TECHNOLOGY OF NON-ALCOHOLIC BEVERAGE

| Mohit Jindal
TECHNOLOGY OF NON-ALCOHOLIC BEVERAGE VOL.1

DETAILED CONTENTS
1. Introduction-Definition, scope and status of beverage industry in India
2. Water: Sources, quality, treatment
3. Ingredients of food beverages; sweeteners, emulsitifiers, coloring agents, flavoring agents,
stabilizers, water and their quality
4. Mineral water and its specifications and standards
5. Carbonated Beverages-Equipment and machinery for carbonated beverages, water treatment, syrup
preparation, containers and closures. Cleaning, carbonation, filling, inspection and quality control
6. Non-carbonated beverages-Technology, specification, equipment and machinery for instant and
normal tea and coffee, fruit juice based beverages, synthetic beverages
7. Sanitation and hygiene in beverage industry
LIST OF PRACTICALS
1. Preparation of carbonated beverages and their evaluation
2. Preparation of instant coffee
3. Preparation of tea
4. Preparation of Ready To Serve beverages (RTS beverages)
5. Preparation of squash
6. Determination of water quality parameters; hardness, pH, turbidity, E-coli Test,
DO, BOD, COD
7. Preparation of flavoured milk
8. Analysis of a spurious liquor sample
9. Determination of CO2 level carbonated beverages
10. Visit to carbonated and non-carbonated beverage industry
2 Technology of non alcoholic beverage-Mohit Jindal, Govt. Polytechnic, Mandi Adampur Vol .1

Definition of Beverage
Beverages are an integral part of human diet, starting from new born. The cycle starts with the infant
formulas- highly complex drink, rich in many key nutrients. As human age and their nutritional
requirements change, product designer keeps pace by developing new and innovative beverages to meet
these needs.
Beverages can be defined as “any fluid which is consumed by drinking” or any one of various
liquids for drinking, usually excluding water. It consists of diverse group of food products, usually
liquids that include the most essential drink “water” to wide range of commercially available fluids like
fruit beverage, synthetic drinks, alcoholic beverage, milk, dairy beverages, tea, coffee, chocolate drinks etc.
Despite differences in their properties one common feature that exists in all beverages is their ability to act
as thirst quencher. In simple words beverages can be defined as “liquid which is essentially designed or
developed for human consumption”. The beverages are rarely consumed for its food value but it is vital for
life. Although their prime role is to fulfill the human need but these are part of our culture.
Classification of Beverages
Beverages may be classified on various ways. The classification criteria may depends on various
factors as mentioned below:
 Natural and Synthetic (Ingredients used in manufacture)
 Carbonated and Non-carbonated (Degree of mechanical carbonation)
 Alcoholic and Non-alcoholic (presence or absence of alcohol)
 Hot and Cold (Temperature of serving)
 Stimulating and Non-stimulating (Based on physiological effect)
Present Status of National and Global Beverage Market
As the beverage industry looks to the future, India is the country that offers the greatest potential, even
more so than China. Right now, India accounts for approximately 10% of global beverage consumption.
That makes beverage consumption in India the third largest in the world, after the United States and China.
And when it comes to carbonated soft drinks, the market has not even been properly tapped. The situation
is similar in the case of bottled and packaged juices and water and PET packaging. Given its size, the
Indian market is still in its infancy. For the future, beverage manufacturers must INVEST in plants and
equipment. "Drink technology India" is the perfect place for them to prepare for and initiate those
investments. According to an estimate Indian consumers drink 120 billion litre of marketed beverages out
of which only 4 percent is ready-to-drink packaged once. The carbonated soft drink industry in India
consists of more than 100 plants spread throughout the country. The current value of Indian beverage
industry is around 1,049 million US$. In fact the soft drinks form the third-largest packaged food sector
Introduction-Definition, scope and status of beverage industry in India

after packaged tea and packaged biscuits. However, the penetration of soft drinks in Indian market is still
low. For a long period the Indian beverage industry was dominated by aerated synthetic drinks. However,
the situation has changed dramatically, the aerated soft drinks, which had registered a whopping 20%
growth during late 90's, could manage its present share in market against possible slide. In contrary to this
last few years have witnessed a significant development in fruit based beverages newly introduced fruit
beverages fall into the category of functional foods or nutraceuticals. Energy drinks, isotonic (sport)
beverages herbal and green teas, fortified waters, caffeinated drinks, recreational soft drinks are some of
the functional beverages which have gained popularity in recent years. The market size for the bottled
water in India had an estimated value of US$ 570 million in 2008. With annual growth rate of 14.5 percent,
the market of bottled water is expected to increase rapidly in coming years.
Fruit juice market is growing at the rate of 15 percent annually and expected to reach 796 million liters
by 2013 from the current volume of 624 million liters. The market of packaged fruit juice is in the range of
Rs. 500-600 crores, which is quite smaller as compared to fruit drink market which is around Rs. 1300
crore. The major sale of these beverages occurs in summer months which are quite extended in India. The
sale volume of beer is highest among alcoholic beverages followed by spirits. Drinking milk products
constitute the largest segments among the dairy products and are growing at the annual rate of 6.8 percent.
Future of Indian beverage market is quite promising and sectors that may attract processors and consumers
alike include the functional dairy drinks, fruit beverages and wine. Advancement in processing and
packaging technology in the form of UHT/Aseptic processes and tetra pack packaging offers newer
opportunity to deliver nutritious beverages in log-life version.

