Apple juice production equipment. Apple juice production technology. Basic monthly costs

FEDERAL AGENCY FOR EDUCATION

STATE EDUCATIONAL INSTITUTION

HIGHER PROFESSIONAL EDUCATION

KAZAN STATE

UNIVERSITY OF TECHNOLOGY

TEST

By discipline: Enterprise Technology

Topic: Apple juice production technology

Kazan 2010

Introduction

1. From the history of juice production

2. Technology for the production of fruit juices

2.1 Preparation of raw materials

2.2Juices without pulp (pressed juices)

2.3Production of juices with pulp (homogenised)

3. Extracts and syrups

Conclusion

Bibliography

Introduction

Juice production is of great importance for humans. Everyone understands that for health it is necessary to get vitamins, and juices contain the necessary amount of them. For example, vitamin C, vitamin P, folic acid, provitamin A - carotene are mainly found only in fruits and vegetables.

Juices are a necessary and indispensable part of baby food.

Juices are tasty and fragrant.

They perfectly remove thirst, and a glass of juice drunk in the morning will charge you with energy and good mood for the whole day.

Therefore, it is necessary to develop the production of juices, improve the technology of processing fruits and berries. Help the human body to receive valuable vitamins, especially in spring, when most people have beriberi.

1. From the history of juice production

The development of technology for storing and processing fruits began a long time ago.

Initially, the simplest methods were used: products were stored in pits, cellars, deep storages of small volume, processing was limited to rinsing fruits and berries, pickling, and drying.

With the development of science and technological progress, they began to build large-capacity stationary storage facilities, refrigerators, sterilization, and rapid freezing. But the most intensive and systematic development of the industry began after the Great October Socialist Revolution.

Through the efforts of scientists and specialists, such progressive technologies as storage of fruits in a controlled gas environment (CGA), the use of polymeric materials for packaging, packaging and thermal insulation of products, and others have been developed and introduced into production. Mechanized production lines are widely used for commodity processing and packaging of fruits and vegetables.

Automated systems for remote control and regulation of storage and preservation of fruits are also used.

However, there are still many untapped reserves to reduce fruit losses during storage and processing, as well as to preserve high quality fruit and vegetable products.

It is necessary to build and reconstruct the existing storage facilities and canning factories.

It is also necessary to intensively develop scientific research on the development of low-waste technologies for the storage and processing of fruits.

To solve the tasks set, agro-industrial complexes (AIC) and scientific and production associations (NGOs) have been created, which are engaged in the cultivation, harvesting, commodity processing, storage, processing and sale of fruits.

Evaluate the effectiveness of the final result - the quantity and quality of products delivered to the consumer. Much attention is paid to the training of highly qualified specialists.

Future fruit growers, while studying at agricultural educational institutions, need to acquire theoretical knowledge and acquire practical skills on the specifics of commercial quality, chemical composition, nutritional and vitamin value of fruits, the basics of their standardization, the basics and technology of long-term and short-term storage, the basics and technology of processing.

2. Technology for the production of fruit juices

2.1 Preparation of raw materials

The following requirements are imposed on raw materials for the production of juices: first of all, they evaluate the taste, aroma, content of nutrients and physiologically active substances, take into account the degree of ripeness of the fruit to increase the yield of juice.

All fruits are stored in different ways. For example, different varieties of apples perceive the effects of temperature during storage differently.

Some of them endure a long-term state of hypothermia down to minus 2 - minus 3 C, while being stored with minor losses and with slow defrosting (defrosting).

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

All this requires a special technology for growing and storing products. The content of solids in fruits reaches an average of 10-20%, of which a smaller part is insoluble (2-5%), and a large part is dissolved in cell sap (5-18%).

Insoluble solids are cellulose and its accompanying hemicelluloses and protopectin, as well as some nitrogenous substances, pigments, waxes, and starch.

Soluble dry substances in fruits include sugars, acids, nitrogenous substances, phenolic substances, soluble pectin and others.

The value of the chemical components of fruits is different, but all of them are necessary for rational human nutrition. Carbohydrates determine the calorie content, which for fruits is 50-70 calories per 100g. Sugars in combination with acids play a major role in determining the taste of fruits.

The composition and ratio of anthocyanins and fat-soluble pigments determine an important quality indicator - the color of the fruit.

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

There are two main types of juices: without pulp (pressed) and with pulp (homogenized).

According to the technology of preparation and recipe, there are several types of them (natural, blended, fortified, sterilized through sterilizing filters, etc.).

