New Mango Juice Processing Machine for Beverage Production Food and Manufacturing Plants
Description
A mango juice processing machine, also known as a mango juice production machine, is a specialized piece of equipment designed to convert fresh mangoes into commercial-grade mango juice.
These machines typically integrate several key functions to streamline the juice-making process, ensuring efficiency, hygiene, and product consistency.
Here's a breakdown of the main components and stages involved in a typical mango juice processing machine:
1. Reception and Preparation:• Washing unit: An automated system to thoroughly wash and clean the mangoes, removing dirt, dust, and any surface contaminants using water sprays and brushes.• Sorting and grading: Machines equipped with sensors, cameras, or mechanical devices to sort mangoes based on size, ripeness, and visual defects, ensuring only suitable fruits enter the juice production process.
2. Peeling and Destoning:• Automatic peeler: A device that efficiently removes the mango skin without causing significant damage to the flesh, often using a combination of mechanical pressure and rotating blades.• Destoner: A specialized mechanism that separates the mango stone (pit) from the pulp, either through mechanical force or vacuum suction, leaving behind only the edible fruit tissue.
3. Pulping and Extraction:• Pulper: A machine that breaks down the peeled and destoned mangoes into a homogeneous pulp. This can involve crushing, grinding, or pressing actions to release the juice while minimizing fiber content.• Juice extractor: A device, such as a screw press or centrifuge, that separates the juice from the pulp fibers. Centrifugal force or pressure is applied to extract as much juice as possible while minimizing the amount of insoluble solids in the final product.
4. Clarification and Filtration:• Clarifier: A settling tank or a centrifugal separator where suspended solids, pulp fibers, and other impurities settle out or are separated from the juice, improving its clarity and appearance.
• Filtration system: One or more filtration stages (e.g., mesh screens, filter presses, or membrane filters) to further refine the juice by removing fine particles and achieving the desired clarity and viscosity.
5. Pasteurization and Sterilization:• Heat exchanger or pasteurizer: A closed system that heats the juice to a specific temperature (usually around 70-90°C) for a set period to eliminate harmful microorganisms and extend shelf life without significantly affecting the taste, color, or nutritional value.• UHT (Ultra-High Temperature) treatment (optional): For longer shelf-life products, the juice can be subjected to even higher temperatures (around 135-150°C) for a short time, ensuring complete sterilization and allowing storage at ambient temperatures.
6. Homogenization (optional):• Homogenizer: A high-pressure device that reduces the size of fat globules and other suspended particles, ensuring a uniform texture and preventing separation during storage.
7. Filling and Packaging:• Filling machine: An automated system that accurately measures and dispenses the juice into bottles, cartons, cans, or other packaging formats, often incorporating sealing or capping mechanisms.• Labeling and coding equipment: Machines that apply product labels, batch codes, expiration dates, and other relevant information onto the packaged juice containers.
In summary, a mango juice processing machine is a comprehensive system that integrates multiple stages-washing, peeling, pulping, extracting, clarifying, filtering, pasteurizing (or sterilizing), homogenizing (if needed), and filling/packaging-to transform fresh mangoes into commercially viable, hygienic, and consistently high-quality mango juice. These machines can be customized to varying production capacities and specific process requirements, catering to small-scale artisanal producers as well as large-scale industrial operations.
Advantages and strong points
The processing capacity is varied from 60 tons/day to 1500 tons/day.
The line Can deal with similar characteristics of fruits.
Using the high efficient of mango destoner to improve the mango output percentage effectively
Using efficient belt juice extractor to improve the juice efficiency and the output percentage of pineapple.
The production process fully automatic PLC control to save labor and Facilitate production management
Low-temperature vacuum evaporation ,Maximize reserve the flavor substances and nutrients also save energy.
Tubular UHT sterilizer and Aseptic filling machine, produce high-quality aseptic juice products
Automatic CIP cleaning ,ensure the entire line equipment of food hygiene and safety requirements
Parameters
| Raw material |
Fresh Mango / pineapple |
| End product |
Concentrated juice, clear juice, ,cloudy juice |
| Processing capacity |
From 60tons/day to 1500 tons/day |
| Yield |
50-75% |
| Fruit consistance |
10- 20Brix |
| Product consistance |
60~72Brix |
| End package |
Aseptic bag/gable top box/PET bottle |
Installing and debugging a mango juice production machine is a multi-step technical process that ensures efficient and safe operation and produces high-quality products. The following is a general installation and debugging process, but please note that specific operations should refer to the user manual and safety guidelines provided by the equipment manufacturer, as different models and brands of machines may have specific requirements.
Preparation before installation
1. Environmental inspection: Ensure that the installation area is clean, ventilated, and meets the environmental requirements of the machine (such as temperature, humidity, etc.).
2. Infrastructure inspection: Confirm that the power supply, water source, drainage system, and compressed air (if necessary) meet the machine requirements.
