Modern technologies for obtaining apple juice. Apple juice production technology Industrial methods of collecting apples for juice

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" Technolotechnology of apple juice production"

INconducting

Juice is a food product popular in almost all countries of the world. The most common juices are squeezed from edible plant fruits (fruits, berries or vegetables). However, there are juices obtained from the stems, roots, and leaves of various edible herbs (for example, juice from celery stalks, juice from sugar cane stalks).

Apple juice is juice squeezed from apples. The sweet taste is due to the natural sugar content in apples. In the modern world, a significant part of apple juice is produced industrially, including pasteurization and aseptic packaging. Apple juice is also produced in large quantities from concentrate. In a number of countries, including the USA, China, Germany and Poland, apple juice is one of the most common soft drinks.

It is believed that apple juice was first made in England; references to it are found in documents of the Anglo-Saxon era. According to a number of medical scientists, this drink, due to the large amount of vitamin C and other components, is good for health, reduces the risk of diseases associated with smoking, and improves memory; in many countries it is used for baby food.

Apple juice is the only fruit juice that works best with vegetables, in terms of compatibility. It contains such important vitamins and microelements as phosphorus, magnesium, sodium, folic acid, potassium, copper, vitamins A, C, B1, B2, B6, pectin, biotin and many others.

Apple juice is the most popular of all fruit juices. There are two main types of juices; without pulp (pressed) and with pulp (homogenized). Apple juice is mainly made natural without pulp, clarified or not clarified.

All fruits are stored in different ways. For example, different varieties of apples react differently to the effects of temperature during storage. Some of them tolerate a long-term state of hypothermia down to minus 2 minus 3 C, while being stored with minor losses and with slow defrosting (thawing). Therefore, it is worth taking this factor into account. For long-term storage, leave varieties of apples that can withstand cold, and use less stable and easily spoiled ones during the technological process.

Juice production is of great importance for the population and national economy of our country. The high content of minerals and vitamins in vegetable juices determines their high nutritional value. Fruit juices are produced unclarified and with pulp, from one type of fruit and mixed from two or more types of fruit. Canned food products can significantly reduce labor and time costs for preparing food at home, diversify the menu, provide year-round nutrition for the population, and also create current, seasonal and insurance stocks.

It is worth noting that, despite the decline in demand, apple juice production volumes still continue to grow. Thus, according to official statistics, in September-October of this year. In Ukraine, 8.9 thousand tons of juice were produced, which is 6% higher than last year’s figures. But the pricing policy for this product remains largely stable. Only some manufacturers increased prices by 5-7%, arguing that this was due to increased production costs. In particular, sugar prices increased by an average of 40-45%.

foodproductApple juice

Research companies give different estimates of the volume of the SNF market last year - from 510 to 560 thousand tons. According to the State Statistics Service, in 2011 the juice market capacity was 592 thousand tons. Moreover, the volume of production of natural reconstituted juices (including orange) decreased by 5.6% compared to 2010, and blended (mixes of various juices) - by 12.1%. Manufacturers believe that the drop was even stronger - 15-20%. And before the crisis, our juice market annually increased by 10-20%, reaching a record 950 thousand tons in 2008.

But in monetary terms the market is growing. This is obvious, because juice products rose in price by an average of a third in 2011. Last year, the market reached a volume of 6.2-6.3 billion hryvnia compared to 5.4 billion hryvnia a year earlier. The outlook for 2012 does not seem too optimistic for most companies. They definitely do not expect an increase in volumes in physical terms, but prices for juices may increase by another 10-15% due to unfavorable weather conditions in the main fruit-producing countries.

1. Xcharacteristics of raw materials and auxiliary materials

1.1 ChemicalcompoundAndfoodvalueapples

Each variety of wild and cultivated apples has its own characteristics and different chemical composition. It all depends on the origin, growing conditions, and degree of ripeness of the fruit.

The chemical composition of apples is very diverse and rich. 100 grams of the edible part of fresh apples contains 11% carbohydrates, 0.4% proteins, up to 86% water, 0.6% fiber and 0.7% organic acids, including malic and citric. In addition, volatile acids were found in the apple: acetic, butyric, isobutyric, capronic, propionic, valeric, isovaleric.

Table. 100 g of apples contain nutrients:

Calorie content


Saturated fatty acids
Unsaturated fatty acids
Carbohydrates
Monosaccharides and disaccharides
Dietary fiber (fiber)
Starch

Organic acids

Apple contains tannins and phytoncides, which are bactericidal substances. Starch has basic nutritional value. Its high content largely determines the nutritional value of products.

In human diets, starch accounts for about 80% of the total amount of carbohydrates consumed. Starch contains two fractions of polysaccharides - amylose and amylopectin. The conversion of starch in the body is mainly aimed at satisfying the need for sugar. Starch is converted into glucose sequentially, through a series of intermediate formations. Contains in the body in the form of glycogen.

Based on the table. 1. It can be seen that the chemical composition of apples is very diverse and contains large amounts of pectin and starch. Due to their high pectin content, apples are the main product for pectin production.

There are two main types of pectin substances - protopectin and pectin.

Protopectins are insoluble in water. They are contained in the cell walls of fruits. Protopectin is a compound of pectin with cellulose, and therefore, when split into its component parts, protopectin can serve as a source of pectin.

Pectins are soluble substances that are absorbed in the body. The main property of pectin substances, which determined their use in the food industry, is the ability to be converted in an aqueous solution in the presence of acid and sugar into a jelly-like colloidal mass.

Modern research has shown the undoubted importance of pectin substances in the diet of a healthy person, as well as the possibility of using them for therapeutic (medicinal) purposes in some diseases, mainly of the gastrointestinal tract. Pectin is obtained from the waste of apples, watermelons, and sunflowers.

Pectin substances are capable of adsorbing various compounds, including exo- and endogenous toxins and heavy metals. This property of pectins is widely used in therapeutic and preventive nutrition (carrying out fasting apple days in patients with colitis, prescribing marmalade enriched with pectin, etc.)

1.2 Regulatorydocumentation

The following regulatory documents apply to fresh apples in Ukraine:

GOST 16270-70 Fresh apples of early ripening varieties;

GOST 21122-75 Fresh apples of late ripening varieties;

GOST 27572-87 Fresh apples for industrial processing;

DSTU 2849-94 Fresh apples. Technology of conservation in refrigeration chambers;

RST of the Ukrainian SSR1922-82 Fresh apples. Technology of storing in containers.

For fresh apples of early ripening varieties, harvested (purchased) and shipped (delivered) before September 1, sold for fresh consumption, GOST 16270-70 applies. In accordance with it, apples must meet the following requirements.