2.2 Juicing without pulp (pressed juices)

Juices without pulp are obtained by pressing.

The plant tissue is prepared in such a way that the cell sap comes out as far as possible from each cell. It depends on the careful grinding of the fruit.

In this case, most of the cells should be disrupted. But the pieces of fabric should not be very small either, otherwise the sieves are clogged during pressing, and the juice yield is reduced.

So, when crushing apples into pieces about 0.3 cm in size, the juice yield can be increased to 705, with a greater degree of crushing, it decreases. For crushing raw materials, a crusher with corrugated rollers is used, which, when rotating towards each other, crush fruits, a universal crusher, a roller crusher, and knife cutting.

To increase the yield of juice, the pulp is heated to a temperature of 80-85 C.

However, as a result, an off-flavour may appear and the aromaticity of the product may decrease.

Other methods are also used to increase the yield of juice - freezing, electroplasmolization, processing with enzyme preparations.

When frozen, cell walls are damaged by ice crystals.

During electroplasmolization, under the action of an electrical voltage, the protoplasm coagulates. Enzyme preparations contain pecto- and proteolytic enzymes that loosen the fruit tissue.

Juice is extracted on various presses.

The most common: mechanically driven screw, hydraulically driven, auger.

In mechanically driven presses, the pressure (9-12%kg/cm) is created by turning the nut on the vertical screw, which is transferred to the upper clamping frame of the basket.

In presses with a hydraulic drive, pressure (9-12 kg/cm) is created by a hydraulic plunger pump, in continuous screw presses used to produce grape juice, by rotating two screws with opposite turns, decreasing pitch and increasing diameter (the principle of its operation is similar to extractor for tomato juice).

The pulp is loaded into the presses either in two baskets of wooden planks fastened with hoops, or in packs (in hydraulic presses) mounted on two lattice wooden platforms. While one is freed from the pulp and loaded, the second is pressed. At the same time, the pressure is increased slowly, otherwise the pulp may be pressed. In basket presses, after the first pressing of the juice, the pulp is loosened and pressed again. In pack-presses, the maximum yield of juice is reached after the first pressing.

In screw presses, juice is obtained with a large amount of suspended particles, but in this case, the process of extracting it is continuous, and the yield is high, so such presses are used more and more widely.

The next operation is clarification of the juice.

The simplest method is sedimentation of turbidity particles by settling, but in this case only large particles precipitate and the process is very slow. Sometimes juices (for example, grape) self-lighten: with prolonged standing, a flaky sediment of turbidity exfoliates. Self-clarification occurs as a result of enzymatic and chemical transformations, in which colloidal substances are destroyed. For self-clarification of juices, large reserve tanks are needed.

This method is used for difficult-to-clarify apple and plum juices.

For clarification, gluing of juices is used, adding proteins (gelatin) and tannins (tannin). Forming a sediment, they precipitate suspended particles.

Clays (bentotines) are also used, which have strong adsorbing properties and change the electrical charges of colloids, thereby precipitating them.

But the most common is the filtration of juices, carried out on filters - presses. Between the plates of the filter-press, a filter material is laid (filter - cardboard, pressed asbestos), through which the juice passes, supplied by a pump under pressure through the channels in the flanges of the plates.

After filtering, the first portions of the juice entering the opposite channel in the flanges may be cloudy, they are returned for recirculation. Transparent juice is sent for bottling, capping and sterilization.

Juices can be sterilized without heating on decontaminating filters. To do this, use filters - presses.

The holes in the filter material are so small (no more than 1 micron) that microorganisms do not pass through them.

Juices obtained with the help of sterilizing filters retain their natural taste and aroma and are therefore more valuable than sterilized ones.

Mechanized production lines for the production of fruit juices have been created, which provide for all operations - from crushing raw materials to sterilization and bottling of finished products.

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

2.3 Production of juices with pulp (homogenized)

Juices with pulp include all components of the chemical composition of fruits, including insoluble ones: fiber, semi-fiber, protopectin, fat-soluble pigments.

A liquid consistency is imparted to such juices by grinding the tissues of raw materials to individual particles with a size of 30 microns. Due to the complete preservation of the components of raw materials, the value of juices with pulp is higher than clarified ones. For consumption, they are diluted with 16-50% sugar syrup (up to 50% of the total mass).

Juices with pulp are produced under conditions that impede or exclude contact with air (to prevent the oxidation of polyphenols and other physiologically active substances). As a substance that prevents oxidation, synthetic ascorbic acid (about 0.1%) is added, which helps to preserve the natural color of products and vitamin C.

