Fruit juice production plant low-temperature vacuum apple juice extractor machine
The principle of a fruit juice production plant involves multiple steps, from raw material processing to final product packaging. The following are the basic principles and processes of fruit juice production:
1. Raw material reception and pretreatment
• Raw material reception: Fresh or frozen fruits are received from farms or other suppliers.
Cleaning: Use spraying, soaking, and other methods to remove impurities such as soil and pesticide residues from the surface of fruits.
Sorting: Removing unqualified fruits (such as rotten, unripe, or damaged fruits) through manual or mechanical means.
• Crushing: Send the cleaned fruits into a crusher for crushing, in order to extract juice later.
2. Juice Extraction and Extraction
Juice extraction: Use a press or centrifuge to squeeze out the juice from the crushed fruit. Different types of fruits may require different juicing equipment and techniques.
Enzyme treatment: Some fruits add pectinase during the juice extraction process to improve the extraction rate and clarity of the juice.
3. Clarification and filtering
• Clarification: By adding clarifying agents (such as gelatin, diatomaceous earth, etc.) or using natural settling methods to remove suspended solids in fruit juice, transparency can be improved.
• Filtration: Use a multi-stage filtration system (such as mesh, membrane filtration, etc.) to further purify the juice, removing fine particles and impurities.
4. Concentration (optional)
Evaporation: For juice that needs to be concentrated, vacuum evaporation or film evaporation technology can be used to evaporate the water and increase the solid content of the juice. Concentrated fruit juice is easier to store and transport.
5. Seasoning and mixing
Seasoning: According to the product formula, add sugar, acidifiers, spices and other additives to the juice to adjust the taste.
Mixing: Use a blender to evenly mix the ingredients into the juice, ensuring consistent flavor.
6. Sterilization and filling
• Sterilization:
• Heat treatment: The commonly used sterilization methods are high-temperature instant sterilization (HTST) or ultra-high temperature instant sterilization (UHT), which kill microorganisms in fruit juice by heating and extend the shelf life.
Cold sterilization: For some sensitive fruit juices, cold sterilization techniques (such as ultraviolet sterilization, high-pressure sterilization, etc.) can be used.
• Cooling: Quickly cool the juice after sterilization to prevent further heat from affecting its quality.
• Filling: Using aseptic filling technology to fill juice into bottles, cans, or other containers and seal them.
7. Packaging and Storage
• Labeling and packaging: Label and wrap the product to ensure it meets market requirements.
• Storage: Store finished products at a suitable temperature to ensure product quality.
8. Quality control and testing
• Physical and chemical testing: Conduct physical and chemical index testing on fruit juice (such as pH value, solid content, vitamin content, etc.).
Microbial testing: Detecting the content of bacteria, mold, yeast and other microorganisms in fruit juice to ensure food safety.
Sensory evaluation: Conduct sensory evaluation to check whether the color, aroma, taste, etc. of the juice meet the standards.
9. Automation control and monitoring
PLC control system: Adopting advanced PLC control system to achieve automation control of the entire production line.
Sensors: Install various sensors (such as temperature sensors, pressure sensors, flow sensors, etc.) to monitor key parameters in the production process in real time.
Data recording: Record data during the production process for easy traceability and analysis.
10. Environmental Protection and Energy Conservation
Wastewater treatment: Treat wastewater generated during the production process to meet discharge standards.
• Heat recovery system: Utilizing the heat recovery system to recover the heat generated during the sterilization process, reducing energy consumption.
Energy management: Optimize energy use and reduce energy waste in the production process.
The above are the basic principles and processes of fruit juice production plants. Each step needs to be strictly controlled to ensure the quality and safety of the final product.
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.
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
Ultrafiltation system for clear apple juice
The Ultra-filtration system is designed to produce clear apple juice in the juice processing line.It is consist of tanks,recycling pump,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.And the system process mature and reliable,high degree of automation,simple operation,high labor intensity.
