Process development in the fruit and vegetable industry II

1. Citrus processing Processing plant overview: Orange processing plants are located in the vicinity of the fruit growing area. Fruit should be processed as soon as possible after harvesting because fruit deteriorates quickly at the high temperatures found in citrus growing areas. In the orange industry the basic unit of reporting crop and plant intake is commonly the fruit box: A box of oranges is defined as containing 40.8 kg (90 lb) of fruit In Florida small/ medium size plants typically process 5-10 Mill boxes ( 200-400 000 tonnes) large plants up to 25 Mill boxes Citrusuco, Matao, Brasil ( 60 Mill boxes (2.4 Mill Tonnes) per season, Orange juice as defined is the unfermented juice obtained from mature oranges of species citrus sinensis. Brix /acid ratio is used as an indicator for citrus maturity which is the ratio of the degrees Brix to percent acid as anhydrous citric acid.( min 8) Fruit reception: Fruit is delivered in trucks ,20 tons capacity. The fruit may be prewashed to get rid of immediate surface dirt and pesticide residue before any leaves and stem still attached are removed. Then follows pregrading by manual inspection to remove any unsuitable fruit. Sound fruit is conveyed to storage bins. Prewashing and washing, soaking and brushing water average 30-50 gal/ton: roller conveyor

Sample: A sample of fruit s taken for analysis from each truck ( juice yield, Brix, acidity, colour) Storage: bins with inclined (schrg abfallend) multilevel internal baffers, to prevent too much weight pressing on fruit. Up to 24 hours. Extraction Extraction involves squeezing or reaming juice out of either whole or halved oranges by means of mechanical pressure. After final washing and inspection the fruit is separated according to size into different streams or lanes. Individual oranges are directed to the most suitable extractor in order to achieve optimum juice yield and quality, correct setting of extractor operating conditions is very important. The aim of the juice extraction process is to obtain as much juice of the fruit as possible while preventing rag, oil and other components of the fruit from entering the juice. These may lead to bitterness in taste or other defects later during juice storage. Fruit sizing: rotating rollers the distance between the rollers is pre-set an increases as he fruit travels over the table. Over the first set of rollers the smallest fruit drop between the gap onto a conveyor which carries them to an extractor for their particular size. Normally 2-3 different sizes in an extractor line. A well functioning fruit sizer is essential to producing juice of high quality and or yield. If the fruit is too big or small, then it will be oversqueezed and excessive rag or peel will get into the juicebitterness. If the fruit is undersqueezed, insufficient yield will result. Three streams result from the extraction section: Oil emulsion Wet peel Pulpy juice Extractor Types: Two types dominate in orange processing The squeezer type ( brand:FMC) and the reamer type (Brown)
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Globally squezzer type extractors are the most common. Another type of extraction equipment is the rotary press extractor.( popular in the Mediterranean area) With rotary press extractors the fruit is cut in half and the halves pass between rotating cylinders which press out the juice. Oil is extracted from the peel in a separate step prior to extraction both juice and yield are less optimal compared with the other extractors. The Squeezer Type extractor: These are placed in lines with up to 15 extractors per line. Each extractor may be fitted with 5 heads which are available in different sizes so that they can handle the type and quality of fruit available. (Sizes 2 3/8 ; 3;4;5 inches) The extractor separates the fruit in four parts: Pulpy juice, peel core (rag, seeds and pulp) and oil emulsion The head of the extractor comprises an upper and a lower cup. The cups have metal fingers that mesh together as the upper cup is lowered onto the lower cup. A cutter comes op through the centre of the lower cup to cut a hole through the skin in order to allow the inner parts of the oranges to flow out. The only peel that goes inside the strainer tube is the oneinch diameter plug that is cut at the start of the juicing cycle. The cutter is part of a perforated strainer tube, sometimes referred to as the prefinisher. Once the strainer tube has cut into the fruit, the upper cup squeezes down on the lower cup. This pressure initially forces the juice to burst out of the juice vesicles and pass through the perforations of the strainer tube. The downward pressure of the upper cup causes the peel to break up, disintegrate and pass up through the fingers of each cup. Juice flows through the strainer tube in the juice manifold. The core material is discharged from the bottom of the strainer tube through the orifice tube. As the peel is forced through the fingers of the cup during the last step of the extraction cycle, oil is released from the peel. This oil is discharged from the extractors as an emulsion with water. The throughput of a five finger extractor will vary according to the quality and the size of fruit. The standard operating is 500 oranges per minute. (90% cups filled)-5 tonnes /hr of fruit per extractor corresponding to 2500 L/hr of juice.
