The fully automatic fruit and vegetable juice beverage production line is made from fresh or refrigerated fruits and vegetables as raw materials. The so-called fruit and vegetable juice refers to the fruit and vegetable juice obtained directly from fresh or refrigerated fruits and vegetables (some also use Guangguo) without adding any foreign substances, after cleaning and selection, using physical methods such as pressing, extraction, centrifugation, etc. A juice made by mixing fruit and vegetable juice with water, sugar, acid, or spices is called a fruit and vegetable juice beverage.

Production process of fruit tea beverage

Yangmei/blueberry/kiwi/mulberry/dragon fruit/grape/tomato/plum/pear/apple/orange/green plum/papaya/sea buckthorn/goji berry/blackberry/raspberry/mango/pomegranate/grapefruit/prickly pear/loquat/peach/apricot/sugarcane/pineapple/lemon/strawberry/cherry/cherry/cherry/citrus/hawthorn peach/apple/pear/banana/mango/citrus/pineapple/melon/tomato/passion fruit tea production process:

Water treatment section (steam explosion pool → quartz sand filtration → activated carbon filtration → first stage reverse osmosis → ultraviolet sterilization → aseptic storage) – raw material processing section (honeysuckle tea → extraction → coarse filtration → clarification treatment) – blending standardization section (blending → fine filtration → high temperature sterilization → aseptic storage → canning) – CIP cleaning section (CIP cleaning system is used to clean the entire pipeline and cans of the honeysuckle tea beverage production line.)

Production process of fruit juice beverages

Yangmei/blueberry/kiwi/mulberry/dragon fruit/grape/tomato/plum/pear/apple/orange/green plum/papaya/sea buckthorn/goji berry/blackberry/raspberry/mango/pomegranate/grapefruit/prickly pear/loquat/peach/apricot/sugarcane/pineapple/lemon/strawberry/cherry/cherry/cherry/citrus/hawthorn peach/apple/pear/banana/mango/citrus/pineapple/melon/tomato/passion fruit tea production process:

Fresh strawberries – cleaning – fruit selection – spraying – fruit inspection – preheating – juice extraction – filtration – clarification – filtration – blending – sterilization – aseptic filling – tunnel sterilization – cooling – blow drying – packaging.

Cleaning (Cleaning Machine) – Fruit Inspection (Fruit Inspection Machine) – Crushing (Crusher) – Beating (Beating Machine) – Juice Extraction (Juicer) – Filtration (Filter) – Concentrator (Concentrator) – Mixing (Mixing Tank) – Sterilization (Sterilizer) – Aseptic Storage (Aseptic Storage Tank) – Aseptic Filling – Finished Product Packaging

Production process of fruit and vegetable juice:

Fruits and vegetables – fruit washing – fruit inspection – crushing – enzyme inactivation – juice extraction – filtration – sterilization – cooling – centrifugal separation – clarification – filtration – sterilization – sterile storage – sterile filling – labeling – coding – packaging

Production process of fruit and vegetable juice:

Fruits and vegetables – fruit washing – fruit inspection – crushing – softening – extraction – filtration – centrifugal separation – clarification – centrifugal separation – filtration – concentration – sterilization – aseptic filling – sealing – packaging

Production process of fruit and vegetable leaf juice:

Fruit and vegetable leaves – cleaning – wax removal – baking – crushing – extraction – filtration – de astringency – blending – finished Ginkgo biloba leaf juice. Ginkgo biloba leaf juice is mainly used as an additive in fruit juice drinks, such as Ginkgo biloba pear juice, Ginkgo biloba tea juice drinks, etc

The nutritional value and product characteristics of fruit and vegetable juice

The fruit and vegetable juice extracted from fresh fruits and vegetables, after filtration, although the flesh tissue is lost (including dietary fiber, pectin, a small amount of protein, and other components are lost, making the juice cloudy), almost all of the water-soluble nutrients in the juice are retained in the fruit and vegetable juice. Fruit and vegetable juice contains abundant nutrients such as vitamins, minerals, and organic acids.

1. Vitamin

Various fruit juice drinks contain a variety of vitamins, with the most abundant being vitamin C, beta carotene, vitamin E, and B vitamins.

2. Minerals

Pure fruit juice contains abundant potassium, magnesium, etc., while sodium content is relatively low, which can prevent hypertension. In addition, these elements can produce alkaline substances and maintain acid-base balance in the human body.