Apple/Pear juice sterilizing machine
Clear apple juice uses tubular type or plate type sterilizer to process depending on the filling method.If we use the hot filling,then we can use the plate-type pasteurizer.The sterilizing technological process is 90-95ºC for 15 sec;if we use the aseptic filling,then we use the tubular type sterilizer.The sterilizing technological process is 135-137ºC for 4-6 seconds.
Apple/Pear juice filling machine
There are two types for filling,One is for the hot filling,the other is for aseptic filling.The hot filling machine usually connects with pasteurizer,filling into small bottles or pouches;And aseptic filling machine usually connects with tubular type UHT sterilizer,filling into aseptic bags,tetra pak packages.
Of course, apple juice production machines are widely used in the juice processing industry. Here are several specific application cases of apple juice production machines:
1. A large juice producer in the United States
1.1 Case Background
• Customer: A large juice producer in the United States
• Products: Pure apple juice, mixed juice
• Scale: Annual production of approximately 100 million liters of fruit juice
1.2 Application Scenarios
• Raw material preparation: Purchase fresh apples from the orchard, clean and sort them.
• Crushing: Send the cleaned apples into the crusher and crush them into small pieces.
Juice extraction: Send the crushed apples into a juicer to extract juice.
• Filtration: Through a multi-stage filtration system, the fruit pulp and impurities are removed to obtain clarified juice.
Sterilization: By using the pasteurization method, bacteria in the juice are killed and the shelf life is extended.
• Filling: Fill the sterilized juice into bottles or boxes and seal them for packaging.
• Storage and transportation: Store finished products in refrigerated warehouses and wait for transportation to distribution centers.
1.3 Production line equipment
Crusher: Using high-speed rotating blades to quickly crush apples into small pieces.
• Juicer: Using spiral pressing technology to efficiently extract juice.
• Filtration system: including coarse filter, fine filter, and centrifugal separator to ensure clear juice.
Sterilization system: using plate heat exchangers and high-temperature short-term sterilization methods to ensure sterilization effectiveness.
Filling machine: adopts automatic filling line to achieve high-speed filling and sealing.
2. A German organic juice producer
1.1 Case Background
• Customer: A German organic juice producer
• Product: Organic Apple Juice
• Scale: Annual production of approximately 5 million liters of organic juice
1.2 Application Scenarios
• Raw material preparation: Purchase fresh apples from the cooperating organic orchard, clean and sort them.
• Crushing: Send the cleaned apples into the crusher and crush them into small pieces.
Juice extraction: Send the crushed apples into a juicer to extract juice.
• Filtration: Through a multi-stage filtration system, the fruit pulp and impurities are removed to obtain clarified juice.
Sterilization: By low-temperature pasteurization, the natural flavor of the juice is maintained.
• Filling: Fill the sterilized juice into bottles or boxes and seal them for packaging.
• Storage and transportation: Store finished products in refrigerated warehouses and wait for transportation to distribution centers.
1.3 Production line equipment
Crusher: Using low-speed rotating blades to reduce juice oxidation and maintain taste.
• Juicer: Using hydraulic pressing technology to ensure the natural flavor of the juice.
• Filtration system: including coarse filter, fine filter, and membrane filter to ensure clear juice.
Sterilization system: Adopting low-temperature pasteurization method to maintain the nutritional content of the juice.
Filling machine: Adopting semi-automatic filling line to ensure packaging quality.
3. A small and medium-sized juice producer
1.1 Case Background
• Customer: A small and medium-sized juice producer
• Products: freshly squeezed apple juice, concentrated apple juice
• Scale: Annual production of approximately 1 million liters of juice
1.2 Application Scenarios
• Raw material preparation: Purchase fresh apples from local orchards, clean and sort them.
• Crushing: Send the cleaned apples into the crusher and crush them into small pieces.
Juice extraction: Send the crushed apples into a juicer to extract juice.
• Filtration: Through a multi-stage filtration system, the fruit pulp and impurities are removed to obtain clarified juice.
Sterilization: Ensure the safety of fruit juice through pasteurization.