1.3 Qualityraw materials

Depending on their quality, apples are divided into two commercial grades: first and second. Apples of each commercial grade must be whole, fully developed, clean, without excessive moisture, without foreign smell or taste, and comply with the requirements and standards specified in the table. 2

Notes:

1. Picking maturity - the degree of maturity at which the fruits are fully developed and mature; after harvesting, they are able to ripen and reach consumer maturity.

2. Consumer maturity - the degree of maturity at which the fruits reach the highest quality in appearance, taste and consistency of the pulp.

3. Overripe - fruits that have completely lost signs of consumer ripeness, their pulp is mealy or darkened, unsuitable for consumption.

4. Pressure - damage to the skin and pulp caused by pressure, impact or friction without open, unhealed wounds, without leakage of juice.

5. Excessive external humidity - the presence of moisture on the fruits from rain or watering. Condensation on fruit caused by temperature differences is not considered excessive external humidity.

Calibrated apples are packed in boxes. Second grade fruits may not be calibrated. Each box contains apples of the same pomological and commercial variety. When laying in rows, a layer of wood shavings or a sheet of corrugated cardboard is placed on the bottom and under the lid of the box. When laying randomly, a layer of shavings is placed on the bottom and under the lid of the box, and for more dense placement of fruits, compaction is performed by vibration on a vibrating installation. Packaged apples must be packed in boxes in accordance with GOST 17812-72, packaging equipment in accordance with GOST 24831-81 or containers in accordance with regulatory and technical documentation.

Fresh apples of late ripening varieties, harvested and shipped from September 1, sold for fresh consumption, must comply with GOST 21122-76.

Fresh apples of late ripening varieties are divided into two groups according to pomological varieties: first and second, and depending on quality - into four commercial grades: highest, first, second and third.

The fruits of each commercial grade must be fully developed, whole, clean, without foreign smell or taste, and without excessive external moisture.

Fruits of the highest, first and second commercial grades must be of the same pomological variety. In the third class, a mixture of pomological varieties is allowed.

The degree of maturity at harvest must be such that the fruits can withstand transportation under proper conditions and are suitable for storage, and during the period of sale they have the appearance and taste characteristic of the pomological variety. The quality of fruits of each commercial grade must comply with the standards specified in the table. 3

Table 3.

Rotten fruits are not allowed.

Third grade apples are intended for current sales. They are not subject to storage for long-term storage and shipment outside the region, territory, republic without regional division.

For transportation and storage, it is allowed not to sort apples into commercial grades I and II intended for fresh consumption when supplied to wholesale trade organizations in box pallets in accordance with GOST 21133-87 or special containers. Apples intended for retail trade must be sorted into commercial grades.

Apples are stored in conditions that ensure the preservation of their quality in accordance with the rules approved in accordance with the established procedure.

2. Ttechnologicalschemeproductionapplejuice

2.1 Functionalscheme

To obtain these types of canned food, technological schemes were developed based on technical and technological information from specialized literature.

The initial guidelines for developing a flowchart are technical instructions. Taking into account the documented information in the process flow diagrams, some changes were developed to improve operations and production parameters. In order to obtain a high-quality product, the following was provided when developing the block diagram:

Ensuring high productivity and quality of the finished product;

The use of stainless steel technological equipment, which minimizes the transition of heavy metals into the product;

Production operations should be mechanized as much as possible;

Technological operations must be carried out without interruption.

To obtain high-quality products, the technological scheme provides for the following:

Washing apples is done to remove contamination;

When inspecting apples, microorganisms that may affect the color of the finished product are removed;

Heat treatment aims to inactivate a favorable environment for the development of microorganisms, including the pathogenic botulinium;

Aseptic canning allows you to preserve a large number of semi-finished products per season in order to extend the season.

All these advantages and modern technologies were taken into account when developing a flow chart for operations in the production of apple juice.

The first operation is washing, which is carried out in two washing machines installed in series. Washed fruits are inspected, removing those affected by pests and diseases. After washing, the fruits are crushed using disk or grating crushers: pome fruits (apples, quince, pears) into particles measuring 2...6 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.

The processed pulp is fed for pressing, for which hydraulic batch presses are used, either periodic or continuous - screw or belt.

The clarified juice is filtered and sent for heating and packaging.

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.

2.2 Hardwarescheme

Machine-hardware diagram of a complex of technological equipment for the production of clarified apple juice.

It consists of pumps 1, 9, 17 and 24, a screw separator 2, elevators 3 and 6, a washing machine 4, an inspection conveyor 5, collectors 7, 13, 15, 18, 19 and 22, a crusher 8, a press 10, a pasteurizer - cooler 11, pasteurizer 12, filters 14 and 16, cooler 20, tubular static mixer 21 and dispenser 23 of pectolytic preparations.

The fruits received for processing are poured into concrete baths, 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 lifted to the final washing machine 4.

Water coming from the auger separator and containing large contaminants (stones, branches, leaves, etc.) enters the loading funnel of an inclined auger conveyor with a perforated bottom, which 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 on the conveyor 5, removing fruits unsuitable for processing, and they are lifted by an elevator 6 to the receiving collector 7, 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 in the pressing installation is cleaned of possible large particles and, after the pasteurizer-cooler 11, is sent to one of 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 collector 22, from where it is sucked into the depectinization tank by the dosing pump 24. Along the way, a pectolytic drug is introduced into the pipeline using a dispenser 23 and mixed in a tubular static mixer 21. The processes of depectinization and clarification occur depending on the type of drug 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 sediment collection tank 18, from where it is sent by pump 17 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 once again sent to filter 14 to obtain fully clarified juice, ready for packaging in bottles.

This juice is collected in the receiving collection 13, and then sent to the bottling line, where it is pre-deaerated and pasteurized.

The juice is packed into bottles at 80 °C, followed by additional pasteurization and cooling in a tunnel pasteurizer-cooler.

3. ABOUTscripturemainstagesproductionapplejuice

Juice is prepared from apples of different varieties and ripening periods, so the chemical composition of apple juices can vary significantly, although most industrial varieties of apples have a slight range in the content of dry substances (19...21%) and organic acids (0.3...0.6% ), they also contain pectin substances (0.5...1.0%) and are rich in vitamins. For obtaining juices, the best apples are autumn-winter varieties with dense tissue, which, when crushed, produce pulp with a granular structure that lends itself well to pressing. The juice yield is 80% or more. After crushing, the pulp must immediately go to pressing, since grinding breaks the integrity of the cell walls and releases polyphenolic enzymes. In this case, with the participation of atmospheric oxygen, polyphenolic and other easily oxidized compounds are oxidized, which leads to darkening and deterioration of the taste and smell of the juice. The oxidation products of polyphenols can have a red, orange, brown color and, accordingly, change the color of the juice. Pressed juice, which contains pectin and polyphenolic substances and some starch and nitrogenous compounds, must be clarified using combined methods using pectolytic and amylolytic enzymes and other clarifying substances. To obtain apple juice, complex mechanized lines are used, including the acceptance of raw materials and the production of the finished product.