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The machine is highly automated and the cost is high. It can by cleaned in place. Modifications for premium pulp: As pulpy juices passes through the holes in the strainer tube in the standard extractor, the pulp tend to be broken up into small pieces, typically 2-3 mm in length or less. This is acceptable if the pulp is intended for pulp wash and as commercial pulp for certain markets. Market demands in the juice market are changing and the need for more natural pulp that has been subjected to less shear is increasing. In a squeezer type extr. Of modified design, larger pulp pieces up to 15 20 mm long flow along with the juice stream. The main difference in design is the use of a modified strainer tube with a larger openings which allow more pulp to remain in the juice stream. The pulp is subsequently separated from the juice and treated in a modified pulp recovery system. Premium juice flow oil extractor Certain fruit varieties will express more oil into the juice stream than other varieties. (Valencia) This can lead to oil content in the juice exceeding acceptable levels ( such as 0.035 %, the maximum level permitted for Florida grade A) . In the low oil version of the squeezer type the design of the strainer tube and the orifice tube area are modified. This units cuts a smaller core and puts less pressure on the fruit during extraction, thereby reducing the amount of peel oil getting into the juice what may also lead to a reduction in juice yield. As an alternative hermetic centrifuges or vacuum flashing can be used for deoiling. This allows a higher juice yield to be maintained during extraction, while excess oil is removed after the extraction process. The reamer type extractor: Fruit is fed into the feed wheel and cut in half. The halves are oriented and picked up in synthetic rubber cups mounted on a continuous belt system. A series of nylon reamers are mounted on a rotating turntable. The reamers, in the vertical plane for most models enter each fruit half and rotate as they penetrate them. The speed of rotation varies as the reamer penetrates the fruit being slower towards the end of the operation. Juice ,pulp, rag and seeds pass out through one outlet, and the peel segment
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passes out through the peel chute.(Rutsche). The juice and the pulp are separated from the rag and seeds by a strainer, then pass on the finishers. The size, pressure and rotation speed on the reamer can be adjusted to suit the maturity, size and quality of fruit. The reamer type systems typically gives a better quality of pulp and standard squeezer type extractors. Juice yields are comparable. The oil extraction system Peel oil can be recovered from the peel using a separate oil extraction system which is placed upstream of the juice extractors. It operates on the principles of puncturing oil sacs in the flavedo and washing the oil out to make an emulsion. The juice streams leaving either a squeezer type extractor or reamer type extractor system flow to clarification and the evaporation, or pasteurisation if the end product is NFC. The oil emulsion flows to peel oil recovery for separation by centrifugation. Peel, rag, seeds and other solid material are conveyed to the feed mill. The juice leaving the extraction process is clarified as it contains too much pulp and membrane material to be processed in the evaporator or as NFC.Pulp levels from extractors are generally around 20-25% of floating and sinking pulp. The juice is therefore finished ,that is, pulp is removed from the juice. A finisher is basically a cylindrical sieving screen. There a two types of finisher screw type and paddle. Screw type: Stainless steel screw that conveys the pulpy juice through the unit and presses the pulp against the cylindrical screen. A pulp is discharged through a restricted opening, the resulting backpressure in finisher helps to squeeze out more juice from the pulp mass. Paddle finisher These incorporate a set of paddles rotating on a central shaft within the cylinder. P.F. apply centrifugal force rather than pressure to separate the pulp from the juice. This usually provides gentler pulp treatment than screw finishers.