• Filling: Fill the sterilized juice into bottles or boxes and seal them for packaging.
• Storage and transportation: Store finished products in refrigerated warehouses and wait for transportation to the market.
1.3 Production line equipment
• Crusher: Using manual or semi-automatic crushers, suitable for small batch production.
• Juicer: Using spiral pressing technology to efficiently extract juice.
• Filtration system: including coarse and fine filters to ensure clear juice.
Sterilization system: using plate heat exchangers and pasteurization method to ensure sterilization effect.
Filling machine: adopts manual or semi-automatic filling machine, suitable for small batch production.
Success factors
Equipment selection: Select appropriate production equipment based on production scale and demand to ensure efficient and stable production.
• Raw material quality: Select high-quality fresh apples to ensure the quality of the juice.
Process optimization: Continuously optimize production processes to improve production efficiency and product quality.
Hygiene management: Strictly control the hygiene conditions during the production process to ensure food safety.
• Automation level: Select the appropriate level of automation based on the production scale to improve production efficiency and reduce labor costs.
The customized process can be adjusted according to your specific needs, but generally speaking, the basic process of juice production includes the following main steps:
1. Project planning and requirement analysis
Market research: Understand the needs, competitive situation, and potential customers of the target market.
Product positioning: Determine the type of juice to be produced (such as apple juice, orange juice, etc.), packaging form, and sales channels.
Capacity planning: Determine the scale of the production line based on market demand forecasts.
2. Factory Site Selection and Design
• Geographic location: Choose a location close to the origin of raw materials to reduce costs and consider logistics convenience.
Infrastructure: Ensure sufficient power, water supply, and wastewater treatment facilities.
• Factory layout: Reasonably plan the location of each production area to ensure smooth and efficient production processes.
3. Equipment selection and procurement
Cleaning equipment: used to remove impurities from the surface of fruits.
Peeling/Core Removal Machine: Suitable for removing the skin or core of different types of fruits.
• Juicer: Squeeze fruits into juice.
• Filtration equipment: Remove solid particles from juice.
Concentrating equipment (optional): Reduce moisture content and increase juice concentration through evaporation.
Sterilization equipment: Adopt high-temperature instantaneous sterilization method or other methods to ensure product quality and safety.
Filling machine: Fill processed juice into bottles or other containers.
Sealing machine: Seal packaging to extend shelf life.
Labeling machine: Attach label information to packaging.
Packaging machine: Complete the final product outer packaging.
4. Production process flow
Raw material inspection: Check the quality and freshness of the fruit.
• Cleaning: Thoroughly clean fruits to remove dirt and impurities.
• Peel/Core Removal: Remove the skin or core of the fruit as needed.
Juice extraction: Squeeze fruits into juice.
• Filtration: Remove solid particles from juice.
Seasoning (optional): Add an appropriate amount of sugar or other seasonings according to product requirements.
• Concentration (optional): By heating and evaporating water, the juice concentration is increased.
Sterilization: Sterilize fruit juice to ensure food safety.
• Filling: Fill the finished fruit juice into a suitable container.
Sealing: Seal the container to ensure the shelf life of the product.
• Label: Attach label information to the packaging.
• Packaging: Perform the final outer packaging and prepare for outbound sales.
5. Quality control
Raw material testing: Strictly control the quality of raw materials.
Process monitoring: Implement strict hygiene management and quality control throughout the entire production process.
Finished product inspection: Sampling and testing of finished products to ensure compliance with standards.
6. Compliance with regulations and certification
Comply with relevant laws and regulations: Ensure that the production process complies with national food safety production standards.
Obtain necessary certifications such as ISO, HACCP, etc. to enhance brand image and market competitiveness.
7. Marketing and Sales
Brand building: Creating a unique brand identity and marketing strategy.
Channel expansion: Establish stable sales channels, including supermarkets, wholesale markets, or e-commerce platforms.
• Promotional activities: Regularly carry out promotional activities to attract consumers.
If you have specific customization needs or would like to know more details, please let me know and I can further assist you in finding relevant information.
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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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