Water is a transparent fluid which forms the world's streams, lakes, oceans and rain, and is the
major constituent of the fluids of living things. As a chemical compound, a water molecule contains
one oxygen and two hydrogen atoms that are connected by covalent bonds. Water is liquid at standard
ambient temperature and pressure, but it often co-exists on Earth with its solid state, ice;
and gaseous state, steam (water vapor). Fresh water is a renewable resource. On the surface of earth
71% is covered by seas and oceans and remaining 29% is occupied by land. The remaining unfrozen
fresh water is found mainly as groundwater, with only a small fraction present above ground or in the
air. 97% of the water on the Earth is salt water. However, only 3% percent is fresh water; slightly over
2/3 of this is frozen in glaciers and polar ice caps.
W.H.O. DRINKING WATER STANDARDS
PARAMETER UNIT LIMIT
Aluminium mg Al/l 0.2
Arsenic mg As/l 0.05
Barium mg Ba/l 0.05
Berylium ug Be/l 0.2
Cadmium ug Cd/l 5.0
Calcium mg Ca/l 200.0
Chromium mg Cr/l 0.05
Copper mg Cu/l 1.0
Iron Total mg Fe/l 0.3
Lead mg Pb/l 0.01
Magnesium mg Mg/l 150.0
Manganese mg Mn/l 0.1
Mercury ug Hg/l 1.0
Selenium mg Se/l 0.01
Sodium mg Na/l 200.0
Zinc mg Zn/l 5.0
Chlorides mg Cl/l 250.0
Cyanide mg Cn/l 0.1
Fluorides mg F/l 1.5
Nitrates mg NO3/l 10.0
Nitrites mg NO2/l -
Sulphates mg SO4/l 400.0
Suphides mg H2S/l 0
TOTAL "drins" ug/l 0.03
TOTAL "ddt" ug/l 1.0
Hydrocarbons mg/l 0.1
Anionic Detergents mg/l 0
pH 9.2
Total dissolved solids mg/l 1500
Total hardness mg/l 500
Alkalinity mg/l 500
MICROBIOLOGICAL PARAMETERS
Total Bacteria Count/ml 100
Water: Sources, quality, treatment

Coliform Count/100ml 0
E. Coli Count/100ml 0
Salmonella Count/100ml 0
ug = microgram or ppb
mg = milligram or ppm
Sources of Water: Rainwater, oceans, rivers, lakes, streams, ponds and springs are natural sources of
water. Dams, wells, tube wells, hand-pumps, canals, etc, are man-made sources of water.
Rain Water: Rain water collects on the earth in the form of surface water and underground water.

Surface Water: Water present on the surface of the earth in the form of oceans, rivers, lakes, ponds
and streams is called surface water. The water in rivers and lakes comes from rain and melting of snow
on mountains. Rivers flow into the sea.
Underground Water: Some of the rainwater seeps through the soil on to the non-porous rocks below.
This is underground water. Sometimes due to high pressure, this water sprouts out in the form of
springs. It can be obtained by digging wells, sinking tube wells, etc.
Quality Of water:-
Treatment of raw water to produce water of potable quality can be expensive. It is advisable to
determine the quantity of water needing treatment. In the beverage world, a unique product signature
results from a precise combination of liquid ingredients including flavours, additives, sweeteners,
enhancers, and water. For nearly every type of beverage, water quality has a direct impact on taste,
which is affected by its constituents mixing with other ingredients. Apart from maintaining precise
control of ingredients, their mixing and separation, the most variable ingredient from place to place is
water. Fluctuations in water quality and content affect taste, appearance, and even safety. It can also
affect the efficient operation of any bottling or production facility.
For manufacturers, achieving measurable and repeatable water quality is essential to protecting
the integrity of their brand. Precise treatment of raw water provides the foundation for creating and
protecting the brand. Since incoming water may come from several sources including municipal water
supplies, surface water, ground water, and springs, it presents many different challenges. Waterborne
bacteria and viruses can contaminate source water and have serious health implications while metals
and salts can affect taste, colour, and uniformity. The challenge is to remove the variability regardless
of the source, as well as provide low-SDI (silt density index) feed water for downstream processes.
There are two methods by which manufacturers can purify their water: conventional treatment, which
involves physical and chemical processes, and membrane separation.
Treatment Technology: - The water used for carbonated beverage production is often subjected to
treatment to remove various impurities and make it suitable for production of soft drinks. The water
treatment includes filtration, water softening, coagulation, chlorination, membrane filtration and
ozonization. However, the sequence of pre-treatments depends on the quality of RAW water.
WATER TREATMENT
Raw water
Chlorine dosing
Chlorinated raw water tank (6-8 ppm)
Analysis of water sample
Coagulation Tank
Antiscalent dosing

Intermediate Tank
Sand Filter
Activated Carbon Filter
Sampling for (P&M TDS, Turbidity, Appearance, Chlorine, Taste and odor. filter press 5 Micron)
Water Ready for production
General diagram for water treatment