3. Organic acid

Pure fruit juice contains various organic acids. It can maintain the acid-base balance of the body, increase acid reserves, promote the secretion of digestive juices, assist digestion, and increase appetite. And it can maintain a certain acidity of the juice, reducing the breakdown and destruction of vitamin C in the juice.

4. Other

Fruit and vegetable juices also contain some beneficial plant components for health, such as bioflavonoids, which are natural antioxidants that can maintain the normal function of blood vessels and protect vitamins A, C, E, etc. from oxidative damage. Meanwhile, vegetable juice contains anti-aging vitamins and dozens of highly effective anti-aging substances, such as minerals and pigments.

Production process of fruit and vegetable juice

At present, the main types of fruit and vegetable juice products produced in the world can be divided into five categories based on different processing techniques: ① clarification type, which requires clarification and filtration, and uses dried fruits as raw materials and also requires extraction process; ② Cloudy juice requires homogenization and degassing; ③ Fruit pulp beverages require pre cooking and pulping, and other processes are the same as cloudy juice; ④ Concentrated juice, needs to be concentrated; ⑤ Juice powder needs to be dehydrated and dried. Therefore, the production of various types of fruit and vegetable juices varies mainly in the subsequent processes, and the primary focus is on the production of the original juice. The selection, pretreatment, crushing, juice extraction, and coarse filtration of raw materials are common processes in the production of juice from fruits and vegetables.

The process flow is as follows:

Raw material selection → pretreatment → crushing → juice extraction → coarse filtration → clarification → fine filtration → homogenization → degassing → concentration, etc. The process before coarse filtration is basically the same for different products, and the subsequent processes are mostly specific to a particular product.

（1） Raw material selection

The quality requirements are as follows: ① Fresh raw materials; ② The raw materials for juice production should have excellent flavor and aroma, stable color, moderate acidity, and maintain good quality during processing and storage Rich in juice, easy to extract, and high juice yield; ④ No pests or diseases, no decay. As a raw material for fruits (including fruits and vegetables in vegetables), high maturity is required; ⑤ Carrots, leafy vegetables, edible mushrooms, and some melons in vegetables require less fiber, tender meat, and timely harvesting.

（2） Raw material washing

When making juice, the raw materials must be washed and rinsed with flowing water that meets drinking water standards. For some raw materials with high pesticide residues and heavy microbial contamination, they can be soaked in medication, such as potassium permanganate 0.05% to 0.1%, bleaching powder 0.06%, or dilute hydrochloric acid 0.1%, for 5-10 minutes, and then washed with clean water.

Arrange a dedicated person to pick out rotten fruits, diseased fruits, defective fruits, immature fruits, and dead leaves during cleaning.

（3） Juice extraction

1. Broken

When crushing apples and pears with a crusher, the appropriate size after crushing is 3-4mm. Strawberries and grapes should be 2-3mm thick, while cherries and orange petals should be 5mm thick. In order to prevent enzyme browning during crushing, color protection solution (VC and citric acid) can be added by spray during crushing. Or nitrogen fragmentation or heat inactivation of enzyme activity can be carried out in a closed environment.

2. Processing before juicing

(1) Heating treatment

The general processing conditions are 60-70 ℃ and 15-30 minutes.

(2) Treatment with pectinase preparation

Pectinase can increase juice yield. When adding pectinase preparation, it should be evenly mixed with the fruit pulp. The dosage of enzyme preparation should be controlled at 0.2% to 0.3% according to the variety of raw materials, and the temperature (40-50 ℃) and time (30 minutes) of action should be controlled.

3. Juice extraction

(1) Squeezing

Squeezing and extracting juice is one of the main processes in juice making.

Common juicing equipment: FMC citrus juice extractor and cone juicer are used for juicing sweet oranges and lemon fruits with thick skin; Brown 400 juicer; There are continuous juicers, centrifugal separation juicers, spiral juicers, etc. used for crushing and juicing.

(2) Extraction

For fruits with low juice content, the water extraction method can be used.

(3) Beating pulp

Suitable for the production of fruit pulp and fruit pulp beverages.

After the raw materials of fruits and vegetables are crushed, they need to be immediately pre cooked in a pre cooking machine to inactivate the activity of enzymes in the fruits and vegetables, prevent browning, and then beaten. In production, three rounds of beating are generally used, with sieve sizes of 1.2, 0.8, and 0.5mm in sequence.

