Equipment and technologies
Juice production is one of the fastest growing branches of the fruit and vegetable industry both in our country and abroad. Not only the number of juices produced is increasing, but also their range.
The Soviet Union occupies one of the leading places in terms of production volume and range of juices. Along with clarified transparent juices, which have an attractive appearance but do not contain many nutrients and biologically active substances removed during clarification, a wide range of juices containing the pulp of fruits or berries are produced - juices with pulp, or nectars. In these juices, basically all the components of the raw materials used are preserved, with the exception of indigestible waste, which is why they are also called liquid fruits. An intermediate position between these two groups is occupied by unclarified juices, from which the pulp has been removed, but some colloidal substances of the raw material are left. In appearance they are cloudy and opalescent.
In recent years, the production of drinks based on natural juices, both clarified and unclarified, and various purees has also developed. The need for their production was caused, on the one hand, by the growing consumer desire to consume natural products, especially juices, and on the other hand, by the high extract content of juices, which makes it difficult to use them as thirst quenchers.
Unlike foreign drinks, which sometimes contain no more than 10% fruit base, domestic soft drinks contain at least 40%, which determines their sufficient nutritional and biological value.
Technological process for the production of clarified fruit and berry juices
These juices are produced from fresh or frozen fruits and berries, as well as from appropriately prepared semi-finished products.
Despite the wide variety of juices, their production consists of a number of identical operations, namely: storing raw materials, sorting, calibrating, cleaning, washing and other processes for preparing raw materials, obtaining juices, packaging products in jars, capping and sterilization (pasteurization) cans of juice (Fig. 64). The methods and parameters for carrying out these operations are different for specific types of fruits and berries and the juices produced from them.
Delivery, storage, washing of raw materials. For processing, fruits and berries of certain varieties with a maximum permissible mass fraction of dry substances in raw materials are recommended, since control over this indicator is necessary to ensure the production of high-quality products.
Pome and stone fruits are delivered to the enterprise and stored in wooden boxes with a capacity of no more than 16 kg, berries - in sieves with a capacity of 4-6 kg, blueberries - in boxes or baskets with a capacity of 10-15 kg, lingonberries, cranberries, red
Currants, viburnum, rowan, rhubarb, sea buckthorn - in boxes or baskets with a capacity of 10-15 kg or barrels with a capacity of no more than 50 dm 3. Transportation of pome fruits in containers is allowed.
Rice. 64. Technological scheme for the production of clarified apple juice:
1 - shaking strainer; 2- gooseneck elevator; 3 - fan washing machine; 4 - roller conveyor; 5 - shower nozzles; 6 - crusher; 7 - conical tank; 8 - hydraulic three-frame pack press; 9 - correction tank; 10 - collection; 11 - precoat filter; 12 - plate pasteurizer; 13 - line for preparing, filling and capping bottles with juice; 14 - light screen; 15 - kieselguhr filter; 16 - tubular pasteurizer-cooler.
Typically, raw materials are stored at raw material sites before processing.
| Table 24. Shelf life of raw materials before processing into fruit and berry juices |
|||||
| Raw materials | Storage on raw materials site plant, h |
Storage in the refrigerator camera, days |
Raw materials | Storage on raw materials site plant, h |
Storage in the refrigerator camera, days |
| Raspberries, strawberries Blueberry Blueberry Blackberry Black currant Red Ribes Grape Cranberry, lingonberry, Rowan Dogwood |
5 8 8 8 24 24 12 5 days |
2 2 4 - 4 2 4 30 |
Gooseberry Viburnum, cherry Cherry Plums Pomegranates, rose hips Quince Apples and pears years Autumn apples and pears varieties Barberry non-winter varieties |
48 12 12 12 4 days 5 days 48 7 days |
- 7 4 14 14 40 20 40 |
When processing, it is necessary to observe the order of receipt of raw materials and take into account its quality.
Raw materials are inspected for quality on tables or conveyor belts, and then sent to washing, which is carried out to remove mechanical impurities, microorganisms and pesticides from the surface of fruits and berries.
Wash with clean running water that meets the requirements for drinking water, berries are rinsed in the shower, stone fruits and pomegranates - in a KUM-1 type washing machine, pome fruits - in two machines installed in series (drum and unified). Then, affected and unripe fruits and berries and foreign impurities are removed on a sorting and inspection conveyor. The sepals are removed from rose hips. Pomegranate peels are peeled using pomegranate peeling machines. In purified grains, impurities in the form of scraps of skin and films of no more than 10% are allowed. Peeled pomegranate seeds are sent for pressing without preliminary crushing.
Splitting up. To facilitate the release of juice, fruits and berries are crushed. When crushing, it is necessary to strive to ensure that the number of crushed pulp cells is at least 75%.
Apples, pears and quinces are crushed into particles 2-6 mm in size using universal knife or grater-knife crushers. Stone fruits (cherries, cherries, plums) are crushed on roller crushers so that the stones remain intact. The amount of crushed seeds should not exceed 15% of the pulp mass. During rolling, the plums should only be flattened, but not lose their integrity.
Rose hips are crushed into particles 1-2 mm in size, berries are crushed into large particles, ripe raspberries, strawberries, blueberries and blueberries are not crushed, lemongrass is crushed into large particles, preventing the seeds from being crushed.
Processing the pulp before pressing. Increasing juice yield, facilitating and accelerating pressing can be achieved in various ways. Thus, fruit pulp with a high pectin content is treated with non-political enzymes. The drug is added in the form of a suspension in an amount of 0.01-0.03% by weight of the pulp, left for 1-2 hours. Heating the pulp to 40-45°C accelerates the effect of the drug.
Another way to prepare the pulp for juice extraction is by heating it, which ensures coagulation of protein substances, increasing the permeability of cell tissue, inactivating enzymes, and facilitating the transition of coloring substances from the skin to the juice. Heat the pulp or whole fruits and berries: sea buckthorn to 30-35 °C, plum to 70-72, wild rose hips to 55-70 °C. When heated, 10-15% water is added to these fruits and berries, and 40% to rose hips.
It is allowed to treat crushed or whole fruits and berries with electric current to destroy protoplasmic membranes and increase cellular permeability. For this purpose, electroplasmolyzers such as A9-KED or plasmolysis 2M are used.
Pressing. To obtain juice, the pulp of fruits and berries is pressed using presses of various systems: hydraulic, screw or pneumatic. Peeled pomegranate grains are pressed on a continuous press HPND-5 or a pack press. For other fruits and berries, it is recommended to use hydraulic bag presses of various types (2P-41, ROK-200, MS-437) or stackers (VSSSH-10, RZ-VSR-10, JIJI-33). On basket and pack presses, juice is extracted with a gradual increase in pressure. You cannot immediately apply strong pressure, as this will clog the channels in the pulp for the movement of juice and reduce its yield.
When pressing apples of summer varieties, the thickness of the bag when filling should not be more than 4 cm. To facilitate pressing the pulp of apples of these varieties, it is recommended to add 4-5% rice or oat straw to it.
Pressing pomegranate seeds on pack presses is carried out according to the same regimes as for apples. When pressing them on screw presses, the outlet pressure is regulated in such a way as to prevent grinding of the seeds. The juice of the 1st and 2nd fractions is sent for the production of pasteurized pomegranate juice, the pressed 3rd fraction is sent for the production of pomegranate extract-seasoning “Narsharab”.
The pomace remaining after pressing fruits and berries is recommended to be used to obtain fermented juices, raw alcohol, vinegar, dry pectin or liquid pectin extracts.
Purification of juice to remove large suspended matter is carried out on a coarse impurity purifier type KS-12 or on a sieve with a hole diameter of 0.75 mm.
Clarification is used to remove fine suspended matter and colloidal substances to obtain a transparent product.
Thus, to break down pectin substances, which have a protective effect that prevents the sedimentation of suspended matter, pectolytic enzyme preparations are used. When processing apple, plum, blackcurrant and other juices rich in pectin substances, the drug is added to the juice in the form of a suspension in an amount of 0.01-0.03% by weight of the juice and kept for 2-3 hours at 18-20 ° C or 1 hour at 40-45 °C. For this purpose, fermenters or a closed, thermally insulated collection with a stirrer are used.
Gelatin can be added to pectolytic enzyme preparations. In this case, the splitting and precipitation of pectin substances occurs due to the neutralization of negatively charged particles of pectin substances by positively charged particles of gelatin. A suspension of pectolytic enzyme preparation is added to the juice, kept for 25-30 minutes, then 0.005 to 0.02% gelatin is added in the form of a 1% solution, mixed thoroughly and kept for 2 hours. The optimal temperature for processing the juice is 18-20 ° C.
For apple, cherry, lemon and other juices, instant heating to 80-90 °C and holding at this temperature for 1 minute, rapid cooling to 35-40 °C, then separation are also recommended.
Heating is often combined with other methods of clarification, which increases the coagulation of protein substances, disrupts the stability of the colloidal system and precipitates colloids.
The process is carried out on plate pasteurizers-coolers or in tubular three-section heaters. To clean juices from suspensions, separators of the VSM, G9-KOV or VSS types are used.