Washed and steamed fruits are crushed on mashers, hot sugar syrup is added, then finely crushed in homogenizers. The principle of operation of the latter consists in injecting raw materials under high pressure (up to 150 kg / cm3 or more) into a narrow gap between the body and the valve of the installation.

The valve is tightly pressed against the body by a spring, but under the action of fluid pressure created by powerful pumps, it rises, forming the thinnest gap.

Raw materials pass through it at high speed, due to which it is crushed. The spring pressure on the valve can be adjusted with a special flywheel, thus changing the size of the gap and the degree of grinding of the product.

There are homogenizers and other designs.

Homogenized juice is deaerated (freed from air) in a vacuum apparatus, heated, hot packed and sterilized at a temperature of 90-100 C.

3. Extracts and syrups

Extracts are concentrated juices. Well-clarified juices are boiled by the method of continuous topping up in a vacuum - stainless steel or enameled apparatus. They create a vacuum of at least 86645 Pa and boil the raw material at a temperature of 50-65 C.

At the end of boiling, the density of extracts cooled to 20 ° C should be 1.274, blackcurrant - 1.200. The content of solids in extracts from most of the fruits and berries is 57%. Before packaging, the products are quickly cooled to a temperature of 15-20 C, otherwise a precipitate may form in them.

The most suitable storage temperature for extracts is not higher than 10 C. To prevent the color from changing, the finished product is stored in a glass container in a dark room.

Syrups are juices preserved with sugar.

The required amount of sugar is dissolved in the juice either when heated or cold.

The latter is preferable, since the syrup does not lose flavor. Usually 635-645 kg of sugar are taken for 400 kg of juice.

Syrups are pasteurized by hot filling (in large containers) or in autoclaves (in small containers).

Conclusion

Finished products must meet all the requirements for it.

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

Check the density of the extracts. For example, for blackcurrant extract, the density is 1.200, and for the rest - 1.274. The color of extracts, juices, syrups must comply with generally established standards.

Bibliography

1. Polegaev V.I., Shirokov E.P. “Storage and processing of fruits and vegetables”, Moscow: Agropromizdat, 2006, 302p.

2. Leonenko I. I. "Fruit and vegetable growing", textbook for technical schools, Moscow, 2002, 290p.

Technology for the production of concentrated apple juice

acceptance. Upon acceptance, the quantity and quality of fruits and vegetables are determined, taking an average sample (4-15 kg) for analysis. There are mechanized samplers for selection of tomatoes from the unloading conveyor. The compliance of raw materials with the requirements of GOST is judged by organoleptic and chemical indicators, by the presence of certain defects.

Raw material inspection. All fruits are inspected, rejecting substandard (immature, overripe, affected by diseases and pests), as well as impurities. Raw materials are inspected manually at the conveyor, which moves at a speed of no more than 0.1 m/s. The fruits are distributed on the tape evenly in one layer. For inspection, roller conveyors are used, which allow inspection of raw materials from all sides.

Washing. The fruits coming for processing have surface contamination of mineral or organic origin. A significant part of these contaminants is introduced with dust. The fruit surface abounds with various microorganisms (epiphytic microflora) from the environment and carried by insects. During the washing process, mechanical impurities, microorganisms and pesticides remaining after the chemical treatment of plants should be removed from the surface of the fruit. Fruits and vegetables are delivered for processing in containers, boxes or in bulk by road transport and unloaded into a receiving hopper filled with 1/3 of water (Fig. 1), where heavy impurities (stones, clods of earth, etc.) are removed if they accidentally got into the raw material

Technological scheme for the production of apple concentrated juice

Splitting up. Benign fruits are served in a grater-knife type, which grinds apples into particles of 2-6 mm. The degree of crushing is adjusted depending on the density of the apples.

pressing. The main method of extracting fruit juices under industrial conditions is pressing in batch and continuous presses.

Storage

When pressed, the pulp is subjected to gradually increasing pressure, which leads to the release of juice. After pressing, waste remains - pomace, which is a mass of fruit pulp that is almost dry to the touch. The loaded platform is brought under the squeezing device and a low pressure hydraulic piston is turned on. The pressure is increased gradually, otherwise the pulp may get into the juice or the burlap may break. When a further increase in pressure is difficult, the second piston is used to supply hydraulic fluid, raise the pressure to 2.5 MPa and hold it for 5 ... 10 minutes until the release of juice stops. Then the platform is rolled back for unloading. The total pressing time is 15...20 min. The pomace is unloaded onto the conveyor, which delivers them to the bucket elevator, and the elevator - to the storage bin. The pomace is then taken out of the factory to be fed to livestock or for other purposes. When processing fruits into juice and seeds for nurseries, the juice is squeezed out so as not to cause deformation of the seeds. The specific pressure on the pulp when squeezing juice from apples should be 1.0. .1.2 MPa. In each case, test pressing is carried out.