3. Infrastructure: If necessary, construct or confirm that the foundation required for machine installation is firm and stable, and the levelness meets the requirements.
4. Preparation of tools and materials: Collect all necessary installation tools and accessories, such as screwdrivers, wrenches, sealing materials, etc.
Machine installation
1. Unpacking inspection: Check if all components are intact and check if the parts are complete against the packing list.
2. Main body assembly: According to the instructions, gradually assemble the various parts of the machine, such as the cleaning unit, juice extraction unit, filling unit, and sealing unit (if applicable).
3. Electrical connection: Professional electricians are responsible for wiring work, ensuring that the power supply connection is correct and complies with local electrical standards, and installing necessary leakage protection devices.
4. Pipeline connection: Connect the inlet, outlet, and raw material pipelines to ensure good sealing and no leakage.
5. Pneumatic system connection (if any): Connect the compressed air pipeline and test whether the air pressure meets the machine's operating requirements.
Debugging and verification
1. Empty running: Start the machine for empty running without adding any raw materials, check if all components are running normally, listen for abnormal sounds, and observe for any abnormal vibrations.
2. Adjustment and calibration: Based on the results of no-load operation, adjust the position of mechanical components, tension belts, calibrate sensors, etc., to ensure that all parameters meet production requirements.
3. Trial production: Add a small amount of raw materials for trial production, check the quality of the product, such as taste, color, purity, etc., and monitor production efficiency and machine stability.
4. Cleaning and hygiene: Verify whether the cleaning system can effectively clean the interior of the machine and maintain hygiene standards in the production environment.
5. Safety inspection: Finally, conduct a comprehensive safety inspection to ensure that all safety protection measures are in place, such as emergency stop buttons, protective covers, etc.
Training and Maintenance
Operation training: Provide equipment operation and maintenance training to operators to ensure they are familiar with the machine's operating procedures and safety regulations.
Maintenance Plan: Develop daily and regular maintenance plans, including lubrication, replacement of vulnerable parts, cleaning, etc., to extend the lifespan of the machine.
Remember, every step should strictly follow the safety operating procedures to ensure personnel safety and normal equipment operation. When encountering uncertain situations, promptly contact the equipment supplier or professional technical personnel for support.
In the mango processing production line, the main raw materials and final products involved are as follows:
Main raw materials
1. Fresh mangoes: This is the main raw material. Choosing fresh mangoes with high maturity and excellent quality is crucial to ensure the taste and quality of the final product.
2. Water: Used for cleaning, soaking, and dilution in some processing steps.
3. Sugar/Sweetener (optional): Add as needed to adjust the sweetness of the finished product, such as white sugar, fruit glucose syrup, etc.
4. Food additives (if applicable): such as preservatives, stabilizers, pigments, etc., used to extend shelf life or improve appearance and texture.
5. Packaging materials: including bottles, cans, plastic bags, etc., used for packaging finished products.
Intermediate products
Mango puree: Mash the peeled and pitted mangoes into a paste, which serves as the basis for subsequent processing.
Juice: a liquid component extracted from mangoes by pressing or other methods.
Fiber residue: Solid waste generated during the processing, which may be used as feed or for other industrial purposes.
Final product
1. Mango juice/beverage: can be consumed directly or blended into various flavored drinks.
2. Dried mango: a snack made through processes such as slicing and drying.
3. Mango jam/jam: made by boiling with an appropriate amount of sugar, can be used as a bread spread or cooking seasoning.
4. Frozen mango chunks: Cut into small pieces and store them quickly for long-term storage and transportation.
5. Mango ice cream/ice cream: a cold drink made by combining dairy products and other ingredients.
6. Mango concentrate: a product obtained by evaporating and removing most of the water, which is easy to transport and re dissolve at the destination for use.
Customizing a mango juice production line requires consideration of multiple aspects, including raw material processing, processing technology, equipment selection, packaging methods, etc. Here is a detailed customized solution:
1. Raw material processing
•
Mango procurement: Choose high-quality mangoes with suitable maturity and free from pests and diseases.
•
Cleaning: Use a cleaning machine to remove dirt and impurities from the surface of mangoes.
•
Peel and Core Removal: Use a peel and core removal machine to remove the skin and core of mangoes, and obtain the flesh.
•
Crushing: Use a crusher to crush the fruit pulp into a pulp.
2. Processing technology
•
Enzymatic hydrolysis: Adding enzyme preparations such as pectinase to help break down pectin and improve the clarity of fruit juice.
•
Juice extraction: Use a juicer to extract juice from fruit pulp.
•
Filtration: Use a filter to remove solid residue from the juice and obtain clear juice.
•
Sterilization: Use a pasteurizer to heat the juice to 70-85 ° C for 15-30 seconds to kill harmful microorganisms.
•
Cooling: Use a plate heat exchanger to quickly cool the juice to around 4 ° C to maintain freshness.
3. Equipment selection
•
Cleaning machine: used for cleaning mangoes, removing surface dirt and impurities.
