 Vessel is installed with a scraped surface agitator and

baffle for good heat transfer and rapid but gentle mixing
100
 Upon mixing of the ingredients, the premix is drawn
under vacuum into a vacuum cooking vessel
o Low-speed scraper agitator is installed in the cooking
vessel
o Rapid vacuum evaporator takes place at 60 to 65 ºC
 Evaporation is done at low temperature, thus,

preventing thermal degradation
101
 After evaporation, post-process pasteurisation is done
for jams of a wide rage of total solids with or without
preservatives
 The product is transferred to the buffer tank by top-

filtered air pressure prior to pumping to a flash-
pasteurizing scraped-surface heat exchanger for
pasteurisation
o Rapid pasteurisation take place at 85 to 95 ºC
 The pasteurised products is then filled and packaged
102
High-pressure treated fruit preserve and jam
 Provide fresh fruit jam that is of superior colour and
flavour
 Processed using high pressure (4000 to 6000 kg/cm2)
 Prevent over heating of product that help in preventing
nutritional lost e.g. Vitamin C
 However, refrigeration of jam is required due to
presence of residual enzymes
103
Fruit Drying
Fruits are characterized by:
 Very high moisture content
 High temperature sensitivity
 High susceptibility to microbial attack
o Apples Recalled for Potential Listeria Contamination
http://www.foodsafetynews.com/2012/08/apples-recalled-for-
potential-listeria-contamination/
 High sugar content
 Presence of skin
 Watch a video on fruits drying in a factory
https://www.youtube.com/watch?v=paDdBQYdjLU
104
https://www2.ca.uky.edu/enri/pubs/enri129.pdf 105
Fruit Drying
 Due to these, drying of fruits needs to be a very slow
process and it requires gentle drying conditions
 Drying changes the physical and biochemical form of

fruit, leading to shrinkage and change in colour, texture
and sensory qualities
 Fresh fruits undergoes pre-processing prior to drying
106
Fruit Drying
 Fruit may be dried as:
o Whole: e.g. grapes, berries, apricots
o Sliced form: e.g. banana, mango, papaya, kiwi
o Puree form: e.g. mango, apricot
o Leather or as powder
 Types of drier used depends on;

o Physical form of fruit
o Moisture content
107
Fruit Drying
Fruits
Whole Sliced Paste
*Spray
*Conveyor Belt Dryer
*Sun/solar Dryer *Drum
Drying *Freezer Dryer Dryer
*Tray Dryer *Solar
*Vacuum Dryer Dryer
108
Fruit Drying
Drying system for fruit include:
 Conventional hot-air drying
o Heat needed for drying is provided by convection with hot
air in contact with the product
o Common dryers are: kiln, cabinet, tunnel and continuous

belt dryers
109
Fruit Drying
Kiln dryer
 An oven heated by gas burners in which the product is
placed in slotted trays
 Batch process
 Takes about 6 to 8 hours to dry a batch of slices or

rings of apples to a moisture content of 14 to 40 %
110
Fruit Drying
111
Fruit Drying
Cabinet dryer
 Batch process
 Forced flow of air is passed through the trays where the

fruit is placed
 Air is heated indirectly by steam coils upon entering the

cabinet
 Suitable for small scale operation
 Labor cost is high
 Low thermal efficiency 112

Fruit Drying
Tunnel dryer
 Most common for the drying of fruits
 Trays move along a tunnel in which hot air flows parallel

or counter flow to the fruits
 Can handles larger production rates
 e.g. apricots, peaches, pears, apples, dates, etc
113
Fruit Drying
Continuous belt dryer
 It consist of an endless (permeable or impermeable)
belt on which the product to be dried is placed and
carried through a counter- or co-current flow of hot air
 Automatic continuous operation with minimal labor

requirements
114
Fruit Drying
Other drying system for fruit include:
 Solar drying – use of solar energy
 Microwave drying – use of microwave energy
 Osmotic dehydration – involves the use of concentrated

sugar solution
 Explosion puffing – incorporate explosion puffing in hot

air drying
 Freeze-drying – heating a frozen product in vacuum.
115
Freeze Drying
https://www.youtube.com/watch?v=jNNtJrX7TX8 (2.5 mins)
https://www.youtube.com/watch?v=cKvQaoxfyk0 (2.5 mins)
116
Fruit Juices and Concentrates
Juice production
 Process starts with freshly harvest sound fruit
 Washed – to remove dirt and foreign objects
 Sorting – to remove decayed and mouldy fruit so as to

reduce microbial load of the final juice produced
 Prior to extraction stage, preparation steps like pitting

and grinding may be necessary for some fruits
117
Juice production
 Extraction – By pressing or enzymatic treatment
 Decanting
 The extracted juice is then treated to achieve the

desired characteristics of the final product
 Watch a video on Apple Juice

https://www.youtube.com/watch?v=sb4bhgXKp_U (4 mins)
118
Juice production
 For cloudy juices, clarification may be done
o Coarse filtration or controlled centrifugation process to
remove larger insoluble particles
 For clear juices, complete depectinization is carried out