Technological process

The juices are clarified and represent the liquid phase of the fruit with substances dissolved in it, squeezed from the fruit tissue. Delivery, acceptance and storage of raw materials are carried out in the production of juices in the same way as in the production of other types of canned fruit.

Treatment with enzyme preparations

Most fruits and berries contain pectin substances, which make it difficult to extract juice and reduce its yield. Pectic substances are found in fruits in the form of water-insoluble protopectin and soluble pectin. Protopectin is part of the cell walls and middle plates of plant tissues. The main influence on the process of juice release is exerted by soluble pectin, which has water-holding ability and increases the viscosity of the juice, preventing it from flowing out. Therefore, when treating pulp with pectolytic enzymes, it is necessary, first of all, to destroy insoluble protopectin.

Protopectin must be hydrolyzed only partially, so as to separate cells from one another and partially destroy their walls to increase cell permeability. Pectolytic enzyme preparations not only destroy pectin substances, but also act on cells with toxic substances of a non-enzymatic nature, which are part of the preparations and cause coagulation of protein-lipid membranes and the death of plant cells. As a result of these transformations, cellular permeability increases, protoplasmic membranes rupture, and the release of juice is greatly facilitated. To process fruit pulp in the production of juices without pulp, the enzyme preparation Pectostostidin is used, which is available in powder form. The drug Novoferm 10x (grown by the surface method) is a complex of enzymes pectinase, polygalacturonase, pectin methyl esterase, cellulase and amylase. The optimal temperature for action of pectolytic enzyme preparations is 35…40°C. Increasing the temperature above 55°C inactivates the enzymes and the effect of the drug stops. Treatment duration is 1…2 hours. Novoferm 10x is used both for processing pulp and for clarifying juices. A new type of enzymes that can be used to process pulp in order to increase juice yield are diluting enzymes, which include pectinase and cellulase.

Pectic substances have water-holding ability, form a hydration shell around suspended matter, act as protective colloids for suspended particles, delay their precipitation and increase the viscosity of juice. Therefore, the destruction of the pectin molecule promotes the separation and settling of particles.

Pectolytic enzyme preparations are used to clarify juices. Under their action, the pectin molecule is destroyed to water-soluble galacturonic acids. For this purpose, for example, the enzyme preparation Pectofoetidin P10X is used. This drug contains, in addition to pectolytic and proteolytic enzymes. Processing can be carried out in a batch or continuous manner. In domestic industry, the batch processing method predominates.

An enzyme preparation is added to the juice in an amount of 0.02-0.03% in the form of a suspension. The dose of the applied drug depends on the pectin content in the juice, pH and temperature. To achieve the desired result, the optimal conditions for the action of the drug should be observed: pH 3.7-4.0; processing temperature 40-50 0C; The processing time is 1 hour with stirring. Under such conditions, more than 50% of the pectin is destroyed and the juice becomes clearer. If complete depectinization is required, the process continues for a longer time.

If the turbidity of the juice is due to the presence of starch, then amylolytic enzyme preparations are used. Starch is contained in juices from summer and unripe apple varieties. During heat treatment, most of the starch gelatinizes, goes into solution and, during bottling and storage, can cause cloudiness in the juice due to the formation of complexes with polyphenols. To process such juices, amylolytic enzyme preparations are used, for example, Amylorizin P10X. Processing conditions: temperature 50 0C; pH 4.5-5.5.

If there are pectin substances and starch in the juice, it is recommended to use both pectolytic and amylolytic enzymes.

The optimal dose of the applied drug is determined on the basis of a test lightening. First, the presence of pectin in the juice (by an alcohol test) and starch (by an iodine test) is determined. Then, the dose of the applied drug is determined by the amount of clot formed or by the intensity of color. The correctness of the chosen dose is checked by test clarification in test tubes.

The disadvantage of the enzymatic clarification method is the frequency and duration of treatment (1-2 hours). In recent years, work has appeared on continuous methods for processing juices. For this purpose, enzymes fixed on solid supports (immobilized) are used. Insoluble enzyme-carrier complexes are stable and retain the catalytic properties of enzymes. Inorganic and organic substances are used as carriers. The processing is carried out in special reactors.

INconclusion

It should be especially noted that the production of canned food is a very convenient area for small businesses. Simple technology, low cost (no need for large capital investments or production space), ease of organizing production (minimal amount of technological equipment), technically uncomplicated production equipment (its production is possible in the simplest conditions) allows a large number of small business representatives to actively participate in this.

Apples are rich in pectin. These are natural detoxifiers that remove heavy metals, radionuclides, nitrates and other toxins from the body. Pectin substances are localized in apple peel. But first of all, they make it very difficult to extract juice and reduce their yield, so they use treatment with enzyme preparations. Under their influence, the viscosity of the juices first decreases, and then sedimentation occurs - sedimentation occurs. But even so, apple juice, thanks to natural sugars and organic acids, helps us recover after heavy exercise and strengthens the heart and blood vessels.

Experiments on mice showed that apple juice protects brain cells from oxidative processes that occur during stress, which indicates its antioxidant properties. 300 g of juice per day is enough to avoid the development of cerebral vascular sclerosis.

WITHsqueakusedliterature

1. Technology systems. Description and technical and economic assessment of the technological process. Methodological instructions for performing calculation and graphic work ST-0297. Compiled by: E.L. Feldman. - Donetsk: DIEHP, 1997. - 16 p.

2. Food processing plant. Canning and storage of products compiled by: I. Kravtsov. - "Mayak" Odessa, 1968. -334 p.

3.Handbook of canning production master - compiled by: S.M. Yastrebov. - “Food industry” Moscow, 1980 - 206 p.

4. General technology of food production / Ed. A. P. Kovalskaya. - M.: Kolos 1993-384 p.

5. Technology of canned fruits and vegetables. A. F. Fan-Jung, B. L. Flower menbaum, A. K. Izotov - M.: Food industry

6. Rogachev V.I. Handbook of fruit and vegetable canning production technologist.

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Federal State Budgetary Educational Institution of Higher Professional Education

Ekaterinburg State Agrarian University

on the topic: Juicing technology

Performed:

Maksimenko A.L.

Orenburg - 2015

Introduction

3. Measures for industrial sanitation and occupational hygiene ONT

Conclusion

Introduction

Juice production is of great importance to humans. Everyone understands that for health it is necessary to get vitamins, and juices contain a significant part of them. They contain the following vitamins: vitamin C, vitamin P, folic acid, vitamin A, carotene. Juices are a necessary and irreplaceable part of the diet of people all over the world.