Two finishers are often placed in series at the end of the extraction line. Typically the pulp content in juice leaving the secondary finisher is about 12%. This pulp is predominately sinking pulp. If the market requires a juice with lower sinking pulp content the juice can be further clarified by centrifugation. Clarification After extraction the pulpy juice ( about 50% of the fruit) is clarified by primary finishers which separate juice from the pulp. The finishing process is a mechanical separation method based on sieving. The juice stream is further clarified by centrifugation. The pulp stream, containing pieces of ruptured juice sacs and segment walls, may go to pulp recovery or to pulp washing. A two phase clarifier is normally used ,if the juice is to be deoiled a three phase centrifuge can be used to lower the pulp content and to some extent deoil the juice. Separation in a disc stack centrifuge takes place in the space created between a number of conical discs stacked on top of each other to provide a large separation area. Most models rotate at 4000-10 000 rpm. Clarification often leads to improved operation of the evaporator system by providing consistent pulp levels in the juice. After clarification the juice undergoes some degree of blending with juice from other batches in order to balance its flavour, colour and acidity and Brix level. If intended for NFC the juice leaving the clarification section should be cooled to 4 C to minimise the potential of microbiological activity before being passed into the buffer/ blending tank. Frozen concentrated orange juice (FCOJ) From buffer /blending tanks and after clarification juice goes to the evaporator. Within the evaporator circuit the juice is first preheated and held at pasteurisation temperature. It then passes through the evaporator stages, where it is concentrated up to 65 Bx. During the evaporation process volatile flavour components flash off and can be recovered in an essence recovery unit.
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Juice concentrate is cooled and blended . It then goes to froze storage in tanks or drums as FCOJ. Globally most orange juice is produced as concentrate. Currently the most widely used citrus evaporators are of tubular design, which can handle very large flow rates. For small and medium volumes plate evaporators are installed. Not from concentrate juice (NFC) production Instead of concentrate production, juice may be processed at single strength as an NFC product. Clarified juice is pasteurised before storage. Deoiling may be required to reduce oil levels in the juice and deaeration to remove oxygen is part of good manufacturing practice. Pulp production For pulp recovery, seeds and rag are removed from pulpy juice from the extractor. The juice is then concentrated in finisher .and evaporator and stored frozen. Pulp wash If the pulp fraction is not recovered for commercial sale, pulp from the final juice finishers and clarifiers can be washed with water to recover juice solubles. This stream is called pulp wash and may, legislation permitting, be blended with juice concentrate. Pulp wash production Pulp washing is carried out to recover juice solubles in pulp coming from the juice finisher and from the centrifuges in the clarification or deoiling process. Thorough pulp washing can increase the total yield of soluble solids by 4-7 %, which contributes significantly to overall plant economics. The juice sugars are gained by a counter-current washing system. The pulp/water slurry is strained through a finisher between the washing stages and the separated juice is called pulp wash. The pulp stream is concentraded by evaporation. IT is added back to concentrated orange juice if law permits or used as a base for juice drinks. Adding back of pulp wash to orange juice
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concentrate is allowed in Brazil In Florida up to 5% pulp wash may be added to concentrate. EU regulations do not allow a product that contains pulp wash to be called orange juice. Pulp washes which has been debittered is , however very difficult to detect in the juice product. Water extracted soluble solids (WESOS) is a well established practice in the citrus industry(Brazil, US) but not in Italy. For the production of WESOS tow consecutive operations are conducted in each of the working stages: A pulp/water mixing operation and a liquor/pulp separating operation. The mixing operation has traditionally been conducted by a mixing screw or by a agitator in tank, but also with static mixers. Finishers are used to separate he liquor from the pulp in all stages and product quality requirement will dictate the pressure to use in each stage. The final step in WESOS recovery can be: Restoration of WESOS to the primary juice stream in line The individualised treatment of WESOS in another evaporator system to give a pulpwash product (out line process). The definition of WESOS is : The simultaneous washing of the pulp from the primary juice stream and the proportional restoration of the primary juice trapped in the juice vesicles to the primary juice stream before the evaporator without further treatment. In order to safeguard the good image of orange juice and to avoid negative comments fruit processors are strongly recommende to comply with the following conditions: The water for extraction of the juice solids from the pulp must be coming from the evaporator (fruit own water) for the following reasons: Sufficiently available World wide the same No chance of contamination