Then the juice is filtered using chamber or asbestos filters through T-grade filter cardboard or AK-3 asbestos mesh. This operation is necessary to obtain a visually transparent product by removing turbid substances from the juice: small tissue scraps, coagulated colloids. After filtering, the juice should be crystal clear.
When filtering, it is necessary to continuously monitor the transparency of the juice flowing from the apparatus. When turbidity appears, the juice is returned back to the filter. If after 20-30 minutes of filtering the juice does not become clear, you must stop filtering and recharge the filter. Typically recharging is carried out 2-4 times per shift.
With the performance slot, the filter can be recharged on the go without stopping the filter by changing the direction of juice flow. To do this, the filter is first disconnected from the line and then reattached so that unfiltered juice passes over the plates on the side where the filtrate previously flowed. The cloudy juice, falling on the clean side of the plate, is filtered and washes off the sediment from the filter plate.
The first portions of juice containing turbidity are collected separately and, after settling, decanted and filtered again.
When clear juice begins to come out of the filter, a switch is made and the juice is sent to subsequent technological operations.
Technological process for the production of unclarified juices
These juices are made from apples, quince, strawberries, gooseberries, viburnum, raspberries, rhubarb, plums, black and red currants, blueberries, dogwoods, cherry plums, tkemali, sea buckthorn, sloe, barberries, pomegranates, rose hips, blueberries, and rowan.
The technological process after preparing the raw material, crushing it, pressing and filtering is as follows. The strained juice is heated in a tubular heater to a temperature of 85-90 °C (pomegranate juice - up to 70-80 °C). Heating is carried out for 20 s. After this, the juice is quickly cooled to a temperature of 30-35 ° C and sent for separation.
The separation mode is selected in such a way that the content of suspended matter in the finished juice is no more than 0.3%. If there is significant turbidity, the juice after separation can be filtered.
Before packaging, prepared juices are subjected to deaeration at a temperature not exceeding 35 °C and a residual pressure of 5-8 kPa. After deaeration, the juice is heated to 75-78 °C and fared.
Pasteurization of juices in jars with a type I whisk and in bottles using basket autoclaves is carried out at a temperature of 85°±1°C for 10-20 minutes.
Hot filling without subsequent pasteurization or sterilization of juice in containers can be used when packaging in containers with a capacity of 2000 cm3 or more. In this case, the juice is heated to 95-97 ° C and immediately poured into hot prepared jars. Jars with hot juice are kept for 15-20 minutes, after which, to reduce the long-term effect of heat on the juice, artificial cooling is carried out by blowing cold air or spraying with water at a gradually decreasing temperature.
Hot filling of juice into bottles with a capacity of 500 cm 3 is allowed on mechanized flow lines with automatic temperature control with mandatory compliance with increased sanitary requirements.
Natural apple juice and with sugar can be pasteurized in a continuous operation apparatus A2-KPO.
The norms of waste and losses during the production of juices depend on the type of raw materials processed and are established by the current regulatory and technical documentation.
Technological process for the production of juices with pulp
These juices are produced natural, with sugar and blended from the same types of raw materials as unclarified ones, as well as from apricots and peaches (Fig. 65).
Delivery, acceptance, storage of raw materials and their pre-processing, including grinding, are carried out in the same way as for the described juices.
Crushed or whole fruits and berries are heated in screw heaters or digesters to soften the pulp. Cherries, dogwoods, plums are heated to 85-90 °C, peaches and apricots - to 70-75 °C. Where stone fruits have been heated prior to pitting, secondary heating is not required.
The crushed mass of quince and apples is heated to 90-95 °C, berries - to 70-75 °C. Rose hips are not heated.
Heating can be carried out with dead or hot steam. When heated with deep steam, it is allowed to add up to 15% water to the fruit mass.
When using filter centrifuges, the crushed mass is heated at the moment of crushing the fruit at a temperature of 90-95 o C for 16-30 s, for which live steam is supplied to the crusher and the hollow shaft of the screw feeder installed under the crusher.
Juice extraction should be carried out immediately after preparing the fruit. It must be taken into account that proper juice quality can only be ensured if the processes of crushing, heating and extracting juice are carried out continuously.
Depending on the type of juice (natural or with sugar), different equipment is used to obtain it.
Natural juices are obtained using continuously operating filter centrifuges NVSh-350, FGSh-401K or extractors of the 2P8-1M type.
Natural juices from apples and quince can also be obtained by rubbing the heated mass on a double rubbing machine and then diluting the strained mass with unclarified pressed juice from the same raw materials.
Rice. 65. Technological scheme for the production of juices with pulp:
1 - machine for removing cherry stalks; 2 - fan washing machine; 3 - sorting conveyor; 4 - elevator; 5 - hammer crusher; 6 - screw heater; 7 - first wiping machine; 8 - second wiping machine; 9 - product pump; 10 - syrup boiler; 11 - collections; 12 - centrifuge; 13 - homogenizer; 14 - tubular heater; 15 - vacuum pump; 16 - deaerator.
When obtaining juice in filter centrifuges, the rotors must be equipped with sieves with round holes with a diameter of 0.06-0.10 mm (for plums, apples, cherries) or slot-shaped ones with holes of 0.1X2 mm (for quince, cherries and apples).
The juice obtained from the centrifuge is passed through a finisher with sieves having holes with a diameter of 0.4 mm. The finisher operating mode is set in such a way that the amount of pulp in the juice does not exceed that required by the standard. To prevent aeration of the juice, live steam is supplied to the finisher to create a steam curtain.
When using extractors, sieves with a diameter of 0.8 mm are installed, and the hot crushed mass is passed through them.
When using double grinding machines, the hot crushed mass of apples and quinces is first passed through a machine with sieves having holes with a diameter of 2-1.5 mm, then through sieves with holes with a diameter of 0.5-0.4 mm.
Natural juice with pulp from rose hips for the production of blended juices is obtained only in continuous filter centrifuges, while water in the amount of 50% of the rose hip pulp is first supplied to the crusher. Then the crushed pulp with water is fed into a centrifuge by a screw feeder to extract the juice. Sieves with slot-like holes measuring 0.1X2 mm are installed in the centrifuge rotor.
When processing light-colored fruits, ascorbic acid is added in the form of a 5-10% solution to avoid darkening of the juice. A solution of ascorbic acid is added to the fruit when crushing or to the juice immediately after it is extracted. When producing natural juices using filter centrifuges, the ascorbic acid solution must be added to the crusher simultaneously with the fruits.
Add 0.04% to apples and quinces, and 0.03% ascorbic acid to plums, peaches and apricots.
To juices from dark-colored plums, gooseberries, strawberries to improve color, and to peach, apricot and apple juices to lower the pH value and improve taste, add 0.15-0.20% citric acid.
Blended juices are obtained by mixing various juices in accordance with the recipe. Sugar syrup is added to some juices to create a harmonious taste.
After mixing, the juice is homogenized. Homogenization of apple and cherry juices is carried out at a pressure of 15-17 MPa, other juices - at a pressure of 12-15 MPa.
Homogenized juice is subjected to deaeration at a temperature of 35-40°C and a residual pressure of 6-8 kPa. The duration of deaeration should not exceed 10 minutes. After deaeration, the juice is heated to a temperature of 70-80 °C and sent for packaging.
Packaged juice is sterilized, pasteurized in autoclaves or continuous pasteurizers at temperatures of 85-100 ° C, depending on the type of juice and the capacity of the container for a pH below 3.8. In case of a higher pH value, sterilize at a temperature of 110 °C.
According to organoleptic indicators, fruit and berry juices with pulp should have evenly distributed finely ground pulp. In this case, slight delamination and a small compacted sediment at the bottom of cans and bottles are allowed, and in cherry and plum juices - sedimentation of pulp. Foreign tastes and smells are not allowed. Depending on the name of the juice, the content of dry substances in them is normalized by the current standard from 8 to 18%, titratable acidity - 0.2-1.9%, for cherry juice - up to 2.4% based on malic acid.
Juices with pulp are of great importance in human nutrition due to their content of easily digestible carbohydrates, organic acids, pectin, polyphenolic and nitrogenous substances. Juices are rich in vitamins and minerals.
Among fruit juices, natural grape juice occupies a special place in the production of canned products and human nutrition. The technology for the production of grape juice differs from the production of other natural juices, therefore, separate regulatory and technical documentation has been developed for it.
Technological process of grape juice production
Natural grape juice is made from fresh grapes, freshly squeezed must or semi-finished juice.
It is allowed to send grapes of one ampelographic variety with a dry matter content of at least 16.2% for processing to obtain vintage juice. The highest grade is prepared from one or a mixture of grape varieties with a mass fraction of dry substances of at least 14.2%. It is not allowed to use hybrid grapes from direct producers for the production of grape juice.
Grapes are delivered for processing in box pallets with a layer of no more than 200 mm, boxes No. 1 and 5, as well as in boat containers with a layer of no more than 500 mm.
The wort is supplied in tanks made of non-corrosive materials, the semi-finished juice is supplied under aseptic conditions in railway or road tanks, as well as in glass jars with a capacity of 10 dm3, sealed with lids.
The shelf life of grapes from harvest to processing should not exceed 12 hours, the must from receipt to processing - 4 hours.