Juice is a liquid product obtained from fruits and vegetables by mechanical action and preserved by physical means. Consuming juices is a quick way to saturate the body's cells with essential nutrients. They are easily digested and quickly enter the blood and lymph. Juice production is one of the fastest growing industries, both in our country and abroad. Not only the quantity, but also the range of juices produced is increasing. The consumption of juices around the world is constantly growing, due to both the high nutritional value and the profitability of juice production. The high technology of juice production processes makes it possible to quickly and effectively introduce the achievements of science and technology into industry.

1. Technology for preparing fruit and berry juices

The following requirements are imposed on raw materials for the production of juices: first of all, the taste, aroma, content of nutrients and physiologically active substances are assessed, and the degree of ripeness of the fruit is taken into account to increase the juice yield. All fruits are stored in different ways. For example, different varieties of apples react differently to the effects of temperature during storage. Some of them tolerate a long-term state of hypothermia down to -2...-3 C, while being stored with minor losses and with slow defrosting (defrosting).

The chemical composition of the raw materials is determined. The main feature of the composition of the fruit is its high water content - 80-90%. This feature determines the high intensity of enzymatic reactions and, consequently, vital processes that cause a large consumption of reserve substances for respiration during storage; high level of moisture loss due to evaporation, which leads to increased weight loss during storage and deterioration in quality; low resistance to pathogens and mechanical stress.

All this requires special technology for growing and storing products. The content of dry substances in fruits reaches an average of 10-20%, a smaller part of which is insoluble (2-5%), and a large part is dissolved in cell sap (5-18%). Insoluble solids are fiber and its accompanying hemicelluloses and protopectin, as well as some nitrogenous substances, pigments, waxes, and starch. Soluble dry substances in fruits include sugars, acids, nitrogenous substances, phenolic substances, soluble pectin and others.

The significance of the chemical components of fruits is different, but they are all necessary for rational human nutrition.

Carbohydrates determine the caloric content, which for fruits is 50-70 cal per 100g. Sugars, combined with acids, play a major role in determining the taste of fruits. The content of other components is often low, but determines their specific characteristics and nutritional value. For example, the content of tannins determines the astringent taste of fruits; as a result of their transformations, the color of processed products may change, and their presence is associated with the clarification of juices. The composition and ratio of anthocyanins and fat-soluble pigments determine an important quality indicator - the color of the fruit.

Vitamins are of particular importance in human nutrition, and some of them (vitamin C, vitamin P, folic acid, provitamin A - carotene) mainly contain fruits and vegetables.

There are two main types of juices; without pulp (pressed) and with pulp (homogenized). According to the preparation technology and recipe, there are several types of them (natural, blended, fortified, sterilized through sterilizing filters, etc.). preparation juice quality sanitation

2. Juicing without pulp

Juices without pulp are obtained by pressing. Plant tissue is prepared so that the cell sap is released from every cell as much as possible. This depends on carefully chopping the fruit. In this case, most of the cells should be disrupted. But the pieces of fabric should not be very small, otherwise the sieves become clogged during pressing and the juice yield decreases. Thus, when chopping apples into pieces about 0.3 cm in size, the juice yield can be increased to 705; with a greater degree of chopping, it decreases. To crush raw materials, a crusher with grooved rollers is used, which, when rotating towards each other, crush the fruits, a universal crusher, a roller crusher, and a knife cutter. To increase the yield of juice, the pulp is heated to a temperature of 80-85 C. However, as a result, an off-flavor may appear and the aromaticity of the product may decrease. Other methods are also used to increase the yield of juice - freezing, electroplasmolysis, treatment with enzyme preparations. When frozen, cell walls are damaged by ice crystals. During electroplasmolization, protoplasm coagulates under the influence of electrical voltage. Enzyme preparations contain pecto- and proteolytic enzymes that loosen fruit tissue.

The juice is extracted using various presses. The most common: screw with mechanical drive, with hydraulic drive, screw. In mechanically driven presses, pressure (9-12% kg/cm) is created by rotating a nut on a vertical screw, which is transmitted to the upper clamping frame of the basket.

In presses with a hydraulic drive, pressure (9-12 kg/cm) is created by a hydraulic plunger pump, in continuous screw presses used to obtain grape juice - by rotating two screws with opposite directions of turns, decreasing pitch and increasing diameter (the principle of its operation is similar extractor for tomato juice). The pulp is loaded into presses either into two baskets made of wooden slats fastened with hoops, or into packs (in hydraulic presses) installed on two lattice wooden platforms. While one is freed from pulp and loaded, the second is pressed. At the same time, the pressure is increased slowly, otherwise the pulp may be pressed in. In basket presses, after the first pressing of the juice, the pulp is loosened and pressed a second time. In pack presses, the maximum juice yield is reached after the first pressing.

In screw presses, juice is obtained with a large amount of suspended particles, but in this case the process of its extraction is continuous and the yield is high, so such presses are used more and more widely. The next step is clarification of the juice. The simplest method is the sedimentation of turbidity particles by settling, but in this case only large particles precipitate and the process proceeds very slowly. Sometimes juices (for example, grape juice) self-clarify: with prolonged standing, a flaky sediment of turbidity peels off. Self-clarification occurs due to enzymatic and chemical transformations during which colloidal substances are destroyed. To self-clarify juices, large reserve containers are needed. The destruction of colloids can be accelerated by enzyme preparations of mold fungi that have a pectolytic effect (the same as when processing pulp). This method is used for difficult-to-clarify apple and plum juices. For clarification, juices are fined by adding proteins (gelatin) and tannins (tannin). Forming sediment, they deposit suspended particles. Clays (bentotins) are also used, which have strong adsorbing properties and change the electrical charges of colloids, thereby precipitating them. But the most common filtration of juices is carried out on filter presses. Between the plates of the filter-press, a filter material is laid (filter - cardboard, pressed asbestos), through which the juice passes, supplied by a pump under pressure through the channels in the flanges of the plates. After filtering, the first portions of juice entering the opposite channel in the flanges may be cloudy; they are returned for recycling. The clear juice is sent for bottling, capping and sterilization. Juices can be sterilized without heating using sterilizing filters. For this purpose, filter presses are used. The holes in the filter material are so small (no more than 1 micron) that microorganisms cannot pass through them. Juices obtained using de-fertilizing filters retain their natural taste and aroma and are therefore more valuable than sterilized ones. Mechanized production lines have been created for the production of fruit juices, which provide for all operations - from crushing raw materials to sterilization and bottling of finished products.