Primary treatment:- There are four methods of primary treatment: chlorination; ozone treatment;
ultraviolet treatment; and membrane filtration.
Chlorination: Fresh or sea water can be chlorinated using either chlorine gas or hypochlorites.
Chlorinated water minimizes slime development on working surfaces and helps control odour.
The main advantages of using chlorine gas are:· It is the most efficient method of making free
chlorine available to raw water.
· It lowers the pH of the water slightly.
· Control is simple; testing simple; and it is not an expensive method.
The main disadvantages of using hypochlorites are:· Calcium hypochlorite is not stable and must
be stored in air-tight drums.
· Sodium hypochlorite is quite corrosive and cannot be stored in metal containers
· Sodium hypochlorite must be stored in light proof containers.
· It is difficult to control the rate of addition of hypochlorites in proportion to water flow.
· Hypochlorites raise the pH in water.
· They are more expensive than chlorine gas.
Ozone treatment: Though the principle is relatively simple, this method needs special equipment,
supply of pure oxygen and trained operators. Ozone is generated by passing pure oxygen through
an ozone generator. It is then bubbled through a gas diffuser at the bottom of an absorption
column, in a direction opposite to the flow of raw water. Retention or contact time is critical and
the size of the absorption column depends on the water flow.
The main advantages of ozone treatment are: Ozone is a much more powerful germicide than
chlorine especially for faecal bacteria.
· It reduces turbidity of water by breaking down organic constituents.
· The process is easily controlled.
The disadvantages are:· Pure oxygen may not be readily available locally.
· Ozonized water is corrosive to metal piping.
· Ozone decomposes rapidly into oxygen.
· Water has to be aerated prior to use to remove the ozone.
Ultraviolet irradiation treatment: This method is often used to treat drinking water. Successful
commercial installations have been made to purify sea water in large fish processing plants.

The main advantages of U-V treatment are:· U-V rays in the range of 2500-2600 Angstrom units are lethal
to all types of bacteria.
· There is no organoleptic, chemical or physical change to the water quality.
· Overexposure does not have any ill effects.

The main disadvantages are:· Electricity supply should be reliable.
· Turbidity reduces efficiency.
· Water may require prior treatment like filtration.
· The unit requires regular inspection and maintenance.
· Thickness of the water film should not exceed 7.5 cm.
Membrane filtration: Osmotic membrane treatment methods are generally expensive for commercial
scale installations. Combinations of membrane treatment with U-V treatment units are available
for domestic use.
Secondary treatment:-
Secondary treatment of water consists of sedimentation and filtration followed by chlorination.
Sedimentation can be carried out by holding the raw water in ponds or tanks. The four basic types
of filtration are cartridge filtration, rapid sand filtration, multimedia sand filtration, and up-flow
filtration.
1. Cartridge filtration: This system is designed to handle waters of low turbidity and will
remove solids in the 5 to 100 micron range.
The main advantages are:· Low cost and 'in-line' installation.
· Change of cartridge is simple.
· Operation is fool-proof. Once the cartridge is clogged, flow simply stops.
The main disadvantages are:· Sudden increase in turbidity overloads the system.
· Cartridges may not be readily available and large stocks may be required.
2. Rapid sand filtration: This system consists of a layer of gravel with layers of sand of
decreasing coarseness above the gravel. As solids build up on top, flow decreases until it stops.
This is corrected by back-flushing the system to remove the solid build up on top.
The main advantages are:· Cost of filtration media is negligible.
· Operation is simple.
The main disadvantages are:· A holding tank for filtered water is required to provide clear water
back flushing.
· Pumping loads increase as sediments build up.
Multimedia sand filtration: This system is similar to the rapid sand filtration method.

MULTI-MEDIA SAND FILTRATION

There is great diversity in beverages and accordingly a wide range of ingredients are
required in their formulations. There are certain additives like sugar or sweeteners (except
in low calorie beverages) which are added in higher amounts whereas additives like
preservatives are added in minute quantity. Hence according to the amount the additives
may be grouped as Major and Minor additives.
1. Sweeteners: - Sweeteners are added primarily as flavouring additive to impart the sweetness in the
beverages. Sweetener serves three basic functions in carbonated beverages; impart sweetness, provide
body and calorie. Sweetener used primarily in carbonated beverages is crystal sugar which must be of
very high purity. It is used in the form of sugar syrup and final concentration of sugar varies between 8
to 14 percent in finished beverage. However, other sweeteners like glucose syrups, invert syrup, High
fructose corn syrup (HFCS) etc. may also be used. Low calorie carbonated drinks invariably contain
high intensity sweeteners or artificial sweeteners such as saccharin, aspartame, acesulfame-k and/or
sucralose. An agent such as carboxyinethyl cellulose or pectin is sometimes added to give the same
mouth feel as the sugar product. Conventionally sugar performs number of basic functions in
beverages.
1. They improve the palatability of certain bland and insipid tasting fruits & vegetables
2. They provide bulk and body to beverages thus enhance mouthfeel
3. They modify the freezing point and control viscosity
4. They also act as mild preservative, modify the osmotic pressure and check spoilage
Sweeteners may be classified in a variety of ways: nutritive or nonnutritive, natural or
synthetic, regular or low-calorie/dietetic.
(A)Natural or Synthetic Sweeteners The sweeteners derived from the food sources are termed as
natural. Example: Crystal sugar obtained from cane sugar or beet root, glucose syrups manufactures
from maize starch, honey etc. The sweeteners which are manufactured by chemical synthetic processes
are termed as synthetic sweeteners. Example includes high intensity sweeteners like saccharin,
aspartame, acesulfame-K etc.
(B) Nutritive or Non-Nutritive Sweeteners Certain sweeteners are metabolized in body and generate
energy, hence are termed as nutritive and caloric sweeteners. Nutritive sweeteners also cause dental
carries. Sweeteners that are metabolized but do not contribute towards the energy significantly are
Ingredients of food beverages; sweeteners, emulsitifiers, coloring agents, flavoring agents, stabilizers, water
and their quality