Filtration. After clarification, a sediment remains in the juice, which is removed by passing the juice through filters of various systems or by separation in centrifuges. Fruit juices are filtered at constant and low pressure. The sediment contained in the juice, consisting of organic particles, is easily compressed at elevated pressure, which causes filter blocking, preventing further process. Filtration requires a pressure differential across both sides of the filter septum. With an increase in pressure, the rate of the process first increases, and then, due to compression and blockage of the filter pores, decreases. The optimal pressure drop is 70 - 80 kPa. For filtering fruit juices, filter presses, pre-wash filters and drum vacuum filters are used. The filtered juice is allowed to be recirculated until transparent, after which the filtered juice is fed to deaeration.

Enzyme processing. Juice with a temperature of about 35-400C enters the reserve with a stirrer, where it is processed with pectolic enzymes for 90 minutes.

Ultrafiltration. After processing with enzymes, the juice is filtered using semi-permeable membranes in special apparatus at a pressure of 0.1-0.8 MPa.

concentration. Concentrated juices are obtained mainly by evaporation, less often by freezing and reverse osmosis with the capture of aromatic substances and their return to the finished product.

a) Concentration by evaporation is carried out in evaporators. The lower the evaporation temperature and the shorter the duration of the operation, the higher the quality of the resulting juice, so it is advisable to carry out the evaporation in vacuum apparatus. Apple juice withstands short-term heating to a temperature of 45...55 0 C without noticeable changes in properties.

b) Freeze concentration is based on cooling the juice below freezing. Part of the water freezes and in the form of crystals is separated from the concentrate by separation. The lower the freezing temperature, the higher the solids content in the finished product. At low temperatures, the juice undergoes minimal changes. The freezing method is used to obtain juice with a solids concentration of 45-50%. Freezing is used to produce concentrated citrus juices.

c) Concentration using membranes - reverse osmosis - improves the quality of the finished product due to the low temperature of the process. The essence of the method lies in the fact that two liquids with different concentrations of dissolved substances are placed on both sides of the membrane. An osmotic pressure develops at the membrane boundary, and water moves from a solution of low concentration to a solution of high concentration until the concentrations are equal. If pressure is applied to a solution with a high concentration, then water will flow in the opposite direction.

Sterilization. The quality of canned food and the duration of their storage without spoilage depend on how carefully and correctly their sterilization is carried out, under which microorganisms die and conditions are created under which the development of spores of microorganisms stops. The sterilization regime depends on the type of product, size and type of container. In an acidic environment, microorganisms die faster than in a neutral one; canned food with solid products warms up longer than with liquid; tin containers heat up faster than glass containers. In this regard, for each type of canned food, its own sterilization regime has been developed. Sterilization temperature ranges from 140-160 0 C. Sterilization is carried out in special devices - autoclaves.

Bottling. Products are packaged in carefully washed containers. At the same time, each jar is filled with a strictly defined amount of products (deviations from the established norm are allowed within 1 ... 2%). The temperature of the juice when pouring into cans with a capacity of 3 liters. is 90-95°C. Packing of products is mechanized. Banks with a capacity of 2000 and 3000 cm3 are filled with a liquid product on an automatic filler. And then seals the jars with the help of special machines.

Storage. Products are stored in well-ventilated warehouses on wooden racks or pallets at a relative humidity of not more than 75%. Storage temperature of canned vegetables packed in glass and metal jars - from 0 to 25 °C; in polymer packaging of the "bag in a box" type - from 0 to 20 °С, unsterilized products in barrels - from 0 to 12 °С, in aluminum tubes - from 0 to 5 °С; fruit and berry canned products in all types of containers - from 0 to 25 °С; salted and pickled vegetables, pickled fruits and berries, boiled, salted and pickled mushrooms in barrels - from minus 1 to 4 °C; canned mushroom products in glass and metal jars - from 0 to 15 °С; fruit, berry and vegetable canned semi-finished products, as well as canned with chemical preservatives in all types of containers - from 0 to 25 ° C.