The nutritional, vitamin and flavoring benefits of clarified juices are high, many of them are dietary products. However, during their production, mainly during clarification (filtration), valuable substances are separated along with the sediment: carotene, fiber, semi-fiber, pectin, protein and many phenolic compounds, some vitamins.

3. Measures for industrial sanitation and occupational hygiene

The layout and arrangement of the enterprise territory provides for the removal of atmospheric precipitation from buildings to drains; utility and fire water supply and sewerage. Directions and passage signs, special inscriptions and parking signs are installed on the territory. Normal sanitary and hygienic conditions (to, humidity, pressure and air purity) are maintained in production premises.

Production, warehouse, auxiliary, utility and household premises, staircases, passages and workplaces are kept clean, preventing workplaces and passages from being cluttered with equipment, materials and spare parts.

The surface of the floor, walls and ceilings is smooth, easy to clean and meets hygienic and operational requirements. To ensure safe working conditions and human performance, the air environment surrounding him at work must comply with established sanitary and hygienic standards.

The rationing is based on the conditions under which the human body maintains a normal thermal balance, that is, due to physiological processes, thermoregulation is carried out, ensuring the preservation of a constant body temperature through heat exchange with the external environment.

The required state of the air environment of industrial premises is ensured by a set of measures that can be divided into the following groups:

a) combating the release of harmful substances at the source of their occurrence;

b) mechanization and automation of production processes, their remote control;

c) organization of the technological process that ensures a minimum release of hazardous substances in the work area;

d) installation of ventilation and heating;

e) use of personal protective equipment.

Environmental protection. The problem of the environment and the rational use of natural resources is one of the most pressing human problems, since life on earth, the health and well-being of mankind depend on its solution.

A sanitary protection zone 50 m wide is provided around the enterprise. This zone is landscaped and landscaped. Green spaces enrich the air with oxygen, absorb carbon dioxide and noise, clean the air from dust and regulate the microclimate. Pollution of atmospheric air and water bodies is within acceptable limits, since treatment facilities are provided for this purpose. After washing the equipment and inventory, water containing contaminants is drained through holes in the floor that are connected to the sewer system, wastewater is treated at treatment facilities, and the resulting sludge is used for sale as fertilizer in agriculture. Purified water is reused at the enterprise, but only for domestic purposes.

4. Quality control of finished products

Quality control of finished products for fruit and berry juices includes:

· organoleptic indicators.

· mass fraction of dry substances.m

mass fraction of acids.

mass fraction of alcohol.

· mass fraction of pulp (for juices with pulp).

· mass fraction of sediment (for clarified juices).

· pH value.

mass fraction of vitamin C.

· preservatives.

· foreign impurities, toxic elements.

Determination of titratable acidity of juices without pulp.

Fifty grams of juice (temperature 18-20°C) is transferred to a 250 ml volumetric flask and adjusted to the mark with distilled water. Then 10-15 cc are pipetted into a flask and titrated (0.1 mol/cc) with NaOH solution in the presence of phenolphthalein (3 drops) until a pink color appears that does not disappear within 30 seconds (analysis is carried out 2 times).

Determination of dry matter in juice. 1. Method of drying the sample.

2. Determination of the mass fraction of dry substances by density. Controlled quality indicators of fruit and berry juices: citric acid content, sucrose content, total D-glucose and D-fructose content, D and L-malic acid content, L-ascorbic acid (vitamin C) content, L and D-lactic acid content , dry matter content, pH (active) and total (titrated), relative density. The naturalness of juices is indicated by the content of malic acid in them, and synthetic malic acid consists of D and L forms. The presence of these forms of malic acid indicates the addition of a synthetic acid. The presence of acetic, D and L-lactic acids in the juice indicates microbiological fermentation of the juice. They should not be present in the juice. Note: apple juice does not contain D-malic acid, so this fact is used to determine the adulteration of apple juices.

Conclusion

High quality of products is one of the most important tasks of any enterprise. When accepting raw materials for production, each enterprise must be confident in its quality, subject it to chemical analysis, control all the most important indicators - the content of free fatty acids, peroxides, the presence of traces of heavy metals and many others. For the production of fruit, berry and vegetable juices, the highest quality raw materials must be selected from the best suppliers.

First of all, taste, aroma, content of nutrients and physiologically active substances are assessed. The transparency of pressed (without pulp) juices is taken into account.

When operating equipment for the production of juices without pulp, safety precautions, sanitary and hygienic standards must be observed to prevent equipment breakdowns, as well as industrial injuries.

List of used literature

1. GOST 13799-81 Canned fruit, berry, vegetable and mushroom products. Packaging, labeling, transportation and storage.

2. Granatkina, N.V. Commodity research and organization of trade in food products - M.: Academy, 2009. - 240 p.

3. Eliseev, M.N. Commodity research and examination of flavored goods / M.N. Eliseev, V.M. Poznyakovsky - M.: Academy, 2006. - 304 p.

4. General technology of food production / Ed. A. P. Kovalskaya. - M.: Kolos 1993-384 p.

5. Leonenko I.I. “Horticulture”, textbook for technical schools, Moscow, 2002, 290 p.

6. Polegaev V.I. “Storage and processing of fruits and vegetables”, Moscow: Agroprmizdat, 2006, 302 p.

7. Rogachev V.I. Handbook of fruit and vegetable canning production technologist.

8. Samsonova A. N. Fruit and vegetable juices

9. Skurikhina, I.M. Chemical composition of food products / - M.: 2003

10. Fan-Yung, B. L. Flower menbaum, A. K. Izotov Technology of canned fruits and vegetables. - M.: Food industry

Posted on Allbest.ru

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Types of juices

Juice products also include nectars, fruit drinks and juice drinks. All these products differ in composition and taste.

Derived directly from fruits or vegetables- straight or freshly squeezed juice.
Refurbished- prepared from concentrate and drinking water. It cannot contain preservatives, dyes, flavors or sweeteners.
Nectar- a liquid food product prepared from concentrated juice (puree), drinking water with or without the addition of natural flavor-forming substances of the same name. In this case, the share of juice (puree) should be at least 20-50% of the total volume, depending on the type of fruit or vegetable. In addition to water, nectar may contain sugar, natural acidulants (for example, citric acid), antioxidants (ascorbic acid), fruit and vegetable pulp, and citrus fruit cells. Preservatives, flavorings and sweeteners cannot be added to nectar. As a rule, nectars are made from those fruits or vegetables whose concentrate cannot be used for making juice because the taste is too sweet or sour (for example, cherries, currants, pomegranate) or because of the thick consistency (for example, bananas, peaches).
Juice drink- a liquid food product made by mixing juices and/or purees, concentrate and drinking water, provided that the proportion of puree is at least 10% (if a juice drink is made from lemon or lime juice, then the proportion of concentrate must be at least 5%) . The range of juice drinks includes the largest number of drinks made from traditional and exotic fruits: blackberries, raspberries, cactus, lime, etc.
Morse- liquid food product - a traditional Russian national drink. Industrial fruit juice is usually made from a mixture of berries (berry puree), drinking water, sugar (or honey), provided that the minimum proportion of juice is at least 15% of the total volume. Instead of water in fruit drinks, it is permissible to use an aqueous extract of the marc of the berries that were used for production. However, it should be taken into account that industrial fruit juice differs in production method and quality from homemade fruit juice made in the traditional way.