The grapes received by the enterprise are washed in fan washing machines of the KUV and A9-KMB-12 types. Processing of grapes without washing is allowed. In this case, container boats are washed with a stream of water after each voyage. Boxes and containers are washed with a stream of hot water at the end of each day. After washing, the grapes are inspected to remove foreign impurities, rotten and moldy bunches.
Grape processing is carried out on complete lines or on prefabricated lines with the installation of VGD type roller crushers, screw stackers and presses.
The wort fraction from the drain, as well as the 1st and 2nd fractions from the press, is sent to the juice. Wort purification involves straining, separating and standing in the cold.
Straining is carried out on coarse impurity separators KS-4 and KS-12, equipped with sieves with a diameter of 0.8 to 1.3 mm.
Separation is carried out on disc separators.
During cold processing, the wort is cooled to a temperature of 0-5 °C and sent to tanks installed in refrigerated rooms with a temperature of - 1 to - 3 °C. The duration of settling is 18-24 hours. At the end of settling, the wort is decanted and the clarified part is sent for storage under aseptic conditions or in refrigerated rooms. The remaining sediment is heated in tubular heat exchangers to a temperature of 96±2°C, cooled to a temperature of 40-45°C and treated with an enzyme preparation in an amount of 0.3 g/l. The duration of treatment of sediment with enzyme preparations should not exceed 4 hours.
Semi-finished juice can be prepared and stored in tanks with a capacity of 24-300 m 3. In this case, an aseptic method is used for canning juices or storing them with sorbic acid.
If self-clarification of the juice material does not occur during storage of the semi-finished juice, then it is artificially clarified with enzyme preparations in combination with bentonite or gelatin.
The optimal temperature for the action of enzyme preparations is 40-50 °C.
The dose of the drug is determined by trial treatment in the laboratory. To do this, seven 500 ml cylinders are filled with juice. In six of them, an enzyme preparation is added in various doses depending on its activity. One cylinder is left for control. The drug is administered in the form of a suspension, which is prepared as follows. The required amount of the drug is weighed into a glass with a capacity of 50 ml with an accuracy of 1 mg, poured with a small amount of warm juice (35-40 ° C) from the appropriate cylinder, stirred thoroughly and left for 35-40 minutes. After this, the suspension is poured into a cylinder, the glass is rinsed with the same juice, the juice is mixed in the cylinder and left for 2 hours. When combined with gelatin, cylinders are placed in parallel with the addition of gelatin of different concentrations.
After sedimentation of the resulting sediment, the dose of the enzyme preparation and gelatin is set according to the cylinder with the lowest dosage, where the best clarification occurred.
Based on the selected dose and volume of the semi-finished wort and sludge being processed, the required amount of the enzyme preparation is weighed out, poured with 3-4 times the amount of juice, kept for 35-40 minutes and added in small portions as the fermenter tank is filled with juice. The required amount of gelatin is added to the fermenter in the form of a pre-prepared solution. To control clarification, the processed juice with added preparations is poured into a cylinder. After about 2-3 hours, the product is decanted from the sediment and sent for further processing.
To obtain crystal clear grape juice, the juice processed in this way is filtered on filter presses through T-grade cardboard.
The main amount of grape juice produced by the enterprise undergoes some aging in tanks.
Juice aging aims to remove tartar.
Cream of tartar is an acidic potassium tartrate, having the formula, with a small admixture of calcium tartrate.
The solubility of tartar is characterized by the following data:
| Temperature, o C |
Solubility, % |
Temperature, o C | Solubility, % |
| 0 10 20 30 40 50 |
0,32 0,4 0,57 0,9 1,31 1,8 |
60 70 80 90 100 |
2,4 3,2 4,5 5,7 6,5 |
Grapes contain up to 0.7% of it, so grape juice at a temperature of 20-25 ° C is a saturated, and in some cases a supersaturated solution. In this regard, the possibility of precipitation of tartar cannot be excluded. Despite the fact that this does not reduce the nutritional value of the juice, the loss of cream of tartar leads to a deterioration in the presentation of the finished product. For this reason, measures are taken to remove excess cream of tartar. There are several ways to remove it.
One of the methods that is most widely used is long-term exposure of juice material in the cold. Self-clarification of the juice occurs for some time, while the protective effect of colloids decreases and, in the presence of
Crystallization centers in the form of mechanical impurities in the juice form crystals of tartar, which begin to grow over time and precipitate. After storage, the cooled juice is filtered.
Rice. 66. Ultra cooler:
1
- pipe for juice; 2
- stirrer; 3
- ammonia shirt.
However, this method is very time consuming. Therefore, searches are underway and an accelerated technology for removing excess tartar has already been developed.
Freshly pressed wort is cleaned and cooled in brine-type plate or tubular heat exchangers to 4-5 °C, and then in ultracoolers (Fig. 66) to a temperature close to cryoscopic (0-1.5 °C). The wort is kept for 36-48 hours to remove tartar and clarify. The wort is then decanted and separated when cooled.
The separated wort is heated to 95±3 °C and cooled to 30-35 °C. Subsequently, the wort undergoes all operations of filtration, packaging, and sterilization.
Another way to prevent loss of tartar is to treat the juice with metatartaric acid.
Metatartaric acid is a mixture of several polymers, the main one of which is the one corresponding to the formula
It is a solid substance, very hygroscopic and easily soluble in water. In aqueous solutions, metatartaric acid gradually adds water and turns into tartaric acid.
Metatartaric acid does not change the taste or color of the juice and is completely harmless. It can be introduced into juice in the form of K, Na or Li salts with the same effect as free. Its stability in juice depends on storage temperature. At 20-23 °C it hydrolyzes within 3 months, after which loss of tartar may occur.
Treatment of juice with metatartaric acid involves the complete preparation of the juice material (cleaning, clarification, heating, cooling, separation and filtration) followed by the addition of metatartaric acid. The amount of metatartaric acid added to the juice should be 0.5-0.6 g/dm3. A concentrated solution of metatartaric acid (250-300 g/dm3) in clarified juice is first prepared, which is then added to the collection for mixing with the juice going for bottling. Mixing the juice with the solution is carried out for 5-6 minutes, after which the juice is transferred to subsequent operations - heating, packaging, capping, sterilization.
To prevent inactivation of the stabilizer due to hydrolysis, high temperatures during heating during pasteurization should be avoided. It is not allowed to hot pack juice treated with metatartaric acid. This juice is stored at a temperature of 10-20 ° C for 6 months, after which the cream of tartar may fall out.
Preventing the loss of cream of tartar can be done by adding soluble calcium salts of organic acids to the juice, resulting in the formation of sparingly soluble calcium tartrate. It precipitates quickly, since its solubility is 30 times less than that of cream of tartar. This process lasts about 10 days at a temperature of - 1 to - 2°C.
Grape juice, which has gone through all technological operations, is sent for packaging.
When packaging followed by pasteurization in autoclaves or continuous pasteurizers, the juice is heated to a temperature of 60-70 °C in plate or tubular heat exchangers.
Hot packing of juice into glass jars with a capacity of up to 3 dm 3 is allowed, which is produced on A2-KLP-75 lines or on automatic fillers ANSM. Packaging is carried out at a juice temperature of 98±2°C, followed by holding the sealed cans for 15-20 minutes, cooling them with water at a gradually decreasing temperature or cold air to a temperature of 30-40°C.
Pasteurization of juices packaged in small containers is carried out at a temperature of 85-90 °C. The duration depends on the capacity of the container. After pasteurization, cans of juice undergo visual inspection in front of a light screen and are labeled.
The norms for product yield and consumption of grapes, must and semi-finished juice are given in table. 25.
According to organoleptic indicators, the finished grape juice should have a natural, well-defined taste and aroma, and in vintage juices they should be characteristic of the given ampelographic grape variety.
| Table 25* Standards for product yield and consumption of grapes, must and semi-finished juice *in the production of grape juice |
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| Production scheme | When processing |
|||||
| grapes on |
wort on |
juice- semi-finished product to natural juice |
||||
| wort |
juice- semifinished |
natural juice |
juice- semifinished |
natural juice |
||
| Production of grape juice with cold purification of the must exit, % consumption, kg/t |
79 |
70,8 |
66,3 |
89,57 |
83,88 |
93,65 |
| Production of grape juice with purification of the must by centrifugation exit, % consumption, kg/t |
79 |
72,2 |
66,5 |
91,41 |
84,2 |
92,1 |
All varieties of grape juice should be clear. In juice of the highest and first grades, slight opalescence and the presence of single crystals of tartar are allowed.
According to the refractometer, the mass fraction of dry substances in the juice should be: vintage and premium grade at least 16%, grade I at least 14%, acidity - 0.2-1%. The mass fraction of sediment in branded juice should be no more than 0.08%, premium - 0.1%, I - up to 0.4%.
Grape juice is a source of carbohydrates in human nutrition. 1 dm 3 of juice contains 160-220 g of mono- and disaccharides. Organic acids are represented mainly by tartaric acid. In addition to it, the juice contains small quantities of malic, citric, succinic, glycolic and other acids.