The shelf life of products from the date of production is set in the regulatory document for products of a particular type. Shelf life guaranteeing bacteriological stability is not established.

Ministerul Educa ţiei, Tineretului si Sportului

al Republicii Moldova

Universitatea Tehnică a Moldovei

FACULTATEA DE TECHNOLOGIE ŞI MANAGEMENT

ON INDUSTRIA ALIMENTARĂ

Catedra: Tehnologia conservarii

Teza de license ţă

theme : „Tehnologia de fabricare a sucului concentrat de mere cu utilizarea principiilor HACCP”

A elaborat Peicov Oleg

student gr. TPFL-021

Îndrumător Tărîţă V

Chisinau, 2006

1. Literature review. Technical and technological progress in the production of concentrated apple juice.

1.1 General characteristics of apples used in

industrial processing ( degree of maturity, chemical composition, gelling components - pectin, starch, etc. )

Each variety of wild-growing and cultivated apples has its own characteristics and different chemical composition. It all depends on the origin, growing conditions, the 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 acids. In addition, volatile fatty acids were found in the apple: acetic, butyric, isobutyric, caproic, propionic, valeric, isovaleric. Apple has tannins and phytocides, which are bactericidal substances. Starch is of primary 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 transformation 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 in the form of glycogen. As follows from the table. 1, apples and cabbage have the most useful properties. Apples contain 2 times more fructose than glucose. They are indicated for liver disease, diabetes and a number of other diseases.

Table 1

Based on table 1, it can be seen that the chemical composition of apples is very diverse, contains a large amount of pectin and starch. Due to their high pectin content, apples are a staple for pectin production.

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

Protopectins are insoluble in water. They are found 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 transform 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 nutrition of a healthy person, as well as the possibility of using them for therapeutic (therapeutic) purposes in certain diseases, mainly of the gastrointestinal tract. Pectin is obtained from the waste of apples, watermelons, and also from sunflowers.

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

1.2 Modern technologies for obtaining apple juice

( pressing, enzyme treatment )

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

Technological process.

Juices are clarified and represent the liquid phase of the fruit with substances dissolved in it, squeezed out of the fruit tissue.

Delivery, acceptance and storage of raw materials are carried out in the production of juices in the same way as in the manufacture of other types of canned fruits. Washed raw materials are inspected, removing fruits affected by pests, rotten and with other defects. Mechanical grinding (crushing) is the main method of influencing plant tissue in the production of juices. However, excessively fine grinding will turn the pulp into a continuous mass, in which there will be no "channels" for the juice to flow out. The degree of cell damage during mechanical grinding depends on the type of fruit and the design of the grinding device. The degree of damage to the cellular structure of apples during grinding on a grinder is about 30 ... 35%. However, when crushing apples on a grater-knife crusher, the proportion of cells with damaged membranes can reach 60...80%. Pressing also damages the membrane. In the process of heating plant materials, protoplasm proteins are coagulated and dehydrated, which leads to an increase in cell permeability. Heat treatment proved to be most effective for fruits with low juice yield. Heating not only increases the yield of juice, but also has other effects on the raw material: it inactivates enzymes, reduces sliminess and viscosity, and promotes the transfer of coloring substances from the skin and pulp of the fruit into the juice. The heating mode must be correctly selected for each type and grade of raw material. Crushed fruits are heated in continuous devices of various devices.

Processing with enzyme preparations.

Most fruits and berries contain pectin, which makes it difficult to extract juice and reduce its yield. Pectic substances are found in fruits in the form of water-insoluble protopectin and soluble pectin. Protopectin is part of the cell walls and median lamellae of plant tissues. Soluble pectin, which has a water-retaining capacity and increases the viscosity of the juice, prevents it from flowing out, has the main influence on the juice yield process. Therefore, when processing the pulp with pectolytic enzymes, it is necessary, first of all, to destroy insoluble protopectin. Protopectin must be hydrolyzed only partially, so as to separate cells from one another and partially destroy their walls to increase cell permeability. Pectolytic enzyme preparations not only destroy pectin substances, but also act on cells with toxic substances of a non-enzymatic nature, which are part of the preparations and cause coagulation of protein-lipid membranes and death of plant cells. As a result of these transformations, cell permeability increases, protoplasmic membranes break, and the release of juice is greatly facilitated. For the processing of fruit pulp in the production of juices without pulp, the enzyme preparation Pectofostidine is used, which is available in powder form. Novoferm10x (surface grown) is a complex of pectinase, polygalacturonase, pectin methyl esterase, cellulase and amylase enzymes. The optimum temperature for the action of pectolytic enzyme preparations is 35…40°C. An increase in temperature above 55 ° C inactivates the enzymes and the effect of the drug stops. The processing time is 1…2 hours. Novoferm10x is used both for pulp processing and juice clarification. A new type of enzymes that can be used to process the pulp in order to increase the yield of juice are thinning enzymes, which include pectinase and cellulase.