•
Peeling and Core Removal Machine: Used to remove the skin and core of mangoes to obtain clean flesh.
•
Crusher: used to crush fruit pulp into a pulp for easy juice extraction.
•
Juicer: used to extract juice from fruit pulp.
•
Filter machine: used to remove solid residue from juice and obtain clarified juice.
•
Pasteurization machine: used for sterilizing fruit juice to ensure food safety.
•
Plate heat exchanger: used to quickly cool fruit juice and maintain its freshness.
•
Filling machine: used to fill juice into bottles or bags to ensure sealing.
•
Sealing machine: used for sealing, ensuring the sealing and safety of packaging.
•
Labeling machine: used for attaching labels and labeling product information.
•
Packaging machine: used to pack finished products into boxes for easy transportation and sales.
4. Packaging method
•
Glass bottle: suitable for the high-end market, with a beautiful appearance but fragile.
•
Plastic bottles: lightweight, drop resistant, suitable for the mass market.
•
PET bottle: high transparency, lightweight, suitable for portable packaging.
•
Composite paper box: suitable for storage at room temperature and easy to carry.
•
Aseptic bag: suitable for mass production and long-term storage.
5. Quality control
•
Raw material testing: Ensure that the purchased mangoes meet quality standards.
•
Process inspection: Quality inspection is conducted at each processing stage to ensure that every step meets the standards.
•
Finished product testing: Microbial testing, physical and chemical testing, etc. are conducted on the final product to ensure product quality.
6. Environmental Protection
•
Wastewater treatment: Set up a wastewater treatment system to ensure that production wastewater meets discharge standards.
•
Waste disposal: Reasonably dispose of waste generated during the production process, such as skin, fruit pits, etc., to reduce environmental pollution.
7. After sales service
•
Installation and Debugging: Provide professional installation and debugging services to ensure the normal operation of the production line.
•
Operation training: Provide operation training and technical support to help customers quickly get started.
•
Maintenance: Provide regular maintenance and troubleshooting services to extend the service life of equipment.
Customized process
one
Requirement analysis: Communicate with customers to understand specific requirements, including production scale, product positioning, budget, etc.
two
Scheme design: Based on the results of requirement analysis, design a customized scheme, including equipment configuration, production process, etc.
three
Quotation and Confirmation: Provide a detailed quotation and confirm the plan and price with the customer.
four
Production and manufacturing: Produce and manufacture according to the confirmed plan.
five
Installation and commissioning: Transport the equipment to the customer's site for installation and commissioning.
six
Training and acceptance: Provide operational training to customers to ensure they are proficient in using the equipment, and finally conduct acceptance.
If you have specific customization or parameter requirements, I can provide more information so that I can offer you more detailed advice.
Pre sales services
After-sale service
1. Equipment warranty period: We provide a one-year free warranty service for mechanical equipment. If any non-human caused problems occur during the warranty period, we will provide free repair or replacement services.
2. Maintenance and upkeep services: We provide regular or irregular equipment maintenance and upkeep services to ensure the normal operation of the equipment. We will provide 24-hour online technical support services.
3. Accessory supply: We guarantee to provide original factory accessories in a timely manner in case of equipment damage or replacement of parts.
4. Training services: In order to enable customers to effectively operate and maintain equipment, we will provide equipment operation and maintenance training.
5. Installation and debugging: We will provide equipment installation and debugging services to ensure that the equipment is installed correctly and can operate normally.
Company Profile
Our Service
Certificate
FAQ
1 ) Q: How can we visit your factory?
A: If you come from abroad, air to shanghai airport, then we can pick you up at airport.
2) Q: How do you ensure the quality of your products?
A: Our Company is a state owned enterprise with more than 16 years experience , strict operation policy is performed, advanced processing machines guarangtee the precision of all components, workers with operation license, parts get multiprocessing, transmission& electrical parts are of international famous brand. Series of test and inspection are done in the whole producing state.
3) Q: What payment methods your company accept?
A: We accept most of the payment methods , but mainly accept T/T, L/C at sight .
4) Q: How long is the warranty time for your products?
A: Our officially promised warranty time is 12 months after commissioning .
5) Q: I am new in this field,can you supply us turnkey services?
A: YES.We can supply all the system including Market Analysis/Product Analysis/Location Choice/Processing Flow Design/Equipment Layout Design/Building Design direction/Equipment mode selection/Equipment Manufacturing/Equipment Mounting/Equipment Debugging/Worker Training.
6) Q: What ' s the shipment terms and delivery time of your company?
A: Well, the delivery time depend on the quantity of your order. Usually is 20 days . For some customized machine 30 days is necessary.
7) Q: Can you supply OEM services?
A: Yes,we have our R&D team,and we have more than 400 workers with workshop area 75000 square meters.
8) Q: Do you give any Discount?
A: I will surely try my best to help you get those by the best price and good service at the same time.
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