Of the microelements, grape juice contains potassium salts to a greater extent, and Na, Ca, Mg, and P to a lesser extent. The juice contains ascorbic acid in small quantities.
Some natural juices produced by industry have a sharp taste due to their high content of organic acids and high overall extract content. These are juices from cranberries, sea buckthorn, rowan, cherries, black currants and some other fruits and berries. Due to the low content of organic acids, juices from apricots, peaches, pears, plums, and summer apples do not have refreshing and thirst-quenching properties.
The technology developed in recent years provides for the production of a finished product that has the advantages characteristic of drinks.
Technological process of beverage production
In the USSR, these products include canned food, which mainly contains no more than 50% fruit, vegetable or fruit and vegetable parts. The rest comes from the added sugar syrup. For some drinks, the use of natural stabilizers, as well as citric, ascorbic acids and other additives, is allowed.
The dry matter content in the finished product is at least 11%, which corresponds to the recommendations of the USSR Ministry of Health and the theory developed by the Institute of Nutrition of the USSR Academy of Medical Sciences on a balanced diet. The release of such drinks with reduced sugar content makes it possible to use them in the diet of various categories of the population. Their production technology basically corresponds to that adopted for the production of blended juices with sugar or pulp.
Puree or juice prepared according to the recipe is mixed in mixers with freshly prepared syrup. The mixture for drinks with pulp is homogenized at a pressure of 15-17 MPa in devices of various designs, followed by deaeration for 10 minutes at a temperature of 35-50 ° C and a residual pressure of 8-6 kPa in deaerators or vacuum heaters.
After deaeration, the mixture for the clarified drink is filtered, heated to 80 °C and sent for bottling.
The technological scheme for the production of fruit drinks is shown in Fig. 67.
The production of fruit drinks contributes to a more rational and economical use of material and labor resources of canning enterprises.
Fruit drinks are also produced for dietary nutrition based on fruit purees with the addition of dairy products and sugar. In the production of fruit and milk drinks, freshly prepared fruit puree is used. Dairy products (skim milk, buttermilk, whey) are heated to a boil, filtered through a thick fabric filter and immediately sent for mixing with other components. Sugar syrup is added at a temperature of 90-95 °C.
The production of fruit-based drinks with the addition of mineral water has been mastered. These include the Sochi drink, made from natural or concentrated clarified apple juice and mineral water with added sugar.
Rice. 67. Technological scheme for the production of fruit drinks:
1 - sifter with a magnetic catcher; 2 - collection; 3 - pump; 4 - filter; 5 - six-wheel pump for viscous products; 6 - homogenizer; 7 - vacuum heater; 8 - filter press: 9 - filler; 10 - automatic capping machine; 11 - autoclave; 12 - container tipper; 13 - calibrator; 14 - washing machine; 15 - conveyor; 16 - steam-thermal apparatus; 17 - inspection belt conveyor; 18 - conveyor-elevator; 19 - crusher: 20 - dehyster.
Technological process for the production of concentrated fruit juices
In the USSR, concentrated fruit juices are mainly produced from apples, grapes and citrus fruits (tangerines).
In the production of concentrated apple juice (Fig. 68), natural juice is obtained, it is purified from suspensions in centrifuges and sent to an installation for capturing aromatic substances. Sometimes freshly squeezed juice is instantly heated to 92-96 °C and cooled to 40 °C to coagulate colloids.
In the installation for capturing aromatic substances, 10-15% of the water evaporates. The amount of aromatic substances sampled and the reflux flow in the column are controlled using rotameters so that the concentration of aromatic substances leaving the installation is 1:150 or 1:200. The concentration of aromatic substances is set in accordance with their yield relative to the volume of juice taken. For example, if 10 m 3 of juice is passed through the installation and 50 dm 3 of aromatic substances are obtained, then the concentration of the latter will be equal to 50:10,000 = 1:200. The density of aromatic substances is periodically monitored using a hydrometer. It should be in the range of 0.97-0.99 g/cm3.
De-flavored, partially concentrated juice is cooled to a temperature of 42-45 ° C and sent for clarification. Juices are clarified in several ways: with enzyme prelarates, gelatin, bentonite, heating, settling and filtration.
The juice is treated in fermenters with purified pectolytic enzyme preparations, for example pectofoetidin P10X, approved for use by health authorities.
Vertical enameled or stainless steel collectors with a capacity of 4-6 m 3 can be used as fermenters, depending on the productivity of the line. Collectors must be equipped with mixers, level indicators and have pipes with taps for loading dearomatized juice, adding an enzyme preparation and draining sediment.
The dosage of the enzyme preparation is determined by the laboratory depending on the activity of the drug, but not higher than 0.03% of the mass of the processed juice.
When obtaining unclarified concentrated apple juice, treatment with enzyme preparations is necessary to partially depectinize and reduce the viscosity of the juice in order to facilitate its boiling and prevent gelation of the concentrate during production and storage. To do this, 0.005-0.01% of the enzyme preparation is added to the juice, kept for 2-3 hours, decanted and sent for filtration. To produce clarified concentrated juice, the dosage of the enzyme preparation is increased to 0.03%. In addition, the juice is additionally treated with a gelatin solution. The juice is mixed with clarifying agents in a tank with a stirrer for 5 minutes and kept at relative rest for 2-3 hours. The resulting large flakes precipitate. After this, the juice is decanted from the sediment, instantly heated to 75 ° C to stop the action of enzymes, cooled to 40 ° C and sent for filtration.
Rice. 68. Technological scheme for the production of concentrated juices:
1 - fan washing machine; 2 - belt conveyor; 3 - elevator; 4 - crusher; 5 - pack press; 6 - collection; 7 - pump; 8 - separator; 9 - tubular heater; 10 - nutrient tank; 11 - rotameter; 12 - evaporator; 13 - reflux condenser; 14 - refrigerator; 15 - distillation column; 16 - absorption column; 17 - low-temperature cooler; 18 - surface cooler; 19 - fermenters; 20 - filter press; 21 - vacuum pump; 22 - evaporation unit ASG-2000; 23 - filler; 24 - seaming machine.
Concentrated grape juice is only available clarified. To do this, various methods are used to clarify the semi-finished juice, as in the production of natural grape juice. Special requirements are imposed on the removal of tartar, since upon concentration its content exceeds the maximum concentration and it precipitates. To do this, freshly squeezed, purified juice is cooled first in plate or tubular coolers to 4-6 °C, and then in ultracoolers to a temperature close to cryoscopic, but not higher than -1.5 °C.
Cherry juice is processed by heating to 85-90 °C and rapid cooling to 35-40 °C. After heating, the juice is separated and sent for filtration.
Cranberry juice is processed in the same way as apple juice, but without gelatin.
Filtered juice is sent for concentration in continuous apparatus at a residual pressure of no more than 26.6 kPa.
Unclarified juice is concentrated to 55% of dry matter, clarified juice - to 70%, except for cranberry juice, which is concentrated to 55% of dry matter.
Concentrated juice with a solids content of 70% is packaged in prepared containers immediately after boiling at a temperature of 45-50 °C. Concentrated juice containing 55% solids is preserved with sorbic acid or sterilized to avoid bacterial spoilage.
When hot filling, the concentrated juice, immediately after boiling, is heated in a tubular pasteurizer to 85-86 ° C and poured into prepared hot jars.
When storing concentrated juice, some darkening of color is observed. The intensity of darkening increases at higher storage temperatures. The darkening of the juice is caused by a non-enzymatic process in which, as a result of the interaction of sugars, nitrogenous and tannin (polyphenolic) substances, and organic acids, dark-colored compounds are formed - melanoidins. Concentrated fruit juice is dominated by monosaccharides, which at low pH and high temperatures undergo chemical transformations resulting in the formation of dark-colored compounds and others, among which 5-hydroxymethylfurfural (5-OMF) predominates.
To prevent the darkening of such concentrates and the formation of 5-OMP, it is necessary to cool them after preparation and store them at the lowest possible temperature (not higher than 20 ° C).
The consumption rates of fresh raw materials for the production of 1 ton of concentrated juice are calculated based on the established amount of waste and losses. For example, when processing apples into clarified concentrated juice, waste and losses in the amount of 51% are accepted, including: losses during technological operations - 15%, waste - 36%.
In the production of grape juice, losses amount to 8% waste - 36-44%.
The rate of raw materials is calculated using the formula
Where X- rate of consumption of raw materials, kg; A- content of dry substances in concentrated juice, %; b- waste and losses during production, %; With- content of dry substances in raw materials, %.
The finished concentrated juice, intended for individual consumption through retail, is mixed with distilled aromatic substances before packaging. To do this, the juice is placed in a reactor or closed container with a stirrer and the appropriate amount (about 2%) of aromatic substances is added to it with continuous stirring. The temperature of the juice when adding aromatic substances should not be more than 40 °C.
Concentrated juices should be shipped to public catering networks and for industrial processing together with aromatic substances in an amount of 2% of the juice volume separately. The labels indicate the amount of water required for dilution.