Juice extraction.

To extract juice from prepared fruit pulp, pressing, centrifugation, diffusion, etc. are used. The main method of extracting juice from fruits and berries - pressing - consists in pressure on the pulp. The main function of the press is not to crush the plant tissue, not to damage the biomembranes of the cell structure, but to squeeze out the juice that has already been released from the cells damaged during the pre-treatment. The press is not designed to extract the juice from the cells, but is used to separate the liquid phase of the pulp - the juice flowing out of the cells that have been ruptured before the start of pressing. A high juice yield depends mainly on proper pre-treatment of the raw material. For pressing, presses of various design and principle of operation are used, which can be continuous (screw, belt) and periodic (batch, basket) action. In batch presses, the pulp is wrapped in napkins (bags) made of durable fabric with a layer of 6 ... 8 mm. The packages are stacked on the platform one on top of the other with a laying of wooden tiles between them. From above, the packages are reinforced with a pressing plate. The platform with the bags is lifted under the pressure plate by a plunger. The Bucher hydraulic basket press is a solid cylinder covered on both sides with disks, one of which is driven by a hydraulic system, the other is stationary. Between the discs there is a drainage system of flexible grooved rods, covered with fabric on the outside. The pulp is pumped through the pipeline into the cylinder and fills the space between the rods. After filling the basket, the movable disk moves inside the basket and presses on the pulp. The released juice passes through the filter fabric and flows down the grooves of the rods into a common pipeline. When the discs approach each other, the rods bend. At the end of one pressing cycle, the movable disk moves back, the rods straighten and loosen the pulp. On this press, the juice yield is 80%, the content of suspensions is 1.3%, the generated pressure is 1.2 MPa. For squeezing juice from apples, screw presses R3-VPSH-5 and R3-VP2-Sh-5 are used. For pressing apples, belt presses are most widely used, which allow pressing in a thin layer at high productivity. The Klein type PF belt press consists of a massive frame with a pulp hopper and two polyester belts passing through groups of rollers. The pulp is loaded into the press with a screw loading device. The first zone is runoff, where gravity juice is separated from the pulp under the influence of gravity. Then the pulp enters the wedge-shaped space between the two belts and is compressed there. Pressed pomace is removed from the upper and lower belts using a folding scraper, which diverge and are washed with water jets on the way back. Juice yield on this press is 72…80%. The press-extraction method consists in squeezing the juice from the pulp in a press, then water is added to the pomace in a ratio of 1:0.5 to 1:1, thoroughly mixed and the resulting juice is extracted on a drum vacuum filter. The juice pressed from the pomace contains less soluble solids than after a single pressing, so it is boiled down or used to make sugar syrup in the production of juices with sugar. The diffusion method consists in the fact that all the juice with soluble dry substances is extracted from the pomace with water. Lightening.

Russia ranks 5th in terms of apple harvest in the world, while raw materials for the production of natural apple juice are affordable and cheap. Apple juice production is considered to be an economically viable and profitable business.

Organization of apple juice production

A business for the production of apple natural juice must be formalized as an LLC or legal form. This format will allow delimiting the responsibility of the founders and attracting investors. It is recommended to choose a simplified taxation system.

A product certification procedure is being carried out in order to obtain the appropriate document. It is necessary to analyze the hygienic characteristics of packaged products. With positive results, an SES conclusion is issued on the quality of the juice.

Stages and technology of apple juice production

The production of apple juice begins with a manual harvesting process from August to late autumn. Apples for juice can be harvested from trees and from the ground. The fruits are placed in wooden boxes, which are delivered by trucks to the plant. After that, the raw materials are loaded into stainless steel bins.

Further, water flows push the fruits along the gutters to the production hall, where they undergo primary cleaning. Jets of water carry away excess debris. Then the apples go to the sink and are washed with cold water from dust and chemical contaminants.

The next stage of production is sorting. Apples are manually culled. Selected fruits are sent to the crusher. The crushed raw material falls under the press. The rotating drum compresses the mixture and produces an opaque squeezed juice. It is sent to special pipes for ultrafiltration.