（4） Coarse filtration

1. Coarse filtration

Filter using a 50-60 mesh sieve filter.

2. Preservation of coarse filtered juice

If the juice is not concentrated after coarse filtration and is stored as a semi-finished product, the fruit and vegetable juice must be sterilized and preserved. The common method is:

(1) Heating sterilization method

Maintain at 80-90 ℃ for 3-5 minutes or at 90-95 ℃ for 40-60 seconds, cool down and store in a clean and disinfected storage container, sealed in a cool place;

(2) Sulfuric acid treatment

Heat the juice to 90 ℃, immediately cool to room temperature or without heating, add sulfite and its salts to make the juice contain 150-200mg/L of sulfur dioxide, stir well, immediately seal and store in a cool place.

(3) Sodium benzoate preservation method

Add 0.1% to 0.2% of the total amount of juice, first dissolve sodium benzoate in a small amount of hot water, then add it to the juice, stir well, and seal it.

(4) Compressed carbon dioxide storage

Put the juice into a sealed, pressure resistant, and corrosion-resistant container, and press in carbon dioxide. The amount of carbon dioxide used is 1.5kg per hundred liters of the storage tank volume. The storage temperature is 15-18 ℃ and the pressure is 0.7-0.8MPa.

(5) Refrigeration method

Enzyme killing and sterilization of fruit juice can be stored in a clean and sealed container at a temperature of 0-2 ℃ for a long time.

(6) Alcoholization method

Manufacturers producing fruit juice and sparkling wine use this method to preserve fruit juice, and adjust the alcohol content to 18% in storage barrels. The above is sealed and stored at 10-15 ℃.

（5） Clarification and fine filtration of fruit and vegetable juice

1. Clarify

(1) There are several commonly used clarification methods in production:

① Natural clarification: Add appropriate preservatives and let it sit for a long time. Limited to the use in the production of semi-finished fruit juice preserved with sulfite.

② Gelatin tannin clarification method: Pectin, cellulose, tannins, and polysaccharides in fruit juice carry negative charges, while acid medium and gelatin carry positive charges. The interaction between positively and negatively charged particles can cause coagulation and precipitation, which can also clarify fruit juice.

Generally, 100L of clarified apple juice can be mixed with 10g of tannins and around 35g of gelatin. After adding the solution, it should be left at room temperature of 8-12 ℃ for about 6-10 hours to allow the colloid to aggregate and precipitate.

③ Enzyme clarification method: using pectinase preparation to hydrolyze pectin substances in fruit juice, causing other colloids in the juice to lose the protective effect of pectin and precipitate together, achieving the purpose of clarification.

The reaction rate of pectinase is related to the reaction temperature. At 50-55 ℃, the general dosage of enzyme preparation is 2-4 kg per ton of juice.

Enzyme preparations can also be used in combination with gelatin, such as in the clarification of apple juice. After adding enzyme preparations to the juice for 20-30 minutes, gelatin can be added and clarified at 20 ℃ with good results.

④ Freezing clarification method: Freezing can change the properties of colloids and form a precipitate when thawed, so cloudy fruit juice is easy to clarify after cooling.

⑤ Heating coagulation clarification method: Colloidal substances in fruit juice are often coagulated by heating and easily precipitate. Heat the juice to 80-82 ℃ within 80-90 seconds, and then cool it to room temperature in the same short period of time. Due to the drastic change in temperature, proteins and other colloidal substances in the juice denature, solidify and precipitate, resulting in the clarification of the juice.

⑥ Ultrafiltration clarification method: Utilizing the selective sieving of ultrafiltration membranes, particles, suspended substances, colloids, and macromolecules in a solution are separated from solvents and small molecules under pressure.

⑦ Adsorption clarification method: By adding substances with large surface area and adsorption capacity, some proteins, polyphenols, and other substances in fruit juice are adsorbed.

⑧ Honey clarification method: Low concentration honey has a clarification effect and anti browning effect.

2. Filtration (fine filtration)

(1) Pressure filtration method

Juice filtration can use diatomaceous earth filtration and filler filter filtration.

(2) Vacuum filtration method

The vacuum filtration method is to generate a vacuum inside the filter screen, and use the pressure difference to make the juice permeate through the filter aid to obtain clarified juice.

In addition, centrifugal separation can be used to remove sediment from the juice, which can also achieve satisfactory juice quality.