called as non-nutritive or non-caloric sweeteners. Traditional sweeteners fall into the category of
nutritive whereas synthetic ones belong to non-nutritive sweeteners.
(c) Regular or High-intensity Sweeteners The classification of sugars on the basis of quantity
required to give equivalence sweetness give rise to two categories i.e. regular or high-intensity. High-
intensity sweeteners required much less amount for yielding the similar sweetness intensity. All low
calorie sweeteners are considered as high-intensity sweeteners.
The relative sweetness of various sugars is listed below (Table 25.2). Table 25.2 Relative
sweetness of various sweeteners
Sweeteners Sweetness Relative to sucrose
Sugar (Sucrose) 1
High-fructose corn syrup 1-1.5
Fructose 1.2-1.7
Invert sugar 1.3
Glucose 0.75
Sorbitol 0.5-0.7
Mannitol 0.7
Xylose 0.4
Maltose 0.32
Galactose 0.32
Raffinose 0.23
Lactose 0.16
Saccharin 300
Cyclamate 30
Aspartame 200
Acesulfame K 200
Various classes of Sweetener
a) Sucrose Manufactured from cane sugar or beetroot and may be added either in dry form or as syrup
(65-70% strength) in beverage manufacture. Sucrose is available in various particle size and colour
grades which depend on the degree of refining. In beverage manufacture normally the cane sugar
obtained by carbon-refining process is preferred as it does not cause blackening of content. In cola
type or malt beverages brown sugar may also be used.
b) Glucose Syrup On industrial scale corn starch is hydrolyzed by using acid or enzymes to produce
corn syrup and these syrups are available in different Dextrose Equivalent (DE) values. The term DE
value refers to the percentage of dextrose in the mixture of carbohydrate produced on hydrolysis. DE
value also indicates the sweetness and viscosity of the syrup. High DE value reflects more sweetness
and less viscous syrup. Typically glucose syrups having DE value 42-65 are used in beverage
manufacture. Glucose syrups are used in energy drink, where a carbohydrate that yields quick energy
is desired. The advantage of using glucose syrups is higher level of solids as compared to sucrose

syrup. However, higher viscosity of glucose syrup at low temperature (below 300C) create problem in
mechanical operations.
c) High Fructose Corn Syrup High fructose corn syrup (HFCS) is manufactured by first hydrolyzing
the corn starch to dextrose then enzymatically converting dextrose into fructose. HFCS contain around
42% fructose plus 51% dextrose and have sweetness equal to sucrose. HFCS is mainly used in USA
and to a lesser extent in Europe. These syrups are also liable for browning.
d) Invert Sugar Syrup Invert sugar syrup is produced by acid or enzymic hydrolysis of the sucrose
into its constituents sugars i.e. glucose and fructose. Invert sugar usually contains a mixture of sucrose,
dextrose and fructose. The major benefits of using invert sugar are an increase in osmo-molality and
decreased tendency of crystallization. The application of invert sugar is also restricted to cola type of
beverages where brown colour is desired.
e) Saccharin Saccharin has been used as a food additive since the early 1900s and is the most widely
used non-nutritive sweetener worldwide. Saccharin occurs as white, crystals or a white crystalline
powder, is odorless, or has a faint aromatic odor. It is slightly soluble in water, sparingly soluble in
alcohol and soluble at 0.05% in a fixed oil. It is about 300 times as sweet as sucrose. In its bulk form,
saccharin and its salts have been shown to be stable for several years. In aqueous solutions, saccharin
demonstrates high stability over a wide pH range. It is commercially available in three forms: acid
saccharin, sodium saccharin, and calcium saccharin. Sodium saccharin is the most commonly used
form because of its high solubility and stability. Due to its bitter aftertaste and health implications,
saccharin has limited potential. It had been linked with occurrence of bladder cancer in rodents,
however later investigations in higher animals did not confirm the relation between bladder cancer and
saccharin consumption.
Non-caloric Sweeteners
1. Acesulfame K has a rapidly perceptible sweet taste 200 times as potent as sucrose. Acesulfame
potassium occurs as a colorless to white-colored, odorless crystalline powder with an intensely sweet
taste.
It dissolves readily in water, even at room temperature, and is very stable, with virtually no
change in concentration observed in the pH range common for foods and beverages after several
months. It is being used in dry beverage bases. Beverages containing acesulfame K can be pasteurized
under normal pasteurization conditions without loss of sweetness. It blends well with other sweeteners
and is especially synergistic with aspartame and sodium cyclamate.
It is non-caloric and has a taste closer to sucrose when combined with other non-caloric
sweeteners. It is not considered to be carcinogenic and mutagenic. The adequate daily intake (ADI) of
acesulfame-k is 15 mg/kg body weight/day of an adult.
2. Aspartame was approved in 1981 for use in dry beverages mixes and later on 1983, in liquid soft
drinks in USA. However, in India application of these artificial sweeteners was permitted in certain
food stuffs including beverages.
Aspartame occurs as off-white, almost odorless crystalline powder with an intensely sweet
taste. The approximate sweetening power is 200 times that of sucrose. It is slightly soluble in water
and sparingly soluble in alcohol. The ADI (adequate daily intake) of aspartame is 50 mg/kg body
weight/day.

