1、 Production process of fruit juice beverages
Weighing - Preparation and constant volume - Homogenization - UHT - Filling - Capping - Lamp inspection - Cold bottle - Air drying - Spraying code - Packing and stacking - Acceptance and warehousing
2、 Introduction to the Production Process of Fruit Juice Beverage
1. Weighing materials
1.1 The batcher shall weigh the materials according to the batching table issued by the R&D department according to production needs.
1.2 Keep a record of material weighing, seal the material after weighing, and place it in a designated location with clear identification.
1.3 Small materials that are prone to moisture absorption need to be weighed before mixing, such as CMC.
2. Raw material dissolution:
2.1 Dissolve Stabilizer: The stabilizer is dissolved in 85 ℃ hot water in a high-speed mixing tank for about 20 minutes. After fully dissolving without particles, it is then pumped into a mixing tank through a colloid mill under atmospheric pressure.
2.2 Dissolve Aspartame and AK sugar: after mixing Aspartame and AK sugar evenly, slowly add 85 ℃ hot water and stir it to make it fully dissolved without particles and then put it into the mixing tank.
2.3 Dissolve Fructose Syrup: Dissolve Fructose Syrup in a mixing tank with cold water (about 7 times water), stir at high speed for 10 minutes, stop stirring, and pour it into a mixing tank (filter with a cloth). Rinse the mixing tank with pure water and pour it into the mixing tank.
2.4 Potassium sorbate, pigment, color fixative, salt, etc. shall be dissolved in warm water.
2.5 Sodium citrate, citric acid and Malic acid are dissolved in warm water (three times in total) and diluted to 7-10 times.
2.6 Vc, essence, opacifier, etc. shall be dissolved in cold water.
3. Blending and constant volume:
3.1 Feeding sequence: stabilizer+sugar substitute+Potassium sorbate+Vc+acid (including sodium citrate)+pigment+color fixative+salt+opacifier+essence.
3.2 Adding acid: slowly add the fully dissolved citric acid and Malic acid solution.
3.3 Constant volume: 4.5 tons, stir for 20 minutes after constant volume, and homogenize after passing the quality inspector's inspection. The sample has a pH of 3.0-3.5, a sugar content of 1.2 ± 0.1 ° Brix, and a total acid content of 0.2565 ± 0.015% (calculated as citric acid).
4. Homogenization: primary pressure: 30MPa, secondary pressure: 10MPa, homogenization effect: eccentricity ≤ 1mm.
5. UHT (Ultra High Temperature Instantaneous Sterilization): sterilization temperature 125-130 ℃, sterilization time 4-6 seconds, discharge temperature 72 ± 2 ℃.
6. Insulation: The temperature of the insulation cylinder is 70 ± 2 ℃.
7. Filtering: Filter with a 300 mesh pipeline filter.
8. Bottle disinfection: (Old bottles need to be disinfected and cleaned in advance: soak and disinfect with 2% Kangle disinfectant for 4 minutes). During production, rinse and disinfect the bottles with 1.0% Kangle disinfectant, and then rinse them with 60-65 ℃ hot water.
9. Lid disinfection: The newly opened bottle cap is directly placed in the storage cap container for UV sterilization for 30 minutes; Bottle caps that have been opened or slightly contaminated should be disinfected with 1% Kangle disinfectant for 3 minutes, then rinsed with water for 3 minutes, dehydrated with a dryer, disinfected in an ozone disinfection cabinet for 30 minutes, and then put into production use; Lids with severe pollution are not allowed to be used.
10. Filling and capping: The filling temperature is 67 ± 2 ℃, the filling capacity is 500 ± 15ml, and the average net content is not less than the marked content; After filling, there is no residual syrup at the thread of the bottle mouth. Production self inspection and quality control personnel inspect the rotating cap and whether there are foreign objects before filling; Before starting the machine, it is required to inspect each head product (self inspection by the production operator and supervision by the quality control personnel) to ensure that the rotating cover does not leak liquid or air, and the tightness is moderate; The bottle cap body is clean and free of foreign objects adhering.
11. Spray code: It is required to be complete, clear, accurate, and the character height is 2-3 millimeters. The spray code position is the bottle cap, and the spray code style is "Previous line 2010/01/21 Next line 08:28:08B Two lines correspond to parallel, and B is the shift".
12. Lamp inspection: Detect products with impurities, flat bottles, low liquid levels, poor coding, and labeling, and prohibit defective products from entering the next process.
13. Washing: The temperature of the bottle washing water requires using hot water at 50-60 ℃ to wash away the slurry attached to the bottle wall and keep it warm.
14. Packing: The quantity of boxes is accurate, and the outer packaging box is clean.
15. Sealing and stacking: The sealing tape is tightly sealed, flat, and aesthetically pleasing; The finished box is square and beautiful; The stacking should be arranged neatly and aesthetically, and the stacking height should be based on not affecting product quality (the stacking height should not exceed 5 layers); The production date should be printed in the "Production Date" of the certificate of conformity, and it should be clear and correct.
3、 Quality requirements for finished fruit juice beverages
1. Internal control physicochemical indicators: solid content=1.2 ± 0.1 ° Brix (20 ℃), pH=3.0-3.5, total acid=0.2565 ± 0.015% (calculated by citric acid).
2. The taste and color of the product shall be based on the standard product.
3. Disinfect according to the sterilization procedure for hot filled beverages.