The most popular fruits and vegetables

Fruit:

Apricot is a product (drink) obtained by squeezing liquid from fresh apricots. Contains provitamin A (carotene), necessary for normal growth and development of the body.
Orange is a popular breakfast drink made by squeezing the liquid from fresh oranges. Rich in vitamins (especially ascorbic acid), has antiscorbutic properties. The term "orange juice" is also used colloquially and commercially to refer to "orange produced from concentrate." To distinguish fresh orange juice from concentrate, Canada, Israel and America use the “not from concentrate” label. In the US, all juices sold on the market are pasteurized.
Grape drink is a popular drink made by squeezing liquid from fresh grapes. It preserves the healing properties of grapes, contains large amounts of sugar, vitamins and mineral salts, and is recommended as a valuable dietary product.
Pomegranate is a popular drink made by squeezing the liquid from fresh pomegranate fruit (granatine). Pomegranate fruits are rich in sugars, tannins, vitamin C, contain fiber, minerals and trace elements: calcium, magnesium, potassium, manganese, sodium. It is possible to squeeze up to 60% juice with a high anthocyanin content from the fruits. The juice of cultivated varieties of pomegranate contains from 8 to 20% sugar (glucose and fructose), up to 10% citric, malic, oxalic and other organic acids, phytoncides, nitrogenous substances, tannin, sulphates, chlorides and other salts. The pericarp, roots and bark contain up to 32% tannins. Pomegranate juice is useful for anemia, a decoction of the peel and membranous partitions is useful for burns and indigestion. The seed pulp is reddish and is used in desserts and salads, as well as for making soft drinks.
Plum - obtained by squeezing liquid from fresh plums, it quenches thirst well, improves digestion, and has a laxative effect.
Apple - obtained by squeezing liquid from fresh apples. Rich in sugar, pectin and mineral salts. Useful for diseases of the gastrointestinal tract and dysentery, helps normalize blood pressure.

Carrot - obtained by squeezing liquid from carrots. The main source of carotene. In addition, it contains calcium, phosphorus and iron salts necessary for the functioning of the body. In terms of calorie content and digestibility (availability to the body), carrot juice is superior to other vegetable juices. Its use is especially useful for children, pregnant and lactating women.
Tomato - obtained by squeezing liquid from ripe tomatoes. Contains almost all the vitamins that are found in plant foods, mainly ascorbic acid and vitamin A. In addition, a large amount of mineral salts, carbohydrates and organic acids. Thanks to the harmonious proportion of their concentrations, tomato juice has a pleasant refreshing taste and quenches thirst well.
Pumpkin. Most often it is used in baby food.

Directly pressed juice production

Directly pressed juices (or natural freshly pressed industrial juices) are produced directly from fruits or vegetables during the harvest period. The harvesting and processing season lasts, depending on the type of fruit and geographic region, from 20 days or more. For example, the apple harvest season for making apple juice in European countries, including Russia, falls on July-November, Chile - May-September, China - August-December, South Africa - February-May. The oranges from which the world's most popular natural orange directly pressed (international designation "NfC" - "Not from Concentrate" are obtained) are harvested in Brazil in January-March and then after a month's break in May-December. Argentina - in May-December, in Cuba - in January-June, in the USA (Florida) - in January-August, then in November-December, in Spain - in January-May, then in December, in Israel - in January-December June, then December.

Collected fresh fruits or vegetables are delivered to a processing plant, the main task of which is to preserve the quality of the juice and, first of all, all the beneficial properties of the raw materials. To process raw materials, various technologies are used, which usually consist of several processes - receiving, washing and inspection of fresh fruits (vegetables), grinding raw materials, actually obtaining juice mechanically (for example, using presses of various designs), single heat treatment - pasteurization, bottling into sterile consumer containers. For bottling directly pressed juices, glass containers are most widely used, which is the best packaging material that preserves quality, beneficial properties and ensures the safety of products for a long time. Product quality and safety control is carried out throughout the entire chain - from growing fruits (vegetables) to the finished product.

In the case of high yields, the processing plant may not pack all directly pressed juice directly into consumer containers during the season, but place it for storage in sterile large-volume containers (from 10,000 liters or more). Storage is carried out at low temperatures (not higher than 10 °C) in a nitrogen atmosphere. Under such conditions, the drink does not lose quality and retains all its beneficial properties for several months (even before the start of the next harvest season). According to another technology, directly pressed juice obtained from fresh fruits (vegetables) during the harvest season is stored at low temperatures (not higher than −20 °C) frozen. In this state, it can be supplied, for example, to another enterprise located in a different region, which will fill it into consumer containers after defrosting it using a special technology. Therefore, it is not surprising that you can often find on sale, for example, apple, pomegranate or other juice from subtropical fruits, made in January-March or packaged in consumer packaging outside the region where this raw material is grown.

Depending on the type of fruit (vegetables), direct extraction technologies may differ in detail, but the main unifying feature of these technologies is the use of a minimum number of industrial processes, which allows, unlike reconstituted juices, to completely preserve the beneficial properties of fruits in the final product - directly pressed juice ( vegetables). For example, direct pressing technologies do not use operations typical for reconstituted juices, such as concentration (obtaining concentrated juices, which is accompanied by the separation of natural water, flavor-forming substances and changes in the physicochemical composition), stabilization, clarification, restoration by adding drinking water and aroma-forming substances. Directly pressed juices are pasteurized only once, while reconstituted juices are subjected to repeated heat treatment during the manufacturing process (several times during the production of concentrated raw materials, then again during reconstitution). It should be mentioned that a separate assortment group of directly pressed juices - chilled - is not pasteurized at all or is pasteurized once per so-called. “mild” conditions, then cooled and delivered to the retail chain in a cooled state. Such products must be stored in undamaged original packaging at low temperatures. The shelf life of chilled directly pressed juices, as a rule, does not exceed one month.

Production of concentrated juice

Concentrated juice is a product produced during the harvest period in regions of agricultural production of fruits and vegetables in specialized factories. To make it, fruits, including berries, or vegetables are used. First, they are cleaned, crushed, and then sent under the press. After this, the resulting juice is sent to a storage tank. From the storage tank, the liquid is sent for concentration, that is, under the influence of heat under conditions of reduced pressure, water evaporates from it as a result of boiling. Compared to the original juice, the concentrated juice has a thick, viscous consistency.