Tangerine concentrated juice is prepared from natural juice obtained by squeezing fresh tangerines on rollers or presses. The juice is passed through a grinding machine with holes in a sieve with a diameter of no more than 0.2 mm. After this, it is sent to an installation for removing aromatic substances (see Chapter 8). De-flavored juice is fed into plate or tubular heat exchangers, where it is heated to a temperature of 90 °C, kept for 1-3 minutes and quickly cooled to a temperature of 50-60 °C.
When concentrating juice, it is necessary to maintain pressure within the range of 14.6-26.6 kPa.
Tangerine juice is concentrated to a dry matter content of 45%. Concentrated tangerine juice is packaged in containers with a capacity of no more than 3000 cm3, sterilized at a temperature of 100 °C for 50 minutes.
The juice is packaged hot in large containers with the addition of 0.067o sorbic acid.
The concentrated juice is shipped to the consumer separately from the essential oil (1.2 kg of essential oil per 1 ton of juice).
The shelf life of juice in jars with a capacity of 3000 cm3 is 3 years, in large containers - 1 year.
Technological process for the production of fruit and berry extracts
Extracts are the same concentrated juices freed from pectin, in the production of which the use of sulfated materials is allowed. Therefore, during their manufacture, aromatic substances are not captured. Extracts are used to prepare soft drinks.
Technological operations for preparing raw materials for obtaining juice materials are similar to those for the production of natural juices. The use of frozen fruits and berries is allowed. Juice from them can be obtained by pressing after defrosting or by diffusion. Frozen berries (for example, lingonberries or cranberries) are defrosted in water heated to 30 °C. To do this, berries in baskets are immersed in water for 1 minute. The baskets are then removed and the water is allowed to drain. Several batches of berries are thawed in the same water until the dry matter content in the water exceeds 1%. This water is then drained and further used for diffusion. After defrosting, the berries are processed in a roller crusher with grooved rollers adjusted so that cracks form on the skin of the berries, but the berries themselves remain intact.
To obtain juice, defrosted berries are loaded into diffusers. For diffusion, water in which defrosting was carried out is used. Diffusers (5-10 pcs.) are connected in series to form a battery. The battery is started as follows. The prepared raw materials are loaded into the first diffuser, filled with water and kept for 40-60 minutes. Then the second diffuser is loaded with raw materials and the diffusion juice is pumped from the first diffuser to the second. Water is poured into the first again and the raw materials are kept in it again for 40-60 minutes. After this, the third diffuser is loaded with raw materials and the juice is pumped from the second diffuser to the third, and from the first to the second. The raw material in the first diffuser is again filled with water, and the entire cycle is repeated until all diffusers of the battery are filled. When the last (head) diffuser is filled with raw materials, juice from previous diffusers is pumped into subsequent ones and the first diffuser is filled with fresh water for the last time. At the end of the extraction, the finished juice is pumped out from the last (head) diffuser, and the extracted pulp from the first diffuser is unloaded and filled with fresh pulp. After putting the diffusion battery into operation, it is necessary to pump out juice from the head diffuser every 40-60 minutes according to the established schedule, depending on the diffusion cycle, pump juice from each previous one to the next one, unload the tail diffuser from extracting pulp and load it with fresh pulp. Sulfur dioxide is added to the resulting diffusion juice in an amount of 0.07% in order to prevent its fermentation and better clarification. Then the juice is heated and sent for clarification. When processing freshly squeezed juices, it is necessary to capture aromatic substances and return them to the prepared extract.
Juice clarification can be carried out with enzyme preparations and bentonite. Treatment with enzyme preparations is recommended for apple and other juices rich in pectin. Clarification should ensure complete destruction of pectin substances. The absence of pectin is determined by an alcohol test. To do this, add 5 ml of 96% alcohol to 5 ml of processed juice and heat to a boil. If there is no pectin, the sample after cooling should be transparent, without sediment.
It is recommended to clarify sulfated apple and pear juices with chemically pure calcium carbonate. The dose of CaCO 3 is established in the laboratory by trial clarification, but not more than 500 mg per 1 ton of juice. Lightening can be carried out at room temperature, but a temperature of 4-8 °C is more desirable. With this clarification, pectin binds with calcium carbonate and precipitates in the form of calcium pectate. Monitoring of pectin removal is carried out using an alcohol test. Treatment with bentonite is carried out in the same way as for natural juices. The clarified juice removed from the sediment is filtered on filter presses. The juice should be completely clear, without opalescence.
Boiling of juice is carried out in a vacuum apparatus of various types at a residual pressure of at least 12 kPa. Before boiling, the juice is heated to 87-92 °C. This is necessary to suppress the activity of microorganisms that cannot be destroyed at low boiling temperatures in vacuum devices.
In batch devices, juice is boiled using the continuous topping method. The readiness of the extract is determined by its density. Due to the fact that when the extract is cooled, its density increases, the finished product should be unloaded from the vacuum apparatus at a density that is 0.011-0.017 less than the density of the product according to the approved regulatory and technical documentation.
Titratable acidity (calculated as malic) for most extracts is 5-7%, for grape extract - 1.8, sea buckthorn - 1.2, cranberry - 20%. According to commercial grade, extracts are produced in the highest and first grades. For the highest grade, the content of sulfurous acid and pectin in the extract is not allowed. In grade I, the allowed content of sulfur dioxide is no more than 0.05%, and pectin is no more than 0.35%.
When determining the norms for juice consumption to obtain an extract, losses and waste of juice in the amount of 7-9% are accepted. The boiled extracts are cooled to 20-25 °C and concentrates of aromatic substances are added to them.
Extracts packaged in small containers are sterilized at 100 °C for 15 minutes for containers with a capacity of up to 1000 cm3, 25 minutes for containers with a capacity of 1000-2000 X5M3.
Technological process for the production of syrups
Another product for which fruit and berry juices are used are syrups. For their production, high-quality natural pasteurized or aseptically preserved fruit and berry juices, as well as juices preserved with sorbic acid, are used.
Freshly squeezed or all unclarified juices are sent for mixing with sugar. Mixing is carried out in two-body steam boilers or vacuum apparatus. Honey is used together with sugar in the production of sea buckthorn-honey syrup. The recipe for this syrup is as follows: sea buckthorn juice 28%, sugar 42% and honey 30%. When using honey, it is carefully melted in two-body boilers at a temperature not exceeding 50 ° C and filtered through a nylon sieve or gauze in four layers. Honey is added to the mixture after the sugar has dissolved in the juice.
Mixing the juice with sugar is carried out with heating and stirring. After the sugar has dissolved, the syrup is brought to a boil. In syrups intended for packaging in containers with a capacity of 3 dm3 or more, after bringing them to a boil, add 0.06% sorbic acid. Packaging of such syrups is carried out at a temperature of 90 °C. Sorbic acid is not added to sea buckthorn-honey and sea buckthorn syrup.
The moment the syrup is ready is determined by a refractometer or specific gravity. Taking into account the evaporation of water from the syrup during cooling, cooking should be stopped when the content of dry substances in the syrup reaches 1-2% lower than they should be in the finished syrup. Finished syrups must have a dry matter content of at least 68%, including sugar (calculated as invert) 62%. Depending on the type of raw material, the acidity of the syrup (calculated as apple) should be at least 0.3% for pear, apple, and blueberry; not less than 0.4% for plum, strawberry, raspberry, apricot, pomegranate; not less than 0.5% for cherry, sea buckthorn; not less than 0.6% for cherry plum, dogwood, rowan; not less than 0.7% for lingonberry, red and black currant; not less than 0.8% for lemon and not less than 1% for cranberry.
Syrups are packaged in tin and glass containers for retail sale with a capacity of up to 0.6 dm 3 and for industrial processing with a capacity of up to 10,000 cm 3.
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Juices are the most valuable component of fruits, berries and vegetables. They contain many water-soluble biologically active and easily digestible substances. Most juices have a pronounced healing effect.
Juice is a liquid product obtained from high-quality ripe fresh or kept fresh by cooling fruits and (or) vegetables, intended for direct consumption or for industrial processing.
The range of juices is extremely wide.
Depending on the production method, juices can be directly pressed or reconstituted; depending on the production method - clarified, unclarified and pulpy juices (nectars); depending on the composition - from one type of raw material, two or more (blended); natural without additives and with additives (sugar or sweeteners, vitamins, minerals, acids, etc.). In addition, concentrated juices with a high content of soluble solids are produced.
Technology for the production of natural juices. The technological process for the production of natural juices includes the following operations: preparation (washing, in some cases cleaning) and crushing of fruit and vegetable raw materials (its features), juice extraction (on a drainer and presses), its purification (straining) and clarification, filtering, packaging, pasteurization.
Crushing prepared fruit and vegetable raw materials. It should ensure the destruction of pulp cells by at least 75%. Quinces, apples, pears, rhubarb are crushed using knife, grating or disc crushers. Apples are crushed into particles of 2...6 mm in size, depending on the density of the fruit tissue and the pressing equipment used. The denser the fabric, the smaller the fruit particles should be.
Stone fruits (cherries, cherries, plums) are crushed using universal crushers. Crushing is adjusted so that the seeds do not crush. The presence of destroyed seeds in the pulp is allowed no more than 15% of its mass.
Currants, gooseberries, and lingonberries are crushed using roller or disk crushers. Ripe strawberries, raspberries and blueberries do not need to be crushed.