（6） Homogenization and degassing of cloudy fruit juice

1. Homogenization treatment of cloudy fruit juice

Homogenization is the process by which fruit juice is homogenized by a homogenizer. The suspended particles in the juice are further broken down, resulting in uniform particle size and promoting the exudation of pectin. Pectin and fruit juice are compatible and evenly and stably dispersed in the juice, maintaining its uniform turbidity,

Homogenization equipment includes high-pressure, rotary, and ultrasonic types. The commonly used high-pressure homogenizer in China crushes suspended particles under pressure of 9.8-18.6MPa (100-190kg/cm2).

2. Degassing and degreasing

(1) Degassing

There are a large amount of gases such as oxygen, nitrogen, and carbon dioxide in fruit juice, especially oxygen, which not only damages the vitamin C in the juice, but also reacts with various components in the juice, deteriorating the aroma and color, and causing corrosion of the inner wall of the tin can. So before heating the juice, it is necessary to remove the oxygen in the juice.

Deoxygenation can prevent or reduce the oxidation of pigment, vitamin C, aroma components and other substances in fruit juice, prevent quality degradation, remove the gas attached to suspended particles, reduce or avoid particle floating, so as to maintain a good appearance, prevent or reduce the foam generated during canning and sterilization, and reduce the corrosion of the inner wall of tinplate cans.

① Vacuum degassing method

Vacuum degassing is the process of pumping processed fruit juice into a vacuum degassing tank for extraction.

The key points are: a. Control the appropriate vacuum degree and juice temperature. In order to fully degas, the juice temperature should be 2-3 ℃ higher than the temperature corresponding to the absolute pressure inside the vacuum tank. The temperature of the juice is 50-70 ℃ for hot degassing and 20-25 ℃ for room temperature degassing. The vacuum degree inside the general degassing tank is 90.7-93.3kPa (i.e. 680-700mmHg); b. The surface area of the treated fruit juice should be large. Generally, the fruit juice should be dispersed into film or mist to facilitate degassing. There are three methods: centrifugal spray, pressurized spray and film downflow; c. Adequate degassing time is required, which depends on the characteristics, temperature, and state of the juice in the degassing tank. Juice with high viscosity and high solid content is difficult to degas, so the degassing time should be appropriately increased.

② Nitrogen exchange method

The nitrogen exchange method is to introduce nitrogen into the juice, so that the juice will lose the attached oxygen under the strong impact of the foam flow of nitrogen, and the last remaining is almost all nitrogen.

③ Enzymatic degassing method

Adding glucose oxidase to fruit juice has a significant deoxygenation effect.

(2) De oiling

In order to remove or reduce the essence oil in orange juice, especially in orange juice, the effective measure to ensure the flavor of finished products is deoiling.

The de oiling operation can be carried out using vacuum de oiling method. The juice is heated to 50 ℃ and sent to a vacuum de oiler for de oiling. At the same time, it can also be de oiled. The removed water and oil are separated into sweet orange oil through an orange oil separator with a flow rate of over 7000r/min, and the remaining water is added back to the juice.

（7） Concentrating fruit juice

1. Vacuum concentration

Quickly evaporate the water in the juice under reduced pressure. The concentration temperature is generally 25-35 ℃, and should not exceed 40 ℃. The vacuum degree is about 94.7kPa (710mmHg).

The currently used concentration equipment includes forced circulation evaporation, falling film evaporation (thin film downflow), flat plate (sheet) evaporation, stirring evaporation, and centrifugal thin film evaporation.

2. Freeze concentration

Freeze concentration method is to freeze fruit juice, and the water in the juice forms ice crystals. By separating and removing these ice crystals, the soluble solids in the juice are concentrated to obtain concentrated fruit juice.

The advantages of freeze concentration method are, firstly, avoiding the effects of heat and vacuum, no thermal denaturation, no heating odor, minimal loss of volatile flavor substances, and far superior product quality compared to evaporation concentration. Secondly, it consumes less heat.

The disadvantage is that during the generation and separation of ice crystals, a small amount of juice components are inhaled into the ice crystals, and the juice components attached to the surface of the ice crystals lose 2% to 3%; In addition, the efficiency is worse than that of evaporation concentration method, and the concentration cannot exceed 55%.