The use of aspartame has been of some concern due to the formation of the potentially toxic
metabolites, methanol, aspartic acid and phenylalanine. Despite it, aspartame is the most successful
high intensity sweetener currently used. Its role as a food ingredient that enhances fruit flavours makes
it suitable for soft drinks and yoghurt.
Two major disadvantages of aspartame are its instability in acidic conditions and its loss of
sweetness during prolonged heating.
3. Cyclamates were discovered in the mid-1950s. It is 30 times sweeter than sucrose and has been
particularly useful in fruit products. In 1969, it was banned because of some carcinogenic effect by
FDA.
i) Sucralose Sucralose occurs as anhydrous, white, crystalline, orthorhombic needle-like crystals with
an intensely sweet taste. It is a chlorinated sucrose derivative that is 500 to 600 times sweeter than
sucrose. It has no calories and is exceptionally stable. The ADI is 5 mg/kg body weight/day. Sucralose
is not metabolized in the body and does not break down as it passes rapidly through the body. The
sweetest of the currently approved sweeteners, it has a clean, quickly perceptible sweet taste. Still the
safety of sucralose is not fully conclusive. Besides these there are other low calorie and high-intensity
sweeteners which need permission from regulatory authorities. These include alitame, neotame,
stevia,nehesperidin dihydrochalcone and glycyrrhizin.
2. Emulsifier: -

An emulsifier is a substance that stabilizes an emulsion by increasing its kinetic stability. One class of
emulsifiers is known as "surface active agents", or surfactants.
Emulsions may be used to impart cloudiness in the form of neutral emulsions and/or as
flavouring agent as flavoured emulsions. The oil phase typically consists of a citrus essential oil
containing an oil-soluble clouding agent, while the aqueous phase consists of a solution of gum arabic,
or a suitable hydrocolloid of similar properties.
An oil-in-water (O/W) emulsion is formed using a two stage homogenizer to yield droplets 1-2
μm in diameter for optimal stability and cloudiness. The clouding agent must contribute to opacity
without affecting stability by producing creaming, ringing or separation and must also have no effect
on colour, taste or odour. Brominated vegetable oil (BVO) was used as clouding agent for many years,
however it is now been banned because of potential toxicity. Many alternatives have been attempted
including sucrose esters, such as sucrose diacetate hexa-isobutyrate, rosin esters, protein clouds,
benzoate esters of glycerol and propylene glycol, waxes and gum exudates. However, none of them
have proved satisfactory. A soy protein based clouding agent has been found effective.
3. Coloring Agent: -
Colours are used in processed foods to improve the appearance and thus also influence the perception
of texture and taste. The colours are permitted additives in beverage to provide different shades and
improve the aesthetic quality of beverages. Food colours are added in beverages because of the
following reasons:-
1. To give attractive appearance to foods that would otherwise look unattractive or unappealing
2. For product identification as majority of fruit beverages are characterized by the colour of fruit
which is used in its formulation
3. To ensure uniformity of the colour due to natural variations in colour intensity because of
variation in harvesting period, variety etc.  Intensification of the colour naturally occurring in
fruits & vegetables
4. Colours also serve as mean of quality assurance during the production, transportation and
storage. Various compounds which are used for colouring purpose may be divided into three
groups; natural colours, nature identical colours and synthetic colours or dyes.
These colours are derived from the natural sources and are exempted from the mandatory certifications
by the regulatory authorities. These are attractive alternatives to artificial colourings and being of
natural origin these are preferred by consumers as well. the poor stability of natural colourant is major
obstacle in their wider application in beverage formulation. The extraction of these colouring pigments
at cost-effective manner is still a major challenge in usage of natural colours. Some of the natural
colourants are listed in

Natural colourants used in fruit based beverages
Compounds Source Colour Impart
Paprika Capsicum anum Red colour
Anthocyanin
(cyaniding,petunidin,
betacyanin)
Beet root, Pomegranate,
grape skin
Blue, Purple and pink
Bixin (Annato extract) Bixa orellana Yellow colour
Cochineal Coccus cacti Orange to Red
Curcumin Curcuma longa Orange yellow
Crocin & Crocetin Crocus sativus Yellowish red
Caramel Heated sugar solution Chocolate Brown
Nature identical colours
These compounds are similar chemically to naturally occurring compounds but are extracted using
solvents. These are relatively more stable than natural counterparts. These include β-carotene,
apocarotenal ( β-apo-8,- carotenal) which produce yellow to orange hue, canthaxanthin that impart
red colour and riboflavin which give greenish yellow to yellow colour. The stability of these
colourants is a major problem. Mostly these are available in oil-soluble forms.
Synthetic colours
These are certified food colours which may be divided into dyes and lakes. These dyes are water
soluble and relatively stable under wide range of pH, processing temperature and storage. Lakes are
generally not used in beverage formulations. These dyes are popularly called as coal tar dyes. Azo
dyes are brighter in colour and of high tinctorial strength. Initially there were 11 permitted synthetic
dyes but now three of them have been omitted due to safety concerns. The permitted dyes are
1. carmosine (Red),
2. onceau 4R (Red),
3. Sunset yellow FCF (Red),
4. Tartrazine (Lemon yellow),
5. Brilliant blue FCF (Green blue),
6. Erythrosine (Pink to Blue),
7. Indigo carmine (Deep blue),
8. Fast green FCF (Turquoise).
The three dyes which have been removed from the list are
1. Amaranth,
2. Fast Red E
3. Green S. The dyes have fastness properties with alkali, acid, light and additives.
They can withstand processing temperature of up to 110o
C. The maximum permissible limit of these
dyes is 100 ppm as higher concentration may cause cancer.
Important colouring agents for carbonated beverages synthetic colours particularly certified coal
tar colours. Caramel obtained from heated or burnt sugar is non – synthetic colour and are widely
used in cola beverages.