To increase the yield of juice during pressing, the pulp is preheated, treated with enzyme preparations or electric current.
When the pulp is heated to 70...76 °C, denaturation of proteins occurs and its juice-giving ability increases.
Treatment of the pulp with enzyme preparations leads to the hydrolysis of proteins, pectin compounds and starch, which also helps to increase the juice yield. A suspension of the enzyme preparation is added to the pulp of pome fruits immediately after crushing, and into the pulp of stone fruits after adding water (10...15% of the pulp mass) and heated to 40...45 °C. The pulp and the preparation are mixed and kept for 40...60 minutes, depending on the type of raw material being processed, and transferred for pressing.
Pressing pulp. To extract juice, the pulp of fruits and berries is fed to presses of various systems.
To press apple pulp on a batch press to increase the juice yield and make pressing easier, it is recommended to install drainers in front of the presses. The time for juice separation in the drain and pressing should not exceed 20 minutes to avoid significant oxidation and darkening of the pulp and juice. The juice yield in the drain is up to 30%. With increasing pressure and a higher yield of juice, it becomes enriched with suspensions and its clarification will be difficult.
To increase the juice yield when using screw presses, it is recommended to additionally press the apples after the screw press using a hydraulic, batch or basket press. The sediment from the separator of coarse impurities is combined with the marc and pressed together with them.
The pulp sediment can be used as an additive (no more than 20%) to applesauce when cooking jam or returned to the pulp for re-pressing.
The yield of juice depends on the quality of the raw materials, the preparation of the pulp, the method of pressing and is, %: from grapes 70...80, apples 55...80, cranberries 70...80, cherries 60...70, red currants 70...80, black currants 55...70.
Straining the juice. The juice flowing out from under the press is filtered through a stainless steel sieve with holes with a diameter of 0.75 mm or a nylon sieve to remove pieces of pulp, seeds and other impurities that got into the juice during pressing.
Further operations with juice depend on what types of juice are produced: clarified or unclarified.
Juice clarification. Clarified juices are prepared from barberries, lingonberries, pears, cranberries, rowan berries, red currants, grapes, apples, etc.
You can clarify the juice immediately after its production or later by preparing semi-finished products, canning them and then clarifying them.
Juices are clarified using the following methods: fining, enzyme preparations, gelatin with enzyme preparations or bentonite with gelatin and enzyme preparations, or silicon dioxide with gelatin and enzyme preparations, or heating.
Filtration. After clarification, the juice is sent for filtration. Filtration on filter presses is carried out at a pressure of 39.2... 157 kPa.
Juice packaging. For packaging juice, bottles or jars with a capacity of 0.2...3 dm 3 are used. The juice heated to 75...78 °C is packaged and sent for pasteurization or sterilization.
Pasteurization of juice. Natural juice, with sugar, blended is pasteurized in jars with a capacity of 0.65 ... 1.0 dm according to the formula 10-20-20 minutes at a temperature of 85 ° C and a pressure of 118 kPa.
It is allowed to preserve juices using the hot filling method. In this case, before packing into a heated container, the juice is heated to a temperature of 96...98°C.
Reconstituted juices from concentrated juices are produced in this order.
The concentrate is weighed on an electronic scale and, according to the recipe, added to the water in the long-term pasteurization bath. In it, concentrated juice is mixed with water. In order to remove the microflora present in the concentrate, pasteurization is carried out. Then, in a rotary-pulsation installation operating on the principle of cavitation or a homogenizer, the mass is homogenized to obtain a homogeneous mixture without lumps and inclusions.
Prepare the container. Then the prepared bottles are sent to the bottling plant, and then to the vacuum capping line.
After bottling, bottles with juice reconstituted from concentrate are inspected on a special screen, where unwanted inclusions in the liquid in the bottle are identified and some of the products are rejected. The bottles are then labeled. The mass fraction of soluble solids in directly pressed juices and reconstituted juices is given in Table 8.3.
Bottles that have passed inspection control are sent to group packaging - into a thermal tunnel, where they are wrapped in stretch film, and they are sent to a warehouse for temporary storage or sale.
Progressive waste-free technology for producing apple juice is the use of microwave energy with a frequency of 2400+50 MHz for 2...3.5 minutes. When processing whole washed apple fruits, the temperature throughout the entire volume of the fruit reaches 80...90 °C, which ensures inactivation of enzymes and prevents oxidation of the resulting juice. The new technological scheme for processing apples includes the following operations: washing, inspection, rinsing the fruit in the shower, microwave treatment, draining the juice through a drainer, pressing (microwave drying of apple pomace), filtering, microwave pasteurization of the juice, packaging the juice into prepared and Microwave-treated bottles, capping, storage. It allows you to obtain not only juice with a natural taste, aroma and color, but also reduce the time of its production and dispose of waste (drying the pomace). According to the scheme considered, tomato, plum, apricot, etc. juices are produced. The cavitation effect when processing whole fruits in a microwave installation makes it possible to eliminate their crushing.
The shelf life of juices depends on the container in which they are placed: in glass containers (light) - 2 years; in glass containers (dark) - 1 year; in metal containers - 1 year; in aluminum tubes - 1 year; in consumer packaging made of combined materials based on aluminum foil and paper (cardboard) aseptic and hot-filled drinks - 1 year.
For liquid products of aseptic preservation, combined materials based on foil, paper, cardboard and polymer, for example, polyethylene/paper/polyethylene/aluminum foil/polyethylene, are widely used.
In consumer containers made of combined film materials, juices are stored for 9 months, and in bottles made of polymer materials - 1 year.
Reconstituted apple juice is obtained by diluting concentrated juice with water.
Concentrated apple juice must meet all the requirements of GOST R 52185-2003. Concentrated juice is used clarified, since the finished product is clarified. During production, the dry matter content in concentrated apple juice is 65 - 68 degrees Brix.
In appearance, the concentrated juice resembles jam, its color is similar to the color of the original raw material (apples) from which it is made, and when frozen, its consistency resembles fruit ice cream.
Water is the most important component in food production. It serves as a medium and an active participant in biochemical, microbiological and colloidal processes.
For technological purposes, water must be used that meets the requirements of the drinking water standard, as well as additional requirements that take into account the specifics of this production.
Water used in food production must be potable, transparent, colorless, odorless and tasteless, and free from harmful impurities and pathogens.
Water hardness requirements depend on individual production goals. So the water hardness for soft drinks (juices) should be no more than 1.5 mEq/l.
The hardness of water is determined by the content of soluble calcium and magnesium salts in it and is expressed in milligram equivalents of Ca 2+ and Mg 2+ ions contained in 1 liter of water. Depending on the amount of hardness, water is classified into very soft, soft, moderately hard, hard and very hard. In the technology for preparing reconstituted juice, very soft water is used (up to 1.5 mEq/l).
Drinking water that meets the requirements of the standard is obtained by purifying natural water from reservoirs by filtration through porous media: sand, gravel, etc. Before filtration, the water is settled in special settling tanks.
Reconstituted apple juice production technology
In the production of reconstituted apple juice, a concentrate is used, which is diluted with water in an approximately 1:5 ratio to a dry matter content of at least 11.2%.
Concentrated apple juices are clarified. When producing apple juice concentrate, the dry matter content increases to 65 - 68%.
The technology for producing concentrated juice involves a number of operations presented in Figure 1.
Preparation of raw materials
Additional processing of raw materials
Juice extraction
Straining the juice
Heating, trapping aromatic substances
Lightening
Filtration
Boiling (or evaporation, or freezing, or reverse osmosis)
Deaeration
Sterilization
Figure 1 - Technological diagram for the production of concentrated juice
Preparation of raw materials. It consists in the fact that it is freed from broken, rotten fruits, foreign impurities - branches, leaves, stalks, etc. Belt conveyors are used for this. At the same time, the raw materials are sorted by color and degree of maturity.
Then washing is carried out in different types of washing machines: drum, fan, rotary, flotation, etc. When washing, soil residues, microorganisms, and pesticides are removed from the surface of the raw material.
Crushing is carried out using knife, grater-knife, hammer or impact centrifugal crushers. Apples are fruits with a hard structure, so they are crushed to a pulpy state. The purpose of crushing is to destroy at least 75% of the cells, which is necessary for the release of cell sap.
Additional processing of raw materials is carried out because during crushing it is impossible to destroy all the cells. In order to be able to extract the maximum amount of juice, the raw materials are subjected to additional treatment with enzyme preparations (pectolytic, which decompose pectin substances that cement the cells); treatment with electric current (electroplasmolysis); The pulp or whole fruits are heated with hot steam, the fruits are frozen and then thawed.
Juice extraction is carried out in several ways: pressing (direct pressing), centrifugation and membrane-ultrafiltration method.
In direct extraction, juice is extracted from fruits using presses: hydraulic (basket, bag), pneumatic, screw and continuous belt.
In centrifugation, the juice is extracted in centrifuges under the influence of centrifugal force. It has a higher content of pulp and polyphenols than directly pressed juice.
The membrane-ultrafiltration method is used to obtain clarified juices. The juice from the pulp penetrates the walls of the porous membranes. It turns out crystal clear and retains the aroma of fresh raw materials.
