Apple processing machine apple processing line apple juice production line
The apple juice production line refers to the complete industrial process of converting fresh apples into drinkable apple juice products.
This process can be roughly divided into the following key steps:
1. Raw material reception and cleaning: Firstly, freshly picked apples will be transported to the factory and then enter the cleaning system through a conveyor belt. Here, apples are thoroughly cleaned to remove surface soil, pesticide residues, and other impurities.
2. Inspection and sorting: After cleaning, apples will be inspected through optical or manual methods to remove pests, diseases, rotten or immature fruits. Subsequently, sorting is carried out based on size, color, and variety to ensure that only high-quality apples are processed in the next step.
3. Crushing and Juicing: The sorted apples are fed into a crusher and cut into small pieces or purees. Next, these pulp will be fed into a juicer and the juice will be extracted by pressing or centrifugation. Enzymes may also be added during this process to increase juice yield and improve taste.
4. Clarification and filtration: The freshly squeezed apple juice contains pulp, peel fragments, and other suspended solids, which need to be clarified through a filtration system. This step may involve the use of filter screens, centrifugal separation, or membrane filtration techniques.
5. Sterilization and filling: In order to ensure the food safety and extend the shelf life of apple juice, the juice will be heated for pasteurization or sterile cold filling technology will be used. Afterwards, the juice will be quickly cooled and filled into pre disinfected bottles, cans, or cardboard boxes.
6. Sealing and packaging: After filling, the container will be sealed and labeled, including necessary information such as production date, shelf life, ingredient list, etc. Finally, the product will be packaged according to different specifications and prepared for factory sales.
7. Quality inspection and delivery: After all processes are completed, the finished products must undergo strict quality inspection to ensure compliance with food safety standards and internal quality control requirements of the enterprise before they can be delivered and distributed to the market.
Modern apple juice production lines are highly automated, capable of efficiently processing large amounts of raw materials while ensuring product quality and safety. In addition, to meet different consumer needs, the production line may also include additional processes such as seasoning, concentration, and reconstitution to produce apple juice products with different flavors and concentrations.
Characteristics and advantages
The processing capacity is varied from 60 tons/day to 2000 tons/day.
1. The line Can deal with similar characteristics of fruits.
2. Automatic disinfection liquid concentration control system, effectively guarantee the sterilization effect and control the disinfection residue
3. Efficient crusher improved the high output percentage of apples and pears
4. Using efficient belt juice extractor to improve the juice efficiency and the output percentage
5. The production process fully automatic PLC control to reduce the labor intensity and Improve production efficiency
6. Low-temperature vacuum evaporation Greatly reduce the flavor substances and nutrient losses
7. A variety of energy recovery measures , increased the energy utilization and greatly reduce production cost
8. Tubular UHT sterilizer and Aseptic filling machine, Isolated from the pollution of bacteria,ensure the safety of the food and extend the shelf life of the product
9. A complete set of production with self CIP system reduce the labor intensity and ensure the high level sanitation.
The installation and debugging of an apple juice production line involves several key steps to ensure efficient, safe, and hygienic operation.
Below is a general outline of the process:
1. Site Preparation• Clear and Clean: Ensure the installation area is clean, clear of debris, and has appropriate utilities (electricity, water supply, drainage) in place.• Layout Planning: Based on the equipment layout drawings provided by the manufacturer, mark out the positions for each machine.
2. Unpacking and Inspection• Carefully unpack all equipment, checking for any damage during transportation. Document and report any issues immediately to the supplier.
3. Equipment Installation• Sorting and Assembling: Organize the components and start with the primary processing machines like washing, crushing, and pressing units.• Leveling and Anchoring: Ensure each machine is leveled correctly using a spirit level and securely anchored to the floor following the manufacturer's instructions to prevent vibrations during operation.• Pipe Connections: Install pipelines for water supply, juice transfer, and waste disposal, ensuring they are properly sealed and insulated where necessary.• Electrical Wiring: Hire a licensed electrician to connect electrical systems, including control panels, motors, and sensors, adhering to local safety standards.
4. Testing Individual Machines• Before integrating the entire system, test each machine separately to confirm its functionality. This includes running water through cleaning systems, testing the crusher and press, and checking electrical controls.
5. Integration and System Testing• Connect all machines according to the system diagram, including conveyors, pumps, and filters.• Conduct a dry run without raw materials to check for proper synchronization, belt alignments, and sensor responses.• Introduce water or dummy materials to simulate the production process and fine-tune settings for optimal performance.
6. Sanitization and Hygiene Setup• Thoroughly sanitize all parts of the production line that come into contact with the juice, following food safety guidelines.• Implement a Cleaning-In-Place (CIP) system if not already integrated, to automate the sanitization process.
7. Calibration and Optimization• Adjust temperature settings, pressure levels, and conveyor speeds to optimize juice yield, quality, and efficiency.• Use pH meters, Brix meters, and other quality control tools to ensure the final product meets desired specifications.
8. Safety and Quality Checks• Conduct safety checks on all machinery, including emergency stop buttons, guards, and warning signs.• Obtain necessary certifications and inspections from local health and safety authorities.
9. Staff Training• Train operators on the safe use, maintenance, and cleaning procedures for each machine and the overall system.
10. Trial Production and Fine-Tuning• Run a small-scale production trial to assess the entire line under real operating conditions. Make any necessary adjustments based on the trial results.
11. Final Handover and Documentation• Once satisfied with the performance, complete a final inspection and handover process.
• Ensure all operation manuals, maintenance schedules, and warranty documents are in place.It's crucial to closely collaborate with the equipment supplier throughout the process, as they can provide specific guidance tailored to your equipment and production needs.
Parameters
| Raw material |
Fresh apple/pear |
| End product |
Concentrated juice, clear juice,NFC fresh juice |
| Processing capacity |
From 60tons/day to 1500 tons/day |
| Output percentage |
60-75% |
| Solid content |
10-12Brix |
| concentrated juice content |
65-72Brix |
| End package |
Aseptic bag/gable top box /PET bottle |
Condition: New
Brand name: Shanghai Beyond;
Type: whole processing Line/turnkey project/fruit and vegetables processing/dairy processing/beverage processing
Voltage: 220v/380v
Power(W): 100-200kw
Weight: Different size different weight/customized
Dimension(L*W*H): Different size different dimension/customized
Certification: CE&ISO
Warranty: 12 months/1 year
After-sales Service Provided: Engineers available to service machinery overseas
Main material: SUS304 or SUS316
Control type: automatic, semi-automatic
energy consumption: Low consumption with high efficiency
capacity: 500-10000L/H-customized
installation period: 1-3months
Period time: 30 days-120 days
Cups material: pouches, paper box, glass bottle, pet bottle, glass bottle
Product storage condition: room temperature; low temperature;
Related machinery of fruit processing line
Fruit storage silo-- Washing, sorting machine-- Grading/classifier machine
Squeeze extractor--Juice refiner-separator-evaporator-- Juice concentrate product
Fruit flesh/pulp collector-sterilizer--filling machine-fruit flesh
Essential oil refiner-fruit oil
Fruit residues collector-animal feed
Soaking extraction, pre-cooking, pulping, quick freeze, stemmer, ultra-filtration, decolor, destoner, crusher, stone washer, brusher washer, pine apple extractor, refiner, enzymolysis, filtration, CIP cleaning system
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
Trade shows
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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