The unit consists of thin tubes made according to the principle of a membrane. The juice is passed under pressure through the membrane and enters the vacuum evaporator, while the pulp particles remain. Under vacuum, the liquid evaporates with aroma-forming substances. The juice thickens, and the vapor condenses and turns into a liquid.

Obtaining concentrated apple juice

Concentrated juice is poured into barrels, in which it can be stored for a long time. The preliminary stage of pouring juice into bags is diluting the concentrate with evaporated water. After which it is mixed, in order to avoid delamination.

A sample of juice is subjected to laboratory analysis, which is carried out for compliance with established standards. A high percentage of dry soluble substances in the juice indicates the need to add additional liquid to the drink in order to obtain an ideal structure.

Then they examine the safety of the drink by placing small portions of the juice in a special thermo-cupboard with a temperature of 36ºС. After obtaining positive results, the drink is restored by adding aroma-forming substances.

Then the finished natural juice is poured into bags, and lids are attached to them. Further, the technical control department tastes the juice, determining the quality of the product in terms of taste, color and aroma. If the sample fully complies with the requirements, the batch of juice is sent for sale.

Video - how apple juice is made

Starting a manufacturing business in the food industry is not easy, as many complex tasks must be solved in the process. But if you approach the matter with all responsibility, without missing a single detail, you can establish a highly profitable enterprise that will pay back all costs in the shortest possible time. But a novice entrepreneur should choose to release a product that is in high demand. And here we include the manufacture of juices and juice-containing drinks. And in order not to make huge investments at first, you can buy equipment for the production of medium-capacity juices by organizing a mini-workshop. Juices and nectars based on fruits and vegetables are constantly in high demand among consumers, and especially in the summer, when it's hot outside. The variability of technology, raw materials and assortment will allow an entrepreneur to organize a business in this niche, taking into account their financial capabilities and skills.

Our business valuation:

Starting investments - from 3,500,000 rubles.

Market saturation is high.

The complexity of starting a business is 8/10.

The production of natural juices in Russia, due to the demand for products, is a highly competitive niche. There are many manufacturers on the market, large and small, supplying their products to store shelves. But one should hardly be afraid of high competition, since even selling fruit and vegetable juices only on the regional market, one can make a good profit. A business in the production of fruit juices is quite real even for novice entrepreneurs - the main thing is to take into account important nuances.

Registration of the future enterprise

The business plan must necessarily contain information about the organizational form in which the entrepreneur is going to register the future enterprise. There is no way without this, because we are talking about the food industry, which requires mandatory certification of products and compliance with all norms and sanitary standards.

Not a single large store will accept fruit juices for sale from an entrepreneur who does not have any permission from supervisory authorities.

After the juice production workshop is registered, in parallel with the search for premises and the purchase of equipment, it is necessary to submit a package of documents to Rospotrebnadzor, which in the future will give the entrepreneur permission to conduct production activities.

Finding a production facility

The premises where the production of juices from concentrates will be located in the future can be located even outside the city. And many entrepreneurs do this - they rent a workshop in the area of ​​the city that is closer to the suppliers of raw materials, since in this case it is possible to significantly reduce the cost of purchasing all the necessary components.

As practice shows, 100-180 m 2 is enough to accommodate a plant of small capacity.

Industrial juice production should have not only a workshop with equipment installed here, but also 2 warehouses - for storing raw materials and for storing manufactured products. Also, do not forget about the sanitary rooms for staff and office space.

In order to obtain permission from the supervisory authorities to conduct activities, the premises must be carefully prepared for work - electricity, water, sewerage must be provided here, ventilation systems must be installed. And this will take away a significant part of the investment from the entrepreneur, if you do not immediately rent premises with good working conditions.

Purchase of raw materials for the production of juices

The technological process of juice production involves the use of a variety of raw materials - everything will depend on the assortment that the entrepreneur plans to release.

Each of the items is produced on the basis of juice concentrate. And depending on its quantity in the finished product, all drinks are divided into:

• natural juices (100% concentrate),
• nectars (25-75% concentrate),
• juice drinks (up to 10% concentrate).

The production of concentrated juice is the most costly of all possible directions. But such products, due to their higher market value, will bring more profit to the entrepreneur. And therefore, it is clearly not worth it to form an assortment only from cheap juice-containing drinks. The best option is to develop a line of juices from 8-15 flavors, where most of the range is represented by nectars.

Juice concentrates are not produced in Russia. This raw material is imported from Asia, Brazil and Turkey. It will be problematic for start-up entrepreneurs to establish direct contacts with foreign suppliers, since it is unprofitable for them to supply products in small batches. This means that you will have to cooperate with intermediaries.