Straining the juice is necessary to cleanse it from coarse impurities (twigs, seeds, pieces of pulp). For straining, stainless steel sieves or clarifying separators are used.
Clarification is the separation of juice into a clear liquid fraction and sediment. Juice clarification is carried out in different ways. The juice is treated with gelatin or gelatin and tannin, as a result of which the pectin substances precipitate; enzyme preparations: pectolytic, which decompose pectin, and amylolytic, which hydrolyze starch.
Clarification is also carried out by heating apple juice to 80 - 90 ° C for 1-3 minutes and rapid cooling.
To clarify the juice, bentonite (special clay) is used, which adsorbs positively charged substances and converts them into sediment, as well as selective membranes.
The clarified juice is decanted (removed from the sediment) and filtered through frame filter presses.
Concentrated juices are produced mainly by evaporating the juice in a vacuum apparatus for a short time at a temperature of 45-50°C to a dry matter content of 55-70%. In some cases, freezing is used at a temperature of minus 10-12°C; part of the water freezes and is separated in the form of crystals by separation. This juice contains 45-50% dry matter. The most modern and promising, but expensive way to obtain concentrated juice is the use of reverse osmosis. This method allows you to improve the quality of the finished product due to the low process temperature. It is based on the ability of selective membranes to pass only water, retaining dry substances with a low molecular weight. Before concentration, it is recommended to free juices from colloidal substances.
Deaeration - removal of air, which contributes to the oxidation of substances, especially vitamin C - is carried out in deaerator-pasteurizers at a temperature of 75-80°C.
Filling of deaerated juice is carried out using filling and capping machines into glass or metal varnished jars with a capacity of up to 1 dm 3 , into glass bottles with a capacity of up to 0.5 dm 3 , aluminum tubes with a capacity of up to 0.2 dm 3 , as well as into consumer packaging made of combined and polymeric materials (up to 1dm 3), in a two-layer polyethylene film.
The spilled juice is sealed and sent for sterilization at a temperature of 100°C for 10-60 minutes, depending on the capacity of the container.
To preserve juices, a hot-fill, aseptic method is used, with the addition of antiseptics (sorbic acid).
Federal Fisheries Agency
Federal State Educational Institution of Higher Professional Education
“Far Eastern State Technical Fisheries University”
Department of Food Technology
Discipline Technology of food production in small enterprises
COURSE WORK ON THE TOPIC
Apple juice production technology in small enterprises
DEVELOPED:
Student gr. PI-41
Katyukov S. V.
CHECKED:
Assistant of the Department of Chamber of Commerce and Industry
Misakovsky A.A.
Vladivostok
Introduction
1. Characteristics of raw materials
2. Development of process flow
3. Raw material demand (grocery supply)
4. Hardware
5. Computer modeling
6. Greening the technological process
Conclusion
Bibliography
Introduction
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.
Currently, about 950 million liters of juice are produced in Russia per year (in 1999 - 500 million liters). Market growth is mainly due to domestic producers. If in 1998 imports accounted for 31% of all juices consumed in Russia, then in 2000 it was less than 5%. The average level of juice consumption per person per year in Russia is 4 liters, in Moscow - 21 liters. Juice consumption in the Central part of Russia will gradually approach Moscow indicators, because... In this region, a culture of consuming juices and caring about one’s health has already formed (in 2000-2001, the juice market in this region grew by 40%). In Siberia and the Far East, juices are still perceived only as fruit substitutes with pronounced seasonal consumption in the spring, but this region may also become promising in the future. Thus, the potential juice market in Russia is quite large.
New developments in the field of technology for canning, freezing and drying fruit and vegetable agricultural products, increasing demand for domestic products and a wide range between the potential and actual market make this branch of the food industry attractive to investors.
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.
Coursework objectives:
1. Development of a technological line for the production of canned sterilized products using physical methods for processing raw materials
2. Conduct product calculations (determining the masses of raw materials, finished products, waste and losses according to the production flow diagram)
3. Selection and calculation of technological equipment
4. Construction of a computer model of technological processes
5. Greening the technological process
1. Characteristics of raw materials
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.
When processing plant raw materials, for the quality of natural juices and nectars, not only the appearance, but also the botanical varieties of fruits and vegetables, which differ in their technological properties, are essential. Plant raw materials must meet the safety criteria established by Medical-biological requirements and sanitary standards for the quality of food raw materials and food products, and do not contain pesticides.
Depending on the types of juices and nectars produced, certain botanical varieties are recommended, which, in terms of their chemical composition and technological properties, are most suitable for the production of these products.
For juice production, apples of the varieties Antonovka, Reneta, Titovka, White filling, Winter golden Parmen, Cinnamon, Pepin saffron, Autumn striped, Mekintosh, Suislepskoye, Bellefleur, White Rosemary, Dzhigradzhi, Sary-Tursh, Kend-Alma, Shirvan-Gazedi, are recommended. Striped anise, Calvil, Wagner prize, Sary-sinap. When using fruits with high acidity (Baltic states, BSSR), 5% sugar is added to the juice. They practice blending apple juice with other fruit or 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 minus 2 minus 3 C, while being stored with minor losses and with slow defrosting (thawing).
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. All this determines the nutritional value, taste and use. 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 fatty acids were found in the apple: acetic, butyric, isobutyric, capronic, propionic, valeric, isovaleric. Apple contains tannins and phytocides, 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. The body contains it in the form of glycogen. As follows from the table. 1, apples and cabbage have the most beneficial properties. Apples contain 2 times more fructose than glucose. They are indicated for liver disease, diabetes and a number of other diseases.
Table 1. Carbohydrate content per 100 g edible part apples , in grams
Based on 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.
Pectic substances are capable of adsorbing various “compounds, including” exogenous 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.
2. Development of process flow
apple juice production
The production of apple juice without pulp consists of the following technological stages: acceptance and preparation of raw materials, washing, inspection, crushing, heat treatment, juice extraction, sterilization, packaging and storage.
Technological diagram of apple juice production
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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.
For some fruits and berries, crushing alone is not enough to obtain juice.
To facilitate the release of juice, additional processing is necessary, which includes heating or electric shock; enzyme preparations are not used.
The pulp of almost all fruits and berries with dense skin can be exposed to the action of electric current in special devices - electroplasmolyzers.
The processed pulp is fed for pressing, for which hydraulic batch presses are used, either periodic or continuous - screw or belt.
When producing clarified apple juice, the strained juice is clarified. When preparing juices for baby food, clarification can be carried out by fining using 1% solutions of gelatin or tannin and gelatin.
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.
The machine and hardware diagram of the complex of technological equipment for the production of clarified fruit juices is presented in Fig. 2.
Fig.2. Machine and 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.
Fruits received for processing are poured into concrete tanks, from where they are sent to the workshop by hydraulic conveyor through underground channels.
Here, using a screw separator 2 located in a concrete bath (pit), the fruits are separated from the water and, using an elevator 3 with a shower device, they are lifted to the final washing machine 4.
Water coming from the screw separator and containing large contaminants (stones, branches, leaves, etc.) enters the loading funnel of an inclined screw 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 packaged into bottles at 80 °C, followed by additional pasteurization and cooling in a tunnel pasteurizer-cooler.
Technical characteristics of a complex of technological equipment for the production of clarified apple juice
Productivity for raw materials, kg/h.................................................... ...............3000
Total installed power of the equipment, kW...................................106.85
Total consumption:
water, m3/h................................................... ........................................................ ..........12
steam, t/h................................................... ........................................... ……… ..500
Number of service personnel, people....................................................12
3. Raw material needs
Raw materials - Antonovka apples.
The finished product is apple juice.
Productivity - 1t/day
Working hours: 12 hours, 1 shift, 7 times a week.
Table 2. Yield rates
where Q1 is the consumption of raw materials, kg;
Q2 – mass of the finished product, kg;
p – the amount of waste and losses from technological operations, % of the weight of the feedstock.
р1, р2, р3...рn – waste and losses from technological operations, % by weight of raw materials or semi-finished products received for this operation;
n – number of technological operations.
Table 3. Output of semi-finished product by technological operations
| Technological operation | Waste and losses, % | Movement of raw materials and semi-finished products, kg | |||||
| per 100 kg | per shift (day) | at one o'clock | |||||
| arrives | waste and loss | arrives | waste and loss | arrives | waste and loss | ||
| 1. Reception of raw materials | - | 1119 | - | G3 | - | - | |
| 2. Washing | 2 | 1119 | G3 | G3 | |||
| 3. Crushing | 4 | ||||||
| 4. Grinding | 5 | P | |||||
4. Hardware
Selection and calculation of technological equipment
(using the example of apple juice production)
The required amount of continuous equipment is determined by the formula
N – productivity of this operation;
M – hourly productivity of the machine;
μ – equipment utilization factor (0.8 – 0.9).
The equipment used on a continuous operation vessel is presented in table. 20.
Table 4 Technical characteristics and calculation of periodically operating equipment
We will calculate the required number of washing machines;
we accept 2 pcs.
Let's calculate the required number of pasteurizers;
We accept 1 piece.