The temperature of the water from the evaporator must be max. 30 C but preferably for the following reason Better sensory product Enzymation and debittering as well as other non physical processes must be excluded during the in-line water extraction process: To keep a continuous and uninterrupted WESOS process To avoid over-proportional adding back of extracted solids and /or solids extracted from other parts of the fruit. Debittering Pulp wash is high in limonin, which causes bitterness. Consequently , non treated pulpwash has limited use as add back into high quality juice drinks. However, the bitter taste can be removed by a debittering process involving ultrafiltration and adsorbing separated bitter components onto the resin out of the clear serum. Processing at the juice packer Reconstitution of the concentrate involves diluting one or a mix of different concentrates with water to the right Brix level. The more accurate the blending process the greater the costsavings achieved. In-line continuous blending offers advantages in certain respects compared with batch blending. Capacities of juice packing facilities vary greatly-from small plants producing 5000 l/hr packaged juice to large plants with an output exceeding 150 000 l/hr. The Brix value of the reconstituted juice is the key parameter for blending operation. Appropriate regulations stipulate minimum concentration of soluble solids for reconstituted juice. The EU demands a minimum value of 11.2 Brix for orange juice made from concentrate (US 11.8 Bx) The Brix value is measured by a refractometer and corrected for temperature and also for acid content for concentrates. A calculation example is shown below:

Quantity of concentrate needed to make 1litre juice Basis Final juice: Concentrate: 11.2 Bx 65 Bx, corrected

Calculation: Juice of 11.2 Brix has a specific gravity of approx. 1.045 kg/L. In other words 1 litre juice at 20C weighs 1045 grams 1litre final juice of 11.2 Bx contains 1045 x 11.2 / 100= 117 grams soluble solids 1 kg concentrate of 65 Bx contains 1000 x 65/100= 650 grams soluble solids. Result to prepare 1 litre of juice you therefore need Concentrate: 117/ 650 x1000 = 180 g Water: 1045 180 = 865 g These values are approximate because juice is not a pure sugar solution! Example of savings in Raw material Blending the final juice 0.1Bx closer to the minimum specification correspnds to the following annual savings Basis: Line capacity: Daily production: Operatating days: Annual production : Final juice (min.conc.) Cost of raw material: Orange concentrate 65Bx 20 000 l/h 10 h/ day 200 days / year 42 000 tonnes juice 11.25 Bx 1300 $ / tonne

Savings: A reducion by o.1 Bx , e.g. from 11.35 to 11.25 Bx gives a reduction in raw material consumption of 0.1 Bx /11.35Bx= 0.9 % Annual savings in concentrate will be:
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42 000 x 0.1 Bx/ 65 Bx= 65 tonnes equal to a value of 84000$ !!! To supply products at competitive prices requires cost-effective operation. High energy recovery that reduces heating and cooling costs and minimising product losses in the plant are two major ways of reducing waste from cleaning procedures these measures also minimise the impact on the environment. Consideration must be given to the fact that fruit juices differ in viscosity and often contain particles (pulp). For both aseptic products and non aseptic filled chilled products with long shell life, high hygiene standards and safety measures are applied to the pasteurisation process and downstream equipment in order to prevent any microbiological recontamination of the product. Process lines: Concentrate storage and preparation Concentrate in tank cars (<0C);drum are warmed before the concentrate is pumped out. Water treatment. Depends on the quality of water supply-Treatment methods sand filtration to remove insoluble solids, active carbon filtration to remove colour, and membrane filtration to reduce dissolved salts and organic matter. Ion exchange techniques may be used to soften the water or reduce its alkalinity. Batch blending The reconstitution step is carried out batchwise or water and concentrate and other ingredients are fed continuously to the inline blending system and mixed . Pasteurisation and deaeration In the pasteuriser juice is heated in plate or tubular heat exchangers. Free air and dissolved oxygen are removed from the juice in a deaerator.