The production of reconstituted juice, in addition to the concentrate, will require a number of other components:

• water,
• sugar,
• nutritional supplements.

Sale of juice can be carried out in different containers - glass, plastic, cardboard. And it is better to provide for the supply of Tetra Pak packaging to the enterprise. Juice packaged in this way will last longer and be better transported.

Development of juice production technology

In order to work out the recipe and production scheme, you can either buy a ready-made specification or invite an experienced technologist to cooperate. And the second option is sometimes more profitable from a financial point of view, since the finished documentation is quite expensive. And the specialist, taking into account the available equipment and the planned assortment, will select specific ingredients and a production scheme.

Technological scheme of apple juice production

Despite the fact that the production scheme may vary, depending on the specific type of product, the technology for the production of juices in general can be described as follows:

• Heating juice concentrate to a boil.
• Cooling the concentrate to room temperature.
• Addition to the purified water concentrate.
• Adding various components to the juice (vitamins, flavors, preservatives).
• Bottling of finished products.

And the production of directly squeezed juice begins with the receipt of the initial component - the concentrate. Such a scheme is rarely used at domestic enterprises, since it is not always cost-effective due to the high cost of the process and the resulting product. But if such equipment is available, it is possible to organize the production of not only natural juices, but also fruit purees within the walls of the workshop. By selling juices and purees, an entrepreneur will be able to make more profit and enter new markets.

Technical equipment of the future workshop

Juice production line

The juice production line can be of different capacity, configuration and degree of automation. And in order to get a quality product at the end, it is important to pay special attention to the choice of technological equipment, taking into account the planned product range and the available finances.

The production of apple juice uses the following names of machines and apparatuses:

• water treatment system,
• containers for mixing components and storing the finished product,
• pasteurizer,
• homogenizer,
• juice filling machine in cardboard containers,
• washing equipment.

The line for the production of directly squeezed juices practically does not differ from other technological complexes - only a machine is added here for obtaining natural juice from whole fruits and vegetables. And such equipment costs a lot - from 500,000 rubles.

European production lines are famous for their quality - they can work continuously for a long time without failing.

The cost of the entire production line will be affected primarily by its capacity. But even in the case of machines of low or medium capacity (0.5-1 t/h), the price of equipment for the production of juices will be quite high - starting from 2,500,000 rubles. And there is only one way to save here - to purchase a supported line. But such transactions must be approached with great caution, since there is a high risk of buying a low-quality installation, which will soon fail.

Problems of sales of finished products

It is not difficult to open a mini juice production, it is much more difficult for an entrepreneur to look for wholesale buyers of finished products. And it is complicated by the high level of competition. Most likely, a novice businessman will have to offer his products to private stores, stalls and wholesale food warehouses. But for the first time, you can not even think about large supermarket chains - they prefer to cooperate with those manufacturers that have proven themselves in the market. In addition, a small production of tomato juice may not “pull” the price that the federal chains are asking for a place on the shelves of their stores.

To overcome high competition, you need not only to make your product excellent in quality, but also to distinguish it from other similar products. And here certain funds will have to be invested in marketing:

• Promotions,
• advertising (at least in local media),
• POS-materials for highlighting on the shelves of retail outlets.

Profitability of the planned enterprise

Equipment for squeezing juice and filling it into containers will begin to pay for itself as soon as all manufactured products are shipped to customers. And as practice shows, this moment can come quite quickly. And this is even taking into account the fact that investments in business are considerable:

• Registration of the enterprise - from 50,000 rubles.
• Development of recipes and development of technology - from 100,000 rubles.
• Purchase of equipment and its commissioning - from 2,500,000 rubles.
• Purchase of raw materials - from 500,000 rubles.
• Preparation of the workshop for work - from 300,000 rubles.

And it will be even more expensive to introduce direct spin into the work of the workshop. Therefore, experts advise leaving this idea until the workshop reaches the break-even point.

If the equipment for bottling juice will produce at least 0.5 t / h of finished products, up to 90 tons of finished products can be sold per month. As for the prices for nectars, everything depends on its specific type and pricing policy in the region. On average in Russia, juice is sold at a wholesale price of 20-50 rubles per liter. It turns out that by selling all the products received, even at the lowest price, you can monthly receive revenue in the amount of ≈2,000,000 rubles. And to calculate the net profit, you will need to know the amount of variable costs that will be spent every month on the production of new batches of juice.