At all stages of production: from the supply of fruits or vegetables to the bottling of finished concentrated juice, the factory laboratory monitors the quality and safety of the product. For preservation, it is brought to a temperature of 87-92 °C and held for 35-40 seconds to prevent microbiological spoilage. After this, the juice is either left unclarified (cloudy) or clarified in a special installation with ultrafiltration, after passing through which it becomes transparent. In parallel with the heat treatment during concentration, the collection of aroma-forming substances is carried out, which evaporate when heated. After this, the resulting concentrated juice is pumped into tanks for storage. To obtain mixed products, specialists blend (mix) concentrated juices made from fruits or vegetables of various types, varieties and harvests. The mixtures are then poured into aseptic containers for transportation.

Production of reconstituted juice

Stage 1. Examination. Concentrates and purees are delivered to the plant either in barrels with aseptic food bags inserted into them, or in stainless steel containers. Testing concentrated juice consists of two stages. At the first stage, it is checked immediately after it arrives at the plant. The inspection includes: verification of accompanying documents, during which specialists determine whether the drink complies with regulatory documents; checking microbiological parameters; checking organoleptic indicators (taste, color, smell); checking physical and chemical parameters (pH, titratable acidity, dry matter content, pulp content). If the first stage of verification shows that all indicators are normal, then a decision is made to use this concentrated juice in production. After this, the concentrated juice is sent for storage, which takes place under special conditions in order to preserve all parameters. The second stage of testing is carried out immediately before preparing the product. It is re-checked for compliance of organoleptic and physico-chemical indicators with the declared standard. If any deviation is detected at any stage of verification, the concentrated juice is rejected and not used in production.

Stage 2. Return of water. To produce reconstituted juice, it is necessary to return the entire volume of water that was removed from it during the concentration process to the concentrated juice. For this purpose, drinking water is used, which does not affect the taste, smell and color. To do this, the water undergoes multi-stage purification: mechanical defoliation, purification from organic impurities, treatment with bactericidal ultraviolet lamps and flash purification. To return the water, the concentrate is sent to blending tanks (special closed stainless steel containers). They mix concentrated juice and drinking water. This process occurs in closed, opaque containers without access to light and with a minimum amount of oxygen. At the same time, natural flavor-forming substances removed during concentration are returned to the concentrated juice. It should be noted that the return of flavor-forming substances is not mandatory.

Stage 3. Sample selection. When mixing concentrated juice, drinking water and flavor-forming substances, plant laboratory employees take a sample and check the quality of the prepared product (taste, color, smell, consistency, titratable acidity, dry matter content, pH). The check takes 10-15 minutes. Until a laboratory conclusion is received that the product meets quality standards, the juice will not be released for bottling. If all parameters are normal, then it is sent for heat treatment.

Stage 4. Pasteurization. The task of heat treatment (pasteurization) is to ensure the microbiological safety of the product and its preservation throughout its shelf life. During the pasteurization process, the product is heated to 90-97 °C and held for 30 seconds. After this, cool very quickly to 25 °C. This temperature regime allows you to destroy all harmful microorganisms and at the same time preserve taste, aroma, and vitamins.

Stage 5. Bagging. The pasteurized reconstituted juice is fed into a packaging machine where it is filled into bags that are sterilized and molded directly inside the machine. Thus, thanks to completely closed production and aseptic processing, the reconstituted juice is completely protected from unwanted external influences. At this stage, experts check the quality of the packaging, the quality of the formation of the package and its tightness, and check the completeness of filling. After this, the bag is marked with indelible ink (production date and expiration date), and a straw or cap is glued on. Then the packages are packed in, singeed in, folded in and sent to warehouse storage. Now the manufacturer has the opportunity to choose different types of packaging. Juice products are packaged in aseptic bags and in glass bottles (jars). The main task of packaging is to preserve the beneficial properties of fruits and vegetables, and of course to ensure high quality and safety of the product for the consumer. There are differences in the method of bottling juice products in different types of packaging. Products are poured into glass bottles (jars) hot and can be sterilized after filling. When bottling into aseptic bags, the products are pre-pasteurized cold. Packaging bags are also pasteurized.

Production of clarified juice

To obtain clear juice, a method of clarifying it is used - removing fine particles and improving its presentation. Among other benefits, clarified fruit juice quenches thirst better. Depending on the specific technological conditions, as a rule, physical (straining, settling and separation or separation), biochemical (enzyme treatment) and physicochemical (treatment with bentonite, organic or, less commonly, synthetic flocculants, for example, polyethylene oxide and polyacrylamide; instant heating and other) methods of lightening.

Not so long ago, bags labeled “directly pressed juice” began to appear on store shelves. My husband and I intuitively immediately gave our preference to these particular juices, although I am traditionally skeptical of all marketing gimmicks. And this is exactly what such an inscription seemed to me. And although it seemed to be implied that this juice should be more natural, there was still some skepticism on this score and, as it turned out, in vain.

Recently I had the opportunity to visit apple orchards and trace with my own eyes the entire path of the juice. This is what I want to tell you about.

Apples for direct-pressed domestic juice are grown by Sad LLC in the Samara region.

The journey of a juice bag until it reaches our table is long and complex. It begins in the fields where apples are grown. There are not many companies that own garden lands. After all, growing apples is a much more complex and labor-intensive process, unlike buying Chinese concentrate.

Even in order to grow an apple tree to the point where it begins to bear fruit, you will need to replant it several times and spend many hours on care.

First, small shoots are grown. This is the so-called “rootstock”. Or "wild". In fact, these are also apple trees, but for now this is only the basis for the future variety, its foundation. The root system and stem of the future tree are called the rootstock. It is responsible for growth rates, fruiting time, resistance to weather conditions, diseases or harmful insects, durability, number of apples and many other factors.

After the rootstocks are grown, they are replanted and a variety is grafted onto them. This is called a "scion."

This is a different field. If you look closely, you can see colored electrical tape on each of the stems. It was there that the cutting was grafted. This is how the apple tree already has a certain variety.

10.

Apple trees begin to bear fruit while still very small. It looks unusual. A small “bush” all covered with apples! But this is much more convenient for manufacturers. And you can process and pick apples from a height of human height, without using a ladder. This greatly simplifies the work. However, trees up to 3.5 meters in size are grown here. This, of course, is the apple size that is more familiar to the average person.

11.