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Peel oil recovery Recovered peel oil represents some 0.3% of the fruit intake. The emulsion of oil and water coming from the extractor section is clarified by centrifugation in two steps. The purified oil contains dissolved waxes which are removed by winterisation (refrigeration) of the oil for a certain time. Feed mill Rejected fruit from grading peel and rag from extraction and washed pulp and other solid waste are sent to feed mil where it is dried an pelletised for animal feed.

2. Apple processing The development of apple processing lines are based on mechanical press- es, flitration, decanters counter current extraction and enzyme treatment. Processing lines: Apples are washed with brush or air stream washers. Vertical transport is done by screw elevators. The ash is produced by grinding mills to give a optimal structure required for pressing. The mash is treated with pectinolytic enzymes to increase the juice yield. The juice is extracted either with a belt pressing system, a Bucher hydraulic press or a decanter centrifuge. Two belt presses with pomace extraction are examples of a concept using a combined pressing-extraction procedure. The amount of extraction water added is important for the yield an the economy of the process, because the added water has to be evaporated in producing a juice concentrate. For all technologies yield increase leads to lower costs and is still economical even at higher expenditure. Combined pressing extraction procedures are the cheapest procedures

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Mash enzymation is economically important because it increases the yield. However enzyme costs amount to about 1/3 of the profits gained from the higher yields. To produce clear apple juice and clear juice concentrate several processes may be employed: Physical process settling, centrifugation, filtration Biochemical processes: enzymes Chemical processes: fining Cloudy or turbid juices are a complex colloidal system containing molecules in solution as well as in particulate suspension. Particles are retained in suspension by mutual charge repulsion and by colloidal stabilising polysaccharides, such as pectins, starch and gums. Large particles up to 100-500 m settle out rapidly and other coarse dispersion material may be recovered by centrifugation or filtration. However it may be difficult or impossible to remove colloidal dispersion material in the size range 0.001-0.1m by these procedures. The application of fining agents with prior enzymatic juice treatment is usually essential for the removal of these colloidally dispersed haze forming compounds and particles. Juice enzymatic treatment is necessary to reduce viscosity and remove compounds which limit filtration rates, block filters and have the tendency to form hazes and sediments during the storage of the clarified juice. To avoid such haze formation the following is important: Enzymatic hydrolysis of pectin should have progressed until a negative alcohol test is obtained. The correct application of gelatine and silica sol in combination with bentonite, this results in a rapid settling and compacting of the lees. Avoid retrogradation of starch and enzymatic degradation with amyloglucosidase and amylase until a negative iodine test is obtained for starch dextrins. The above mentioned applications are the most common used fining agents. There are others which have complementary or specific applications in juice treatment. PVPP (Polyvinylpyrollidone.) adsorption of polyphenols that may contribute to browning in juices.

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In the production of clear apple juice filtration is an important step. The separation of particles can be basically accomplished by 1. kieselguhr filters with sludge frames 2. cloth filters (chamber filter press) 3. horizontal pressure leaf filter 4. rotary vacuum filters 5. sheet filters 6. membrane filters 7. ultrafiltration, cross flow filtration Ultrafiltration is a mechanical separation process wherein particles are rejected and concentrated by a membrane (cut of 5000-200 000 MW).Low molecular weight components pass through the membrane(clear juice) and the haze and suspended solids are concentrated. Ultrafiltration membranes are available in several configurations For fruit juice clarification flat sheet membranes, hollow fibre and tubular membranes are used. Membranes differ in life time and in the prefiltration requirements to prevent plugging of the membranes. In the traditional process juice is coming from the press and is aromastripped. Afterwards gelatine treatment together with enzyme addition for depectinisation and starch degradation is performed in process tanks. Prior to final concentration a dwell period of 2-5 hrs is required before the juice can be preclarified by centrifugation and filtration. After concentration in a multi effect evaporator the clear concentrate is ready to be stored. It may know be rediluted flavoured with aroma sterile filtered, hot or cold filled or aseptically filled in carton. With ultrafiltration as clarification method this process is considerably simplified. By use of UF juice from the aroma recovery is treated with enzymes in a process tank at 50-55C. After an average dwell period of 1 hr the juice is fed to the UF. The clear juice running of the membrane is evaporated to produce 70 Bx concentrate. The haze is enriched by 98%. Cleaning of ultrafiltration membranes is crucial. Both lye and acidic detergents and disinfection are applicated for membrane cleaning, special enzyme preparations are common to regenerate