3. Reverse osmosis concentration and ultrafiltration concentration

Reverse osmosis is generally used for the treatment of small solute molecules. Used to handle solutions with a difference of approximately one digit between solute molecular weight and solvent molecular weight. It is generally used to remove solutes with molecular weights ranging from 0 to 10000. The operating pressure of reverse osmosis method is about 2.9-14.7 MPa, and the semi permeable membrane used is acetate fiber or its derivatives.

Ultrafiltration is a separation phenomenon that occurs when the molecular weight of a solute is more than 100 times lower than that of a solvent. It is generally used for separating solutes with molecular weights ranging from 1000 to 50000. The operating pressure of ultrafiltration method is around 49-588 kPa, and the semi permeable membrane used is polyacrylonitrile and other polyolefin membranes.

Reverse osmosis and ultrafiltration methods move substances through membranes and have the following advantages: ① They do not require heating and can be separated or concentrated at room temperature. Therefore, during the operation process, there is minimal change in quality; ② Operated in a sealed circuit, therefore not affected by oxygen; ③ Operate without any phase change, resulting in less loss of volatile components; ④ Less energy is required during operation.

（8） Adjustment and Mixing of Fruit and Vegetable Juice

The optimal sugar acid ratio for the vast majority of fruit juice products is around 13:1-15:1. The combination of plain flavored juice and strong flavored juice creates a mixed juice that enhances the flavor. The main method of adjustment is to add an appropriate amount of syrup and edible acid (citric acid or malic acid) to the juice to be made.

1. Sugar acid adjustment

(1) Establish a ratio of raw juice to syrup.

(2) Determine the content of soluble solids in the original juice (refractometer method) and acid content (neutralization titration method).

(3) Calculate the concentration and acidity of the syrup to be added.

① Calculate the weight of adding concentrated sugar solution:

X=W(B-C)÷（D-B）

In the formula, X: weight of concentrated sugar solution to be added (kg); D: Concentration of concentrated sugar solution (%); W: Original juice weight before adjustment (kg); C: Sugar content of the original juice before adjustment (%); B: Require the adjusted sugar content (%) of the juice.

② Calculation of acid addition amount

The formula is the same as above.

2. Color mixing, fragrance enhancement, and others

According to the required color of this product, color it with food coloring agents. Various essence can also be used to enhance fragrance. In order to maintain the turbidity of cloudy fruit juice, thickeners can be used, with a general dosage of 0.05% to 0.25%, mainly including agar, pectin, sodium alginate, and sodium carboxymethyl cellulose. 10-20mg/L vitamin C is often added to fruit juice to enhance its antioxidant properties.

（9） Packaging and sterilization of fruit and vegetable juice

1. Can sealing

There are two ways of filling: generally, hot filling is used, which is connected in series with the instantaneous sterilization machine in the front process of the filling machine, and immediately filled and sealed after sterilization; Another method is to fill and seal the prepared juice cold liquid before sterilizing it.

2. Sterilization cooling

Sterilization is aimed at eliminating microorganisms and preventing fermentation from deteriorating quality; The second is to disrupt enzyme activity and prevent the taste of the product from changing color.

The sterilization targets of fruit juice are yeast and mold. Yeast is killed in 1 minute at 66 ℃, and mold is killed in 20 minutes at 80 ℃. To destroy the enzyme activity in the raw material, it takes about 1-2 minutes at 88 ℃ or about 25-45 seconds at 93 ℃. Juice has strong heat sensitivity, and the sterilization temperature is generally above 80 ℃. If the time is long, it is prone to steaming and cooking. In addition, due to the different types and pH of fruit and vegetable juices, the following methods are often used for sterilization.

① Instant pasteurization: After homogenization and degassing of the juice, it is pumped into an instant sterilizer (such as a tube or sheet) at a temperature of 90-93 ℃ for 30-90 seconds. This method has a short heating time and has little effect on the flavor and color of the juice.

② Boiling water sterilization: After preheating, the juice is quickly sealed in cans (bottles), sterilized in boiling water for 10-30 minutes, and rapidly cooled to around 37 ℃.

③ High temperature sterilization: Low acid vegetable juice (except tomato juice) is sterilized at a temperature above boiling point of 106-121 ℃ for 5-20 minutes and rapidly cooled to 37 ℃.

Currently, sterile filling equipment is mostly used for fruit and vegetable juices internationally. After degassing, the prepared juice is subjected to ultra-high temperature instantaneous sterilization, using 118-135 ℃ for 2-10s, then cooled to room temperature and sealed in a sterile state (the packaging has been sterilized) to obtain the finished product.