Fruit Juice Processing.docx
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Fruit Juice Processing.docx
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FruitJuiceProcessing
FruitJuiceProcessing
TechnicalBrief:
Thisisatext-onlyversionoftheTechnicalBrief.Forthefullversion,withillustrations,pleasedownloadthefreeprintablePDFdocument.ToreadthePDF,youwillneedthecurrentversionofAdobeAcrobatreader,whichcanbedownloadedfreefromAdobe'swebsite.
Introduction
Awiderangeofdrinkscanbemadeusingextractedfruitjuiceorfruitpulpasthebasematerial.Manyaredrunkasapurejuicewithouttheadditionofanyotheringredients,butsomearedilutedwithsugarsyrup.Thetypesofdrinkmadefromfruitcanbeseparatedintotwobasictypes;
-thosethataredrunkstraightafteropening
-thosethatareusedlittlebylittlefrombottleswhicharestoredbetweenuse.
Theformergroupsshouldnotrequireanypreservativeiftheyareprocessedandpackagedproperly.However,thelattergroupmustcontainacertainamountofpermittedpreservativestohavealongshelf-lifeafteropening.Thedifferenttypesofdrinkareclassifiedaccordingtothefollowingcriteria:
Type
Description
Juices
Purefruitjuicewithnothingadded
Nectars
Normallycontain30%fruitsolidsandaredrunkimmediatelyafteropening
Squashes
Normallycontainatleast25%fruitpulpmixedwithsugarsyrup.Theyaredilutedtotastewithwaterandmaycontainpreservatives
Cordials
Arecrystal-clearsquashes
Syrups
Areconcentratedclearjuices.Theynormallyhaveahighsugarcontent
Eachoftheaboveproductsispreservedbyacombinationofnaturalacidity,pasteurisationandpackaginginsealedcontainers.Somedrinks(syrupsandsquashes)alsocontainahighconcentrationofsugarwhichhelpstopreservethem.
Equipmentrequired
Peeler
Knives(stainlesssteel)
Cuttingboards
Juiceextractor
Thermometer
Analyticalbalance
Stainlesssteelsaucepan
10kgscales
Measuringcylinder
Cappingmachine
Woodenspoons
Plasticfunnels
Plasticbuckets
Strainers
Cleaningequipment(brushes,scourers,cloths,hosepipesetc)2gascylinders,2-or3-ringburners.
Abuildingwithlargepreparationtable,smallertableforgasburners,shelvesforproducts,sink,drainingboard,taps,cupboardforlabelsanddryingredients.
Thetotalcapitalforequipmentandfurnishingsislikelytobe£500-800($US900-1440),workingcapitalforfruitpurchase,packagingandothermaterialsislikelytobearound£600($US1080).
Thecostofabuildingisnotincluded,butitshouldhavethefollowingfeatures:
Slopingconcretefloorandproperdrainageforwashingdowneachday
Apotablewatersupply
Preferablyelectricity
Screenedwindowsanddoorstoreduceinsects
Nohorizontalledges,windowsills,orrafterswheredust,insectsandbirddroppingscancollect.
Thistechnicalbriefoutlinesthebasicsoffruitjuiceprocessing.Itdoesnotgivespecificdetailsorrecipesforindividualfruits.Thesecanbefoundintheindividualtechnicalbriefs(limecordial,mixedfruitjuicemanufacture,passionfruitjuice).
Methodofproduction
Forallthefruitbasedbeverages,thefirststageistheextractionofjuiceorpulpfromthefruit.Thefollowingarethekeymanufacturingstages:
Selectionandpreparationofrawmaterial
Juiceextraction
Filtration(optional)
Batchpreparation
Pasteurisation
Fillingandbottling.
Anyfruitcanbeusedtomakefruitjuice,butthemostcommononesincludepineapple,orange,grapefruit,mangoandpassionfruit.Somejuices,suchasguavajuice,arenotfilteredafterextractionandaresoldasfruitnectars.
Preparationofrawmaterial
Selectmature,undamagedfruits.Anyfruitsthataremouldyorunder-ripeshouldbesortedandremoved.Washthefruitincleanwater.Itmaybenecessarytochlorinatethewaterbyadding1tablespoonofbleachto5litresofwater.Peelthefruitandremovestonesorseeds.Ifnecessary,chopthefruitintopiecesthatwillfitintotheliquidiserorpulper.Rememberthatatthisstage,youareexposingthecleanfleshofthefruittotheexternalenvironment.Makesurethattheutensilsareclean.Donotleavethecutsurfacesexposedtotheairforlongperiodsoftimeortheymaystarttoturnbrownandthiswilldiscolourthejuice.Thefruitpiecescanbeplacedinwaterthatcontainslemonjuice(250mllemonjuiceperlitreofwater)tostopthembrowning.
Figure1:
Handpresser.DownloadthefullPDFversiontoseethispicture.