Permitted food dyes are generally preferred over natural fruit colours because of their greater
colouring power and stability. Even when natural fruit extracts or juices are used their colours are
generally supplemental with synthetic colours.
4. Flavouring agent
Flavors are concentrated preparations used to impart a specific aroma to food or beverages. The
flavouring component of the sugar syrup has the major influence on the flavour of the final product,
used at very minor amounts i.e. 0.01 to 0.02 %. The nature of flavouring usually is determined by the
type of the product
Flavors may be added to food products for the following reasons:
1. To create a totally new taste
2. To enhance, extend, round out or increase the potency of flavours already present
3. To supplement other more expensive flavors or replace unavailable flavors
4. To mask less desirable flavors- to cover harsh or undesirable tastes naturally present
in some food
5. Stimulation of flavour perception of expensive flavours
Flavouring is most critical operation in food processing as acceptability of any products largely
governed by the flavour perception by consumers. Various food processing operations often lead to
loss of flavouring chemical either due to volatilization or because of conversion of flavouring
compounds into off-flavouring compounds. However, flavour of beverage must be identical to the
fruit which is used as base material. Fruit aroma consists of few hundreds to thousand compounds for
example orange flavour contain more than 200 compounds ranging from simple phenolic to complex
terpenoids, esters etc. Therefore, mimicking of fruit flavour in beverages is quite complex task and
requires great expertise. Various compounds used for flavouring purpose may be categorized into
three groups.
Natural flavours Natural flavours include extracts from natural sources in the form of essential oils,
oleoresins, essence or extractive, distillate or any product formed during normal processing such as
roasting, heating etc.
Example of natural flavour is extracts of vanilla roots, roasted coffee beans, herbs etc. Practically
natural flavours are essential oils, oleoresins, and true fruit extracts. A special type of natural flavour
is fruit flavour concentrate. Fruit flavour concentrate is prepared by removing the water under
vacuum and added back aroma back into the concentrate. The most common fruit flavour concentrate
include apple, berry, grape and citrus fruits.
Synthetic flavours- Term synthetic flavour is used for those substances which are not identified in
naturally occurring products intended for human consumption. They are produced by fractional
distillation process and additionally chemical modification of naturally sourced chemicals, coal tar or
crude oil. Although, they are chemically different from natural compounds but identical in flavour
perception. These are essence and produced by various processes or by mixing various compound
specified in the aroma of any fruit.
Example: esters give the characteristics fruity aroma and γ-undecalactone is included in peach
flavour formulation.

5. Foaming agents: - Presence of foam in headspace is considered desirable in certain carbonated
soft drinks, such as ginger beer and colas. The most effective foaming agents are saponins which are
extracted either from the bark of Quillaia or Yucca trees. The permitted level is up 200 ppm (in
European Union) and 95 ppm in USA.
6. Acids: - Application of acids enhances the flavour and it also contributes towards the preservation
of the beverage. Wide varieties of acids are available for carbonated beverage manufacture, but citric,
malic; fumaric, tartaric and phosphoric acid are most commonly used. Phosphoric acid is mainly used
in cola type of beverages.
7. Stabilizers are used both to stabilize emulsions and also maintain the fruit components in
dispersion. Besides they also improve mouthfeel and viscosity of the beverages. Most commonly
used ones include guar gum, gum arabic, pectin, CMC and alginates These are food additives which
are used to improve and stabilize the viscosity and consistency of foods.
Functions:
• Improve and stabilize consistency
• Inhibit crystallization
• Stabilize emulsions & foams Reduce stickiness of Icings
• Encapsulate flavours.
Example: - Gum Arabic, Guar gum, Carrageenan, Sodium alginic acid, Starch, Carboxy
methy cellulose. The only non protein based material used as a thickener – gelatin.
Mechanism: They readily swell in hot or even cold water & help thicken food. They are
hydrophilic and are dispersed in solution as colloid.
• Agar: Also known as Agar-agar. A polysaccharide complex extracted from
agarocytes of algae of the family Rhodophyceae. It can be separated into a gelling
fraction agarose, and a sulphated non-gelling fraction –agaropectin. Generally used in
pie fillings, custards, Jellies fro thickening purpose.
• Pectin: It is a polysaccharide substance present in cell walls in all plant tissues which
functions as an intercellular cementing material. One of the richest sources of pectin is
lemon or orange rind which contains about 30% of this polysaccharide. Almost
completely soluble in water it forms a viscous solution containing negatively charged
very much hydrated particles. It is widely used as a setting, jellying and solidifying
agent in jam, jellies, and marmalades and as stabilizing agent in beverages.
• Gelatin: Gelatin is obtained from collagen by hydrolytic action. Gelatin is used as a
thickener and stabilizing agent in ice creams, yoghurts and pie fillings.
• Carboxy methyl cellulose: It is modified cellulose and the principal compound is
carboxy methyl D-glucose
8. Carbon dioxide: - Carbonated beverages contain carbon dioxide which “sparkle” the beverage
and impart “fizziness”. CO2 gas is inert, non-toxic, almost tasteless, easy to produce and impregnate
in the liquid as compared to other gases. It is also available at relatively lower cost in liquefied form.