By the way, an apple tree may not produce a harvest just like that. Making it bear fruit (and doing it every year) is a separate and very serious job. To do this, special tricks are used: they weed the flowers (so that more energy goes into the remaining fruits), cut the roots or make cuts on the stem in a special way (so that the apple tree “thinks” that it is finished and finally begins to actively “reproduce”). All this colossal volume is just a normal routine. All that remains is to admire the volume of work. Any agriculture is a lot of hard work.

12.

Apples are picked by hand. No complicated or sophisticated technology - of course it exists, but it spoils the fruit, preventing it from being sent for long-term storage.

13.

After the apples are picked, they are sent to a special storage facility. Here, in a huge hangar, special temperature and humidity are maintained, which allows apples to be stored until the next season.

14.

Before storing, all apples are sorted. This is done more for aesthetic purposes. Apples that go for sale must be smooth, neat, and approximately the same size. Their task is to look beautiful in the window. For apples that are used for juice, appearance no longer matters. And they all taste the same, of course.

15.

16.

The apples remain in the warehouse until an order for a specific batch is received. Some of them are sent to be sold in stores, but mostly these apples will be used to make juice.

16.

The Nectar company plant, at the grand opening of which we feasted on apples, receives either the juice itself (in the case of apples) or a concentrate for some exotic juices (we have not yet learned how to grow guava or mango in our region).

17.

Here, in huge vats, the processes of filtration and pasteurization of the future juice take place. Everything is sealed and hidden from prying eyes.

18.

The plant has installed a line of Tetra Pak equipment. We are accustomed to the fact that this is only high-quality packaging, but in fact the company produces entire production lines to equip factories, including juice production. Modern equipment and the latest pasteurization technologies make it possible, on the one hand, to preserve all the beneficial substances, and on the other hand, to ensure a long shelf life.

19.

The next stage is the actual bottling and packaging. Everything here is already very noisy and dynamic.

First, the machines transform flat Tetra Pak packaging, which arrives at the plant in rolls, into a bag familiar to our eyes, after which juice is poured into it and it is sent further to the conveyor.

20.

21.

There it is repeatedly scanned, weighed, and compared with standard indicators to prevent the release of low-quality products. If an inaccuracy is detected in any package, it is “blown away” with a sharp stream of air from the tape into special mesh-catchers and they will no longer end up on the counter. The process is monitored not only by technology, but also by people.

22.

A little later on the conveyor belt, caps, straws and other accessories are added to the juice packages.

23.

24.

The Nektar plant in Samara produces several brands - Ivanych, Volzhsky Posad and others.

25.

The manufacturer is especially proud of branded bags with Madagascar cartoon characters (in partnership with the copyright holder). Of course, such marketing campaigns are always effective. Children love images of their favorite characters, and such products will always be in high demand.

26.

The last step along the way is packing the juice bags into boxes and assembling pallets for transportation. Now this is done manually, by strong movers. But the plant already has plans to develop production and soon additional equipment will be installed here that will replace human labor.

27.

28.

29.

By the way, if you believe the map, then not only ours. They are also supplied to some foreign countries, including China.

30.

This is the path of juice, from a small cutting - rootstock, to a delicious glass of juice.

31.

Bon appetit! =)

Then the apples are washed and rinsed again under the shower of the washing machine 5. Further along the elevator 6 they are fed into the disk crusher 7. The resulting pulp enters the screw drainer 8, where by gravity and with slight pressing, up to 40% of the juice is separated from the pulp (instead of 60%). during normal processing). The amount of suspended matter in the juice in this case is several times less than in the juice obtained on screw presses.

The squeezed juice enters the collection 16, from which the plunger pump 17 is sent through a pipeline to the settling tank 24. The settled product is decanted, and the piston pump 14 sends it to the pasteurizer-cooler 23 for heating to a temperature of 80...90 ° C and subsequent cooling to 25 ...30 °C.

For more efficient cooling, the juice is passed through a tubular cooler 22. With rapid heating and cooling, protein substances coagulate, resulting in improved clarification of the juice during filtration.
The cooled juice under pressure first enters the collection 20 installed on the platform 21, and from there it flows by gravity into the separator 19 for cleaning. When served by gravity, the juice is better cleared of suspended matter. The purified juice is collected in a collector 18, from which it is sent for final purification to a filter press 28. The filtered juice is collected in a collector 29. Then, using a pump 14, the juice is pumped into a tubular heater 30, where it is heated to a temperature of 90 degrees C and fed into a double-walled boiler 31 for maintaining a constant temperature before packaging begins.

The bottles are washed in a machine 43 and viewed through a screen 42. When leaving the washing machine, the temperature of the bottles must be at least 50 degrees C. For this, a special scalder 40 is equipped: two inch pipes 1.5 m long with bubblers are installed on both sides of the conveyor 41. into which steam is supplied. The bubbler holes on both sides are directed towards the body of the bottles. The section of the conveyor with bubblers is covered with a casing with an exhaust hood.
Hot bottles are conveyed by a conveyor to the filling machine 32, then to the capping machine 33. The bottles are sealed with crown caps with polyethylene liners, which are pre-treated for 3...4 minutes with live steam in a cabinet or hot water (85...100 °C ) in a double-walled boiler.

After capping, the bottles, while moving along the conveyor 35, are checked on the rejecting machine 34. From the storage table 36, the bottles are placed in baskets 37 in three rows. Each row of bottles is arranged with a wooden lattice. Using an electric hoist 38, the baskets are installed in the autoclave 39 for sterilization. They are then unloaded onto a storage table, labeled, placed in boxes, sent to a warehouse or sold.

The pomace obtained on the drain and containing up to 20% juice is fed into a screw scalder 9. In this case, protopectin is hydrolyzed and the pulp is separated from the skin and seed chambers. To prevent the product from burning, it is heated in a scalder to a temperature of 100...110 "C. After scalding, the pomace is fed into a one-stage universal rubbing machine 10 (sieve hole diameter 1...1.2 mm). The pureed puree is collected in a collection 15 , from it the pump 14 is sent to the second rubbing machine 25 (hole diameter 0.6...0.8 mm).Next, the product enters the vacuum apparatus 26 for cooking jam or for sulfitation.

The sugar required for cooking jam is sifted on a vibrating sieve 11, the required amount is weighed into a collection 12 on scales 13 and fed into a vacuum apparatus 26 in puree. The finished jam is packaged in jars or barrels with a capacity of 50 liters with polyethylene liners. If the jam is packaged in jars with a capacity of 0.65... 1.0 liters, then they are then sterilized in autoclaves. If the puree is intended to produce a semi-finished product, then after the second grinding it is cooled in digesters 27, packaged in barrels with polyethylene liners, sulfated and sent for storage.

Modern technologies for obtaining apple juice. Apple juice production technology Industrial methods of collecting apples for juice

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