 Addition of enzymes, fine filtration and/or high speed
centrifugation to achieve visual clarity
 Heat treatment – To achieve safe and stable juice
 Packaging
119
For juice concentrate production
 Juice is fed to an evaporator
o To remove excessive water until the desired
concentration level is obtained
o Other concentrating method may include reverse

osmosis and freeze concentration which is used for heat-
sensitive juices
 Concentrated juice is then heat-treated, packaged and

stored
120
Fruit (Fresh or thawed)
Cleaning/Washing
Sorting/Culling
Preparation for extraction

(pitting, Crushing, heating, enzymatic treatment)
121
Juice Extraction (Pressing, Decanting)
Cloudy Juice Clarification

(coarse Filtering, centrifuging) (Depectinizing, centrifuging, filtering)
Concentration
Pasteurization, Cooling (evaporation, reverse osmosis, freeze-
concentration)
Filling, Labelling & Storage Pasteurization, Cooling

Single Strength Juice
Filling, Labelling & Storage

Juice Concentrate
122
Summary
 Name the different types of fruit-based products
 Describe the processing technology for the production

of
o Fruit Jams
o Dried Fruits
o Fruit Juices & Concentrate
123
References
 Arthey, D. and Ashurst, P. R. (2001). Fruit Processing:
Nutrition, Products and Quality Management. USA:
ASPEN
 Barrett, D. M., Somogyi, L., Ramaswamy, H. (2005).

Processing Fruits: Science and Technology. (2nd
Edition). Florida: CRC Press
 Jongen, W. (2002). Fruit and vegetable processing:

Improving quality. Florida: CRC Press
124

FPPKG Lec 4 Fruit Processing AY19-20 S

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TOPIC 5:

Food Processing and Packaging AY19/20, Oct Sem

■ Are these fruits?

o Cucumber, Pumpkin, egg plants, tomato

 Similarities in fruit type

o Stone fruits (apricot, cherry, nectarine, peach, plum)

o Citrus fruits (orange, lemon, mandarin, grapefruit)

o Berries (blueberries, cranberries, strawberries)

o The tropics are warm, year-round, and they are also

o Has acceptable eating quality at the time of harvest

o Can be mature but unripe

o Bananas, kiwi, avocados

o Involves physiological transformation of the fruit

o In fruits that ripen after harvest, starch or organic

o Ripeness is attained when biochemical changes

o Increase in respiration rate, heat evolution and often

o Fruit softens and develops flavour and aroma

o Can be induced to ripen by treating with ethylene

o Apple, avocado, banana, peach, mango

o Mature slowly while attached to parent plant

o Eating quality cannot improve after harvest

o Low rates of respiration and ethylene production

o Application of ethylene has little effect – hasten

o Cherry, lychee, orange, lemon, lime

o Final product may have poor colour, texture and

o Canner contracts with the grower for supply of fruits

o Variety, maturity, size, shape, colour, quantity,

Children Red fresh, King of

 Methods employed depend on:

o the nature of the raw material

o the contaminants to be removed

o the desired condition of the cleaned material

 Screens – remove contaminants based on size

 Aspirators – differing aerodynamic properties

 Magnets – remove metallic contaminants

 Detergents and sanitizers improve efficiency

 Treatment of effluent is expensive

 Passive soaking, agitation with propellers/paddles,

 More precise size separation

 Screens of various designs e.g. concentric drum

o Thermal shock (steam) peeling

o Tends to be wasteful especially if the fruit has not

o Removes loosen skin with water jets or brushes

o 2-10 % lye (sodium hydroxide) for 1-2 mins at 80 °C

o Consumes considerable quantities of water and

o Depth dependent on the temperature and time of

o Followed by immediate and rapid cooling

o Skin removed by friction and/or water jet

o Needs large quantities of steam

o Brushed and rinsed to remove the charred layers

o Low peeling losses but great care needed to remove

o To produce particles that have regular size and

o To reduce preparation by consumers

 Facilitates packing into cans with minimum physical

 Permits greater weight-to-volume ratio

o Removal of intercellular air and other gases

o Hot water blanching has greatest reductions

o Water flows counter-current to the product flow and

o Hydrostatic tunnels using higher steam pressure

 More expensive and complicated to operate

Canning extends the availability of the product

o Comply with legal standards e.g. drained weight, net