It is soluble in liquids where its solubility increases when the temperature of liquid is decreased and it
can exist as gas, liquid or solid. CO2 produces carbonic acid when dissolved in water which in
combination with other ingredients produces acidic and characteristic biting taste of carbonated water
and beverages.
Above a certain level of carbonation carbon dioxide has a preserving property, having an
effective antimicrobial effect against moulds and yeasts. CO2 may be obtained from carbonates,
limestone, burning of organic compounds and industrial fermentation processes. CO2 obtained by
any process is purified to ensure that it is free from impurities and fit for human consumption.
Purification of CO2 is done by scrubbing with water to remove sulphurous compounds and passing
through activated charcoal or carbon tower to remove odorous compounds. Many beverage
manufacturers produce their own CO2 on site by using packaged system.
9. Water-It is the main ingredient of carbonated beverage that comprises more than 90% of the total
volume. The water which is used in preparation of carbonated beverages must of very high potable
standards. Therefore, water pre-treatment is necessary to ensure the high standards of finished
beverage such as removal of microscopic and colloidal particles by coagulation, filtration, softening
and pH adjustment in the areas where water is of poor quality. Disinfection and chlorination remains
the preferred method for the destruction of microorganisms. High level of nitrates in the water could
be considered as possible risk for infants. It may also cause corrosion of tin plate and perforations of
lacquer lining of cans. De-aeration of water is also required to facilitate subsequent carbonation and
filling operations to minimize foaming problems.
Water should be free from
• high levels of elements and mineral salts
• objectionable tastes and odours
• organic material.
It should also be
• clear and colourless
• free from dissolved oxygen
• sterile, that is, free from micro-organisms.
Water used in carbonated beverage must possess following properties:
 Low alkalinity–to check neutralization of acids otherwise it would affect flavours and may
decrease preservation effect of acids.
 Low iron and manganese – to prevent reaction with flavouring and coloring compounds
 No residual chlorine- as it affects flavour adversely and cause oxidation
 Very low turbidity and colour – to impart attractive appearance to the drink.
 Organic matters and inorganic solids must be very low – as it provides nuclei for CO2 –
resulting in beverage boiling and gushing at the time of filling or opening of bottles. Water used in
carbonated beverage manufacture must meet the following standards.

Particulars Maximum Permissible Limit
Alkalinity 50 ppm
Total solids 50 ppm
Iron 0.1 ppm
Manganese 0.1 ppm
Turbidity 5 ppm
Colour Colourless
Residual chlorine None
Odour Odourless
Taste Tasteless
Organic Matter No objectionable content

Process flow diagram for the manufacture of carbonated beverages
Introduction:-
Carbonated nonalcoholic beverages are generally sweetened, flavored, acidified, colored,
artificially Carbonated, and sometimes chemically preserved. Their origin goes back to Greek and
Roman times when naturally occurring mineral waters were prized for "medicinal" and refreshing
qualities. But it was not until about 1767, when the British chemist Joseph Priestley found that he
could artificially carbonate water, that the carbonated beverage industry got its start. An early method
of obtaining the carbon dioxide was by acidification of sodium bicarbonate or sodium carbonate, and
from the use of these sodium salts came the name "soda" which remains today, although most carbon
dioxide is no longer generated in this fashion. Gradually, fruit juices and extracts were added to
carbonated water for improved flavor. Until the 1890s soft drinks were produced manually, from
blowing bottles individually to filling and packaging. During the following two decades automated
machinery greatly increased the productivity of soft drink plants. Probably the most important
development in bottling technology occurred with the invention of the "crown cap" in 1892, which
successfully contained the carbon dioxide gas in glass bottles.
INGREDIENTS IN A CARBONATED DRINK
Carbonated Beverages- Equipment and machinery for carbonated beverages, water treatment, syrup
preparation, containers and closures. Cleaning, carbonation, filling, inspection and quality control

Carbonated drinks are made from:
• water (about 86%)
• a sweetening agent
• an acid
• a flavouring
• carbon dioxide
and may also contain:
• fruit or fruit juice
• colouring
Manufacturing Process
Most soft drinks are made at
bottling and canning companies. Brand name franchise companies grant licenses to bottlers to mix the
soft drinks in strict accordance to their secret formulas and their required manufacturing procedures.
Clarifying the water-
The quality of water is
crucial to the success of a
soft drink. Impurities,
such as suspended
particles, organic matter,
and bacteria, may degrade
taste and color. They are
generally removed
through the traditional
process of a series of
coagulation, filtration, and
chlorination. Coagulation
involves mixing a
gelatinous precipitate, or
floc (ferric sulphate or
aluminum sulphate), into
the water. The floc
absorbs suspended
particles, making them
larger and more easily
trapped by filters. During

the clarification process, alkalinity must be adjusted with an addition of lime to reach the desired pH
level.
Filtering, sterilizing, and dechlorinating the water-
• The clarified water is poured through a sand filter to remove fine particles of floc. The water
passes through a layer of sand and courser beds of gravel to capture the particles.
• Sterilization is necessary to destroy bacteria and organic compounds that might spoil the
water's taste or color. The water is pumped into a storage tank and is dosed with a small
amount of free chlorine. The chlorinated water remains in the storage tank for about two hours
until the reaction is complete.
•
• Next, an activated carbon filter dechlorinates the water and removes residual organic matter,
much like the sand filter. A vacuum pump de-aerates the water before it passes into a dosing
station.
Mixing the ingredients
• Syrup preparation: - Syrup is usually prepared by mixing 1 part (volume) syrup to 3-6 parts
(volume) water in stainless steel tanks fitted with top driven agitators. Heated water at some