Let's calculate the required number of filters;
accept 1 piece
We will calculate the required number of crushing plants for semolina;
accept 1 piece
Table 5 Volumetric weight of materials
Table 6 Calculation and selection of auxiliary equipment
5. Computer modeling
The computer models of technological processes being developed can be used in production through the use of microprocessor control and monitoring systems (MCCS).
The functioning of the MSKU is carried out on the basis of some model that reflects the main physical and chemical processes occurring in the product. Based on the model, an algorithm and process control scheme were constructed.
MSKU provides the following functions:
Determining when the product is ready;
Control of machine organs (equipment);
Regulation of modes (one-, two- or multi-speed);
A system of equations connecting response functions with influencing factors is called a mathematical description of the process. The method of full factorial experiment makes it possible to obtain a description of the process in the form of a segment of the Taylor series, which has the form:
Y = В0 + В1Х1 + В2Х2 + ... + Вn Хn + B1.2 Х1Х2 – ... – В (n – 1)n Х (n – 1),
It is called a regression equation, and the characteristics included in it are called regression coefficients, where X1, ..., Xn are independent variables that influence the course of the process, called factors (temperature, pressure, composition of the reaction mixture, etc.): Y - a value showing equipment performance, production costs, etc., called the response function. All possible non-repeating combinations of factor variations allow planning the matrix of a complete two-factor experiment (Table 2.1).
Table 2.1. Matrix of a complete two-factor experiment
Based on a complete two-factor experiment, regression coefficients are calculated:
B0 = 1/4 (Y1 + Y2 + Y3 + Y4),
B1 = 1/4 (-Y1 + Y2 – Y3 + Y4),
B2 = 1/4 (-Y1 – Y2 + Y3 + Y4).
Assuming the significance of the regression coefficients and the adequacy of the equation with a confidence probability of 0.95 and three degrees of freedom, the magnitude of the coefficients and their significance determine the ranking of the influence of factors X1 and X2 on the response function Y.
The number of full factorial experiments for choosing a socially oriented technological solution increases sharply with an increase in the number of factors. However, finding regression coefficients does not always require much experimentation. In such cases, it is possible to reduce the amount of experimental work by using the fractional replica method. This method consists of finding a mathematical description of the processes in a certain part of a complete factorial experiment: 1/2, 1/4, etc. Such experimental systems are called fractional replicas.
Then the matrix of the complete three-factor experiment and its fractional replicas will look like (Table 2.2).
Table 2.2. Matrix of a complete three-factor experiment and its fractional replicas
The calculation of regression coefficients, checking their significance and the adequacy of the mathematical description in this case are carried out in the same way as in a full factorial experiment, for example in the form of a regression equation:
Y = B0 + B1X1 + B2X2 + B3X3.
If you use a full three-factor experiment to calculate regression coefficients, then you need to conduct 8 experiments. However, this problem can also be solved using a two-factor experiment, if in the matrix the product X1 X2 is equated to the factor X3 (Table 2.3).
Table 2.3. Simplified matrix
Regression coefficients are calculated using the following formulas:
B0 = ¼(Y1 + Y2 + Y3 + Y4), B1 = ¼(-Y1 + Y2 – Y3 + Y4),
B2 = ¼(-Y1 – Y2 + Y3 + Y4).
Coefficient B3 cannot be determined separately, so we calculate the sum:
B1,2 + B3 = ¼(Y1 – Y2 – Y3 + Y4),
then the required equation will look like:
Y = B0 + B1X1 + B2X2 + (B1,2 + B3)X3.
When choosing a socially oriented technology for processing raw materials from an economic and environmental point of view, you can get results faster using a PC.
During the research process, it is also necessary to calculate the correlation coefficient, which is calculated using the formula:
where YiВ, YiР - the value of the first virtual (V) and second real (P) indicators;
n is the size of elements in the sample (number of correlation pairs).
If necessary, the reliability of the correlation coefficient is calculated. If, in terms of the absolute value of μ, the degree of correlation between indicators is less than 0.4, the dependence is weak; 0.4-0.59 - average; 0.6-0.78 - significant; more than 0.8 - high.
When modeling the production of functional products using a PC, it is necessary to virtually assume processes and identify their patterns for the subsequent practical use of these dependencies in real production conditions of a particular production. Therefore, it is necessary to regulate the technological process taking into account SMS by modeling them in virtual conditions based on IR methods.
6. Greening the technological process
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.
Conclusion
The course work examined the technological line for the production of apple juice in small enterprises.
During the work, the following goals were achieved:
1. got acquainted with the characteristics of raw materials, identified the best varieties of apples for the best quality juices. I got acquainted with the chemical composition of apples.
2. Developed design and technological schemes for the production of apple juice, created a technological scheme for the production of apple juice and an operator diagram.
3. Made product calculations, determined the mass of raw materials, finished products, waste and losses according to the production technological scheme. Determined the production capacity of the line.
4. Selected and calculated the technological equipment, determined the number of machines (devices), their dimensions and main structural elements.
5. Performed computer modeling, became familiar with methods for solving basic equations, algorithms for their implementation and computer programs.
6. Familiarized himself with the greening of the technological process and became familiar with the rational use of resources.
List of used literature
1. General technology of food production / Ed. A. P. Kovalskaya. – M.: Kolos 1993–384 p.
2. Samsonova A. N. Fruit and vegetable juices
3. Technology of canned fruits and vegetables. A. F. Fan-Yung, B. L. Flower menbaum, A. K. Izotov - M.: Food industry
4. Rogachev V.I. Handbook of fruit and vegetable canning production technologist.
Federal Fisheries Agency
Federal State Educational Institution of Higher Professional Education
“Far Eastern State Technical Fisheries University”
Department of Food Technology
Discipline Technology of food production in small enterprises
COURSE WORK ON THE TOPIC
Apple juice production technology in small enterprises
DEVELOPED:
Student gr. PI-41
Katyukov S. V.
CHECKED:
Assistant of the Department of Chamber of Commerce and Industry
Misakovsky A.A.
Vladivostok
Introduction
1. Characteristics of raw materials
2. Development of process flow
3. Raw material demand (grocery supply)
4. Hardware
5. Computer modeling
6. Greening the technological process
Conclusion
Bibliography
Introduction
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.
Currently, about 950 million liters of juice are produced in Russia per year (in 1999 - 500 million liters). Market growth is mainly due to domestic producers. If in 1998 imports accounted for 31% of all juices consumed in Russia, then in 2000 it was less than 5%. The average level of juice consumption per person per year in Russia is 4 liters, in Moscow - 21 liters. Juice consumption in the Central part of Russia will gradually approach Moscow indicators, because... In this region, a culture of consuming juices and caring about one’s health has already formed (in 2000-2001, the juice market in this region grew by 40%). In Siberia and the Far East, juices are still perceived only as fruit substitutes with pronounced seasonal consumption in the spring, but this region may also become promising in the future. Thus, the potential juice market in Russia is quite large.
New developments in the field of technology for canning, freezing and drying fruit and vegetable agricultural products, increasing demand for domestic products and a wide range between the potential and actual market make this branch of the food industry attractive to investors.
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.
Coursework objectives:
1. Development of a technological line for the production of canned sterilized products using physical methods for processing raw materials
2. Conduct product calculations (determining the masses of raw materials, finished products, waste and losses according to the production flow diagram)
3. Selection and calculation of technological equipment
4. Construction of a computer model of technological processes
5. Greening the technological process
1. Characteristics of raw materials
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.
When processing plant raw materials, for the quality of natural juices and nectars, not only the appearance, but also the botanical varieties of fruits and vegetables, which differ in their technological properties, are essential. Plant raw materials must meet the safety criteria established by Medical-biological requirements and sanitary standards for the quality of food raw materials and food products, and do not contain pesticides.
Depending on the types of juices and nectars produced, certain botanical varieties are recommended, which, in terms of their chemical composition and technological properties, are most suitable for the production of these products.
For juice production, apples of the varieties Antonovka, Reneta, Titovka, White filling, Winter golden Parmen, Cinnamon, Pepin saffron, Autumn striped, Mekintosh, Suislepskoye, Bellefleur, White Rosemary, Dzhigradzhi, Sary-Tursh, Kend-Alma, Shirvan-Gazedi, are recommended. Striped anise, Calvil, Wagner prize, Sary-sinap. When using fruits with high acidity (Baltic states, BSSR), 5% sugar is added to the juice. They practice blending apple juice with other fruit or 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 minus 2 minus 3 C, while being stored with minor losses and with slow defrosting (thawing).
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. All this determines the nutritional value, taste and use. 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 fatty acids were found in the apple: acetic, butyric, isobutyric, capronic, propionic, valeric, isovaleric. Apple contains tannins and phytocides, 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. As follows from the table. 1, apples and cabbage have the most beneficial properties. Apples contain 2 times more fructose than glucose. They are indicated for liver disease, diabetes and a number of other diseases.
Table 1. Carbohydrate content per 100 g of the edible part of apples, in grams
| Glucose | 2.0 |
| Sucrose | 1.5 |
| Hemicellulose | 0.4 |
| Cellulose | 1.6 |
| Starch | 0.8 |
| Pectin | 1.0 |
Based on 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.
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