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the membrane and to achieve the starting capacity(usually with water) 3. Berry fruit processing One of the common characteristics of these kind of fruits is that they are soft, of small size and are carrier of anthocyanin pigments and an with few exceptions attractive flavour. Juice production from berry fruits involves identical operations like the above mentioned such as thermal treatment, use of enzymes and juice extraction. Raw material is either delivered fresh or frozen. Depending on the sate of the delivery to the processing plant they are usually not washed . In some cases it is necessary to detach the stems ( like cherries).The fruit is disintegrated by roller mills. Use of pectolytic enzyme preparations has been generally accepted. (reaction tanks stirred,1-2hrs) To protect the fruit mash against oxidation and to minimise the influence of micro-organisms the mash is heat treated prior to enzymation in tubular heat exchangers up to 80C. Selecting a system for separating juice from the insoluble solids: belt press systems hydraulic press mechanical horizontal basket press mechanical pneumatic press continuous screw press decanter All presses are suitable for obtaining juice from berry fruits. When juice is obtained by pressing the pomace or cake from the press is sometimes extracted with water and subjected to repeated pressing to achieve a greater juice yield. For the production of grape juice this is not permitted according to the EU fruit juice directive. Juice clarification include the treatment of pectolytic enzymes ,fining agents such as gelatin, kieselsol, bentonite, PVPP. Treatment with pectolytic enzymes for purpose of juice
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clarification is directed primarily towards reducing the systems viscosity by decomposing pectin. The juice is thereafter clarified with centrifugation to separate from the lees. The final processing consist of filtration by DE filtration or sheet filtration. Juice concentration by evaporation is associated with the processes of aroma recovery and concentration. Research has shown that a relative high percentage of juice evaporation is required for successful aroma recovery in the berry fruits.(20-40 % currants and cherries 80 % strawberries) Due to the high amount of acidity and the low sugar content which is typically found in berry fruits it is necessary to corrected by the addition of water and sugar to produce a pleasant taste with a harmonic acid sugar ratio. These additions must be declared in accordance with the regulations of the fruit juice directive. Due to their distinct aroma and pleasant taste berry fruit juices are often mixed with juices made from other kinds of fruit especially with a less marked aroma. 4. Exotic fruit processing (mango, banana, pineapple) Mango: The mango is native to South and Southeast Asia. It is one of the most important tropical and subtropical fruits in terms of production ,acreage and popularity. The largest production is in India. Mangoes are climacteric. The usually are harvested in a mature but unripe stage. The are not allowed to ripe on the tree. Tree ripe mangoes are inferior in taste, aroma and keeping quality to those ripen after harvest. In Mango fruit that is good for processing the flesh must be of good taste, colour and flavour and without a terpeney door. The peel constitutes a significant portion of the fruit. The peel may weight 6.5-25% of the fresh fruit, while the edible pulp or flesh is 32-85%. Although there exists indication not to peel before pulp production it is highly recommended. Mangoes should be thoroughly washed to remove dirt. (soaker washer with warm
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water, brushes and chlorine 20-60 ppm followed by a rinse washer. Hand or lye peeling.(only with thin peel) sodium 20% and wetting agent sodium lauryl sulfate. Freeze peeling expensive Hot water or steam peeling 90C 5 min or steam 2-3 min. Pulping: Paddle pulper is used Puree yields depend very much on the thickness of the peel and the size of the seed. (~70% of the fruit weight) The use of enzymes during pulping may improve juice yields. The pH of mango flesh can be low as 2.6 and as high as 5.8.It is advisable to lower the pH of puree to below 4 by adding citric acid before heat treatment. Before heat treatment deaeration is recommended (<1ppm O2) for example 92 C for 2 min. (scarped surface heat exchangers. Aseptic packaging or deep freeze storage around 18C. Mango nectar can be made either directly from fresh mango fruit or from mango puree which has been conventionally canned aseptically packed or pasteurised and frozen. A typical mango nectar is one with 20-30% puree, 12-13 Bx, (sugar