60◦C is fed to the vessel in a predetermined quantity dependent on the amount of granulated
sugar added and the required final Brix In sugar based product the syrup typically consists of
sugar syrup of 67º Brix strength, citric acid, flavouring, colourings, preservatives and water.
Sugar syrup is passed through a plate heat exchanger to decrease the microbial load.
• Syrup is pre-prepared, tested and diverted to proportioner for mixing with water and
carbonation. Flow meters are most frequently used for proportioning. The syrup is dosed
through a mass flow meter and the water dosing is done volumetrically by using a magnetic
induction flow meter.
Carbonation: - Carbonated product that is held in a container that is open to the atmosphere will
gradually lose carbonation. This is due to the gas being liberated to the atmosphere as the liquid/gas
interface continually strives to achieve the equilibrium condition. In a closed container the gas fills the
container headspace, thus increasing the headspace pressure. The higher the temperature the greater
the pressure required to maintain the carbon dioxide in solution. Lower the temperature the greater the
amount of carbon dioxide that is retained in solution.
Carbon dioxide gas is heavier than air, having a density of 1.98 kg/m3 at 298 K, some 1.5 times that of
air. Carbon dioxide gas is readily soluble in cool or cold water. Solubility of CO2 gas in water
decreases with increase in temperature. CO2 is the only gas suitable for producing the sparkling in the
soft drinks. We should minimise the amount of air present during carbonation The higher the air
content the more difficult it is to hold carbon dioxide in solution. Solubility allows the retention in
solution at ambient temp and also allow the release of attractive bubbles from the body of the drink
when rightly agitated, the gas is
• Inert
• Nontoxic
• Tasteless
• Available in liquid form at moderate cost
The optimum level of carbonation varies with the type of beverage. Higher level of carbonation in
orange type of carbonated beverages and too low in cola or ginger ale is not liked by consumers. The level of
carbonation varies between
a) 1 to 4.5 volumes of CO2 per liter of beverage;

b) 1 volume for fruit based
carbonated drinks,
c) 2-3 volumes for colas
d) 4.5 volumes for mixer
drinks like tonic water,
ginger ale.
Carbonation may be
considered as the impregnation of a
liquid with CO2 gas. In modern
procedure sugar syrup; water and
CO2 gas are combined in the
correct ratio before transfer to the
filler. The final beverage thus
prepared before filling and
regulation of carbonation and of the
relative proportions of syrup and
the water is of critical importance.
The fundamental role of the
carbonator is to obtain close
contact between CO2 gas and the
liquid being carbonated.
Factors determining the degree of carbonation are:
• Operating pressure in the system and temperature of the liquid
• Contact time between the liquid and CO2
• Area of the interface between the liquid and CO2
• The affinity of the liquid for CO2 (affinity decrease as the sugar content increases);
• Presence of other gases. Presence of air in syrup or water affects the carbonation process.
Presence of air in beverage may also lead to mould growth and other oxidative reactions.
Generally 1 volume of air excludes 50 volumes of CO2. Carbonation may be done in three
different ways as follows:
I. Pre-syruping or syruping-filling process or post mix process: Containers are filled with
flavored syrup and now carbonated water is added in it to prepare carbonated drink.
II. Finished Product filling or Pre-mix: Flavored syrup is added to water in correct
proportion and then homogenous mix is carbonated to produce beverage.

III. Carbonation of water is done in the first stage, then flavoured syrup is metered and
added into it to prepare carbonated beverage.
Use of polyethylene terephthalate (PET) bottles also requires slightly higher level of carbonation as
some loss of CO2 is bound to occur during storage. Carbonated soft drinks are filled into either bottles or cans.
Thick-walled, reusable, glass bottles were used for many years, but are being replaced by thin-walled, non-
reusable glass and increasingly, PET bottles.
Filling: - Carbonated beverages
are filled mainly by gravity filler
or Counter-pressure filler.
Returnable glass bottles are first
washed in a bottle washer when
soaking in caustic solution, hot
water and then washing is done.
a) After washing bottles are
enter the filling system. Bottles
are first lifted by the filling
heads through lift cylinder.
b) As the bottles are allowed to the
head, there is a sudden flush of
co2 into the bottle. This co2
flushes the air out from the vent
tube which allow the beverages
to flow down there is a spring
which is also attached to the system, it compress during the upward movement of the ring.

c) As the beverage is filled into the bottles, the spring is released gradually and come back to its
normal position with this the ring also come back to its initial position which stops the filling
capping and crowing.
d) Once the bottles filled shift valve open to releases pressure and the bottles are caped.
Different caps are used for different bottles. Glass bottles are topped with a metal crown. Filling
speeds for glass bottles of 800–1200 bottles/min are now commonplace,
In counter filling system this steps takes place
(a) Basic position. (b) First evacuation. (c) Flushing phase. (d) Second evacuation. (e) Pressurising. (f)
Filling. (g) Completed filling cycle. (h) Correction phase. (i) Completed correction phase. (j) Snifting.

Quality Control
Soft drink manufacturers adhere to strict water quality standards for allowable dissolved solids,
alkalinity, chