The fully automatic apple juice production line integrates advanced technology from Europe and America, combined with the characteristics of China’s large land investment, to form a refined processing plan for apple, pear, and prickly pear processing production lines. Based on the investment status and production reality of the enterprise, it can design individual projects for customers and hand them over to customers as a truly turnkey project. We are committed to developing innovative equipment that greatly reduces capital investment.

Technological Flowchart Of Apple Juice Processing Line:

Concentrated and NFC apple juice: Fresh apples or pears after washing and sorting, crushing, color-protecting, belt press juicer, disk separator, enzyme treatment, ultra-filtration treatment, then we will get the fresh clear apple juice. If we concentrate apple juice, then we will obtain the concentrated apple juice, then after sterilizing, the end products will be filled into aseptic bags; If we do not concentrate, then will get NFC clear apple juice, after sterilizing, the end products will be filled into aseptic bags in bulk or blended with water or other additives, homogenizing and degassing filled into small bottles.

Reconstituted apple juice: Use concentrated apple juice as raw materials, after blending with water, sugar and other additives homogenizing, vacuum degassing, sterilizing, and then filling into small bottles or cartons.

Characteristics of Apple Juice Processing Production Line

*The processing capacity ranges from 60 tons/day to 1500 tons/day.
*Can handle fruits with similar features, such as apples, pears, and prickly pears.
*Utilize a belt juicer to improve juice extraction efficiency and yield.
*The entire production process is controlled by PLC, and all electrical components are imported products, saving labor and greatly reducing operational technical difficulty.
*Low temperature vacuum concentration ensures flavor compounds and nutrients, while greatly saving energy.
*Tube sterilization and aseptic filling ensure the aseptic state of the product.
*Comes with CIP automatic cleaning system.
*The contact parts of the system materials are all made of SUS304 stainless steel, which fully meets the requirements of food hygiene and safety.

raw material	Fresh apple/pear/prickly pear
Finished product	Juice concentrate or clear juice or jam
capacity	60 tons/day -1500 tons/day
Juice yield	75% (25% fruit fiber, peel and pit)
Solid content	10-12Brix
Juice concentrate	70~72Brix
Finished product packaging	Sterile large bag/tin/glass bottle /PET bottle
Finished product	Customized according to customer needs

Performance characteristics of concentrated juice production line equipment:

The concentrated juice production line equipment of the apple juice production line combines the functions of flushing, filling, and sealing on one machine, achieving automation throughout the entire process. It is suitable for filling juice drinks, fruit tea drinks, and non carbonated drinks such as mineral water and purified water in high-temperature resistant polyester bottles. The SUS304 material is used for the juice beverage production line, and the main components are precision processed by CNC machine tools. The whole machine adopts advanced photoelectric detection to check the operation status of each component. It has a high degree of automation and a simple human-machine interface operation display screen with no bottle filling and no bottle cap delivery.

Main performance of equipment for concentrated juice production line:

1. The bottle is fed with an air delivery device and a hanging card bottleneck method, which allows for fast bottle loading without causing deformation of the bottle;
2. The small-scale juice beverage production line uses advanced bottleneck technology to wash bottle mouths, avoiding contact with threaded mouths and ensuring hygiene. All bottle transportation uses bottleneck technology, and changing bottle shapes does not require adjusting the height, only changing the diameter of the bottle body related protective plate;
3. The filling adopts valve lifting technology, and the filling valve adopts a new micro pressure filling principle for accurate quantification;
4. The screw cap adopts the instant catch and turn screw cap technology introduced from France, and the lid sorting device is installed at a low position and horizontally fed;
5. The main PLC and frequency converter of the juice beverage production line are both branded, such as Mitsubishi and Omron from Japan;
6. The machine has a compact structure, a complete control system, easy operation, and a high degree of automation;
7. Changing the bottle shape only requires replacing the star wheel and arc-shaped guide plate of the cap part;
8. The parts in contact with the materials in the juice beverage production line are made of stainless steel, with no dead corners in the process and easy to clean;
9. Adopting high-speed filling valve, the liquid level is accurate without liquid loss, ensuring the filling process requirements;
10. The sealing head of the small-scale juice beverage production line adopts a magnetic constant torque device to ensure the quality of the sealing and not damage the bottle cap;
11. Adopt an efficient lid system with complete self-control and protection devices.

Key Machine Of Apple Juice Processing Line

Apple&Pear washing and sorting machine:
Before cleaning, there are a lot of microorganisms on the surface of the apple and pear. By air-blowing washing, the microorganisms are reduced to 5%. The cleaning effect depends on the cleaning temperature and time, PH value, hardness, and mineral content of the cleaning solution.

The fruit is sorted by roller conveyor so that the apple is turned during the transporting process. The advantage is that it can more thoroughly remove bad and insect fruits and mechanical wounds fruits, weeds, and foreign matter.

Apple crushing machine
Apple or pear before juice extracting needs to be crushed, the crushing process can increase the juice yield rate. During crushing, VC or citric acid can be dosed into the fruits to protect the color of the fruits.

Fresh apple or pear after crushing, the piece size is 3-9mm even particle, The crushing method is using of mechanical crushing. The principle is crushing by roller squeezing and blade cutting. Finally, the sieve surface with a certain aperture is the size of the fruit particles in accordance with the standard. The crusher rotated speed and the sieve screen can be adjusted according to the requirements.

Optimum mash enzyme dosing system
Dosing mash enzyme preparations into the apple or pear mash or pomace can increase the juice press working efficiency and juice yield rate. Dosing Pectinex Ultra SP-L enzymes, the dosing quantity is 100ml/ton of fresh apples, enzymatic hydrolysis for 1 hour at 25℃-30℃, then the apple juice yield rate can increase from 75%-78% to 88% with the belt press.

Apple Juice color protecting system
During the crushing process of the apple, the apple pulp is in contact with the air, which easily causes the pulp to undergo oxidative browning. The mixed solution of ascorbic acid and citric acid can be used for color-protecting. And color-protecting system mainly includes a mixing tank, diaphragm metering pump, valves.

Apple juice extractor
The belt press juicer is specially used for extracting juice from apple or pear, The equipment adopts multi-stage folding bar and pneumatic roller to press, after the juice is pressed, it will be fed into the vibrating screen to filter the fruit pomace in juice. At the same time, it also has the characteristics of energy-saving, high degree of automation, automatic feeding and discharging, continuous work, strong universality, sufficient pressure and filtration, low water filtration of filter cake, convenient operation and maintenance, etc. The juice yield rate can reach 70%-90% with belt press, which can increase the yield rate of by 20 ~ 35% compared to other fruit juice extractors, so it can greatly reduce the production cost and improve the economic benefit of the enterprise.

When the production capacity is less than 2 tons per hour, the screw press juice extractor can also be used for extracting apple or pear juice. The advantage of the screw press is a low investment, flexibility and easy operation, which is an ideal equipment for small-scale apple juice processing manufacturers, but this machine has lower juice yield rate compared to belt press, and during juice extracting, the juice will be heated, so the flavor and VC in juice will also be loss in some extend.

Apple juice pasteurizer
After the juice is extracted, one plate pasteurizer is preferred to use to inactivate the enzymes in the juice. The pasteurizing process is 30℃ juice inlet pasteurizer, 90-95℃ hold for 15-30S, then 50℃ cooling for the enzymatic hydrolysis process.

Apple juice enzyme treatment system
Pectin and gum and other colloidal substances exist in apple juice, pectinase must be added to make pectin juice reach a clear state. The enzymatic hydrolysis tank is for adding enzymes to juice, the adding amount is determined according to the nature of the apple juice, the content of pectin and the activity of the enzyme.

There is a hot and a cold method for enzyme treatment. In the hot method, the enzyme is mixed into juice at 55°C and held for 1 to 2 hours. In the cold treatment, the enzyme is mixed into the juice at room temperature, 20°C and held 6 to 8 hours. The enzyme activity can be monitored by adding five milliliters of juice to 15 ml of HCL-acidified ethyl alcohol, and observing the mixture for 5 minutes for gel formation. No gel formation means that the depectinization has been completed. Equipment used in this process is liquid mix tank, steam jacket, temperature sensor, level sensor and valve.

Apple juice pasteurizer
After the juice is extracted, one plate pasteurizer is preferred to use to inactivate the enzymes in the juice. The pasteurizing process is 30℃ juice inlet pasteurizer, 90-95℃ hold for 15-30S, then 50℃ cooling for the enzymatic hydrolysis process.

Apple juice enzyme treatment system
Pectin and gum and other colloidal substances exist in apple juice, pectinase must be added to make pectin juice reach a clear state. The enzymatic hydrolysis tank is for adding enzymes to juice, the adding amount is determined according to the nature of the apple juice, the content of pectin and the activity of the enzyme.

There is a hot and a cold method for enzyme treatment. In the hot method, the enzyme is mixed into juice at 55°C and held for 1 to 2 hours. In the cold treatment, the enzyme is mixed into the juice at room temperature, 20°C and held 6 to 8 hours. The enzyme activity can be monitored by adding five milliliters of juice to 15 ml of HCL-acidified ethyl alcohol, and observing the mixture for 5 minutes for gel formation. No gel formation means that the depectinization has been completed. Equipment used in this process is liquid mix tank, steam jacket, temperature sensor, level sensor and valve.

The Ultra-filtration system is designed to produce clear apple juice in the juice processing line. It consists of tanks, a recycling pump, a membrane stack as the core part, clear juice pump, clear juice tank, and control system etc. This system has high filtration accuracy and less loss of effective nutrients and aromatic components in the juice. The system process is mature and reliable, high degree of automation, simple operation, and high labor intensity.

Apple juice concentration machine
The concentration-time of apple juice is usually a few minutes, and the evaporation temperature is usually 55-60 ℃. Under such a short evaporation time and such a low evaporation temperature, it will not have a big effect on product ingredients and quality.

Apple concentration is mainly using a falling film evaporator to evaporate 12brix apple juice to about 70brix. The falling film evaporator is fully automatic and the material is SUS304/316 material. material inlet, material outlet, Brix value, and concentrating temperature are all full automatic. All the key parts like PLC, touchscreen, steam valve control system, and refractometer all use first-class world famous brand like SIEMENS, SCHNEIDER, ATAGO, Spirax Sacro brand.

The Ultra-filtration system is designed to produce clear apple juice in the juice processing line. It consists of tanks, a recycling pump, a membrane stack as the core part, clear juice pump, clear juice tank, and control system etc. This system has high filtration accuracy and less loss of effective nutrients and aromatic components in the juice. The system process is mature and reliable, high degree of automation, simple operation, and high labor intensity.

Apple juice concentration machine
The concentration-time of apple juice is usually a few minutes, and the evaporation temperature is usually 55-60 ℃. Under such a short evaporation time and such a low evaporation temperature, it will not have a big effect on product ingredients and quality.

Apple concentration is mainly using a falling film evaporator to evaporate 12brix apple juice to about 70brix. The falling film evaporator is fully automatic and the material is SUS304/316 material. material inlet, material outlet, Brix value, and concentrating temperature are all full automatic. All the key parts like PLC, touchscreen, steam valve control system, and refractometer all use first-class world famous brand like SIEMENS, SCHNEIDER, ATAGO, Spirax Sacro brand.