added) pH around 3.5 and acidity 0.2-0.3%. The ingredient of the recipe are thoroughly mixed (power stirrer or homogenised) and after thermal processing filled into cans ,glass or aseptically packed in cartons. Juice concentration is possible ( serum pulp process) Pineapple: Today pine apple juice ranks fourth on the juices consumed in the US after oranges apple and grapefruit. Thailand is the words largest canned exporter in. (Philippines, US, Malaysia)Thailand continued to be the worlds leading producer of pineapple juice concentrate. (Brazil) There are two basic types of processing plants currently used to produce single strength and concentrated pineapple juice. A: fresh fruit that do not pass quality specifications such as overripe are diverted to the processing plant for production of single strength juice or concentrate B: This operation is canned fruit oriented consisting basically of canning solid pack pineapple products. Juice is a by product.
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The juice processing in A is typically simpler than in B. The fruits processed by GINACA (henry Gianaca 1913) deliver parts of the fruit that are processed top juice such as core, meat between fruit and shell and fruit cylinder and the top and bottom of the fruit. Speed of Gianaca depends on size 56/min large 96 small size) Juice is collected from the slicing and trimming operation. Small fruit may be extracted in a PINE-O-MAT. The fruit is cut into halves and are fed to an extraction drum. The extraction drum draws the fruit into a contracting chamber between the extraction drum and a perforated grid. The meat is sheared and pressed from the shell. Pineapple juice may be extracted from fruit pieces using multistage screw press to maximise recovery to about 90%. Juices from liquid sources and solid fruit constituents are blended with agitation in tanks, to which up to 10pp anti foam may be added to reduce foaming due to the presence of gums. Preheating (60C in plate or tubular exchangers) Centrifugation Should guarantee an content of 5-30% of insoluble solids.These suspended solids are important to the mouthfeel and improve the flavour. Single strength juice may be further processed: Hot filled into cans Cold filling Aseptic process. HTST and aseptical filling Concentrate: multiple effect plate or tube. Essence is separated in the first effects for optimal quality and added back to the final concentrate. Concentrate is produced as 61 to up to 72 Bx. The concentrates are packed both aseptic and frozen. Heat resistant spore forming moulds Bysochlamys fulva. Quality standards: Single strength juice is covered by the voluntary FAO/WHO codex alimentarius and the AIJN code of practice To insure that minimum standards are met for a production lot the following checks are necessary: 1. Brix 2. pH 3. Total acidity
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4. Insoluble solids 5. Colour 6. Flavour 7. Mould count 8. Vit. C content 9. Dimethylpolysiloxane content 10. % added sweetener 11. processing parameters Banana: The production of banana puree is rather difficult and is seldom used for the production of beverages. Lately the production of puree increased in the US and in Europe. Problems concerning the processing of banana arise from The action polyphenol oxidase causes an instant browning of the fruit after peeling. This may be overcome by the instant steam treatment or the use of ascorbic acid or sulphuric acid. Banana show a high pH (5) and require sterilisation or the addition of citric acid to lower the pH to 4.0. Banana essence is heat sensible. The HTST is recommended and processing should be as fast as possible. To gain a better quality oxidation should be lowered to minimise quality deterioration. Processing of banana puree starts from the ripe fruit. The fruit contains 22Bx, 2% starch and shows a pH of 4.8-5. The fruit are washed in a soaker the addition of chlorine is recommended (5-10ppm) The peel is separated by manual work. After peeling the banana are immersed into a solution of ascorbic and citric acid. The fruit is there after disintegrated and heated in tubular heat exchanger up to 93 C. The puree passes a finisher with a screen width of 0.8 to 0.5 mm. It is vacuum treated to lower the oxidation of flavour and colour. Thereafter it is homogenised 10300 bar and instantly sterilised in a scraped surface heat exchanger to about 100C for 40-45 seconds. The puree may be packed in polyethylene bags ,frozen to 18C or aseptically packed.
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It is possible to produce banana juice with satisfaction yield by the application of amylolytic and pectinolytic enzymes.( up to 80% yield)

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