Juiceextraction
Thereareseveralmethodstoextractjuicedependingonthetypeoffruityouuse.Forcitrusfruitswhicharenaturallyjuicy,thebestoptionistouseahandpresser(seefigure1)orarevolvingcitrus'rose'.Somefruitssuchasmelonandpapayaaresteamedtoreleasethejuice.Applesarepressedandfruitssuchasmango,guava,soursop,pineapple,strawberrymustbepulpedtoextractthejuice.Thefruitpiecesarepushedthroughaperforatedmetalplatethatcrushesandturnsthemintoapulp.Somefruitscanbepulpedinaliquidiserandthenfilteredtoremovethefruitpieces.Thereisarangeofequipmentavailablethatvariesinsizeandinthetypeofpowersupply(somearemanualwhilethelargeronesrequireelectricity).Forthesmallscaleprocessor,theMouliLegumeorahand-poweredpulper/sievewhichforcethefruitpulpdownthroughinterchangeablemetalstrainers(figures2and3)issufficient.
Atslightlyhigherproductionlevels,itisnecessarytouseapowersourcetoachieveahigherthroughputofjuice.Themulti-purposeKenwoodCheffoodmixer,isstronglyrecommended.ThishasapulpingattachmentthatissimilartotheMouliLegumeanditcanalsobeusedforotheroperationssuchasliquidisingandmixing.
Figure2:
Handpoweredpulper.DownloadthefullPDFversiontoseethispicture.
Figure3:
Handpoweredpulper.DownloadthefullPDFversiontoseethispicture.
Forlarge-scaleproduction,anindustrialpulper-sievingmachineisnecessary.Thisalsoactsbyforcingthefruitpulpthroughafinecylindricalmesh.However,thesecostinexcessof£2,500.
Filtering
Tomakeaclearjuice,theextractedjuiceorpulpisfilteredthroughamuslinclothorastainlesssteelfilter.Someofthelargerfilterpresseshaveafilterincluded.Althoughjuiceisnaturallycloudy,someconsumerspreferaclearproduct.Itmaybenecessarytousepecticenzymestobreakdownthepectinandtohelpclearthejuice.Pecticenzymesmaybedifficulttofindandexpensiveandthereforeshouldonlybeusedifreallynecessaryandreadilyavailable.
Batchpreparation
Whenthejuiceorpulphasbeencollected,itisnecessarytopreparethebatchaccordingtothechosenrecipe.Thisisverymuchamatterofchoiceandjudgement,andmustbedonecarefullytosuitlocaltastes.Juicesaresoldeitherpureorsweetened.Fruitsquasheswouldnormallycontainabout25%fruitmaterialmixedwithasugarsyruptogiveafinalsugarconcentrationofabout40%.Squashesaredilutedwithwaterpriortouseand,asthebottleisopened,partlyusedandthenstored,itisnecessarytoaddapreservative(forexample800ppmsodiumbenzoate).
Anotherpopularproductisfruitnectar,whichisasweetmixtureoffruitpulp,sugarandwaterwhichisconsumedona'oneshot'basis.Essentially,theseconsistofa30%mixoffruitpulpandsugarsyruptogiveafinalsugarlevelofabout12-14%.
Allfruitscontainsugar,usuallyaround8-10%.Theactuallevelsvaryfromfruittofruitandwiththestageofripenessofthefruit.Theyalsovarywithinthesamefruitgrownindifferentpartsoftheworld.Theadditionofsugartothefruitpulptoachievetherecommendedlevelsforpreservationmusttakeintoaccounttheamountofsugaralreadypresentinthejuice.Itisimportanttoachievetheminimumlevelthatwillpreventthegrowthofbacteria,however,oncethatlevelhasbeenachieved,itispossibletoaddmoreiftheconsumersrequireasweeterproduct.Theamountofsugaraddedinpracticeisusuallydecidedbywhatthepurchasersactuallywant.ThePearsonSquareisausefultooltousetohelpwithbatchformulation(seetheappendix)andtocalculatetheamountofsugartobeaddedforpreservation.
Inallcases,sugarshouldbeaddedtothefruitjuiceasasugarsyrup.Thesyrupshouldbefilteredthroughamuslinclothpriortomixingtoremoveparticlesofdirtwhicharealwayspresent.Thisgivesaclearer,higherqualityproduct.
Pasteurisation
Alltheproductsmentionedaboveneedtobepasteurisedat80-95°Cfor1-10minutespriortohot-fillingintobottles.Atthesimplestlevel,thismaybecarriedoutinastainlesssteel,enamelledoraluminiumsaucepanoveragasflame,butthiscanresultinlocalisedoverheatingatthebaseofthepan,withconsequentflavourchanges.
Careisneededwhenproducingpineapplejuiceduetoaheatresistantenzymeinthejuice.Theenzymedamagesskinafterprolongedcontactandworkersshouldthereforewearglovestoprotecttheirhands.Thejuicemustbeheatedtoahighertemperatureforalongertimetodestroytheenzyme(egboilingfor20minutes).
Itisbesttousestainlesssteelpanstoheatfruitjuiceastheacidityofthejuicecanreactwithaluminiuminaluminiumpansduringprolongedheating.However,largestainlesssteelpansareveryexpensiveandmaynotbeaffordablebythesmallscaleprocessors.Togetroundthisproblem,itispossibletousealargealuminiumpantoboilthesugarsyrup.Theboilingsyrupcanthenbeaddedtoagivenamountoffruitjuiceinasmallstainlesssteelpan.Thisincreasesthetemperatureofthejuiceto60-70°C.Thejuice/syrupmixtureisthenquicklyheatedtopasteurisingtemperature.
Bottlesize(litres)
Pasteurisationtimeat80°C(minutes)
0.33
10
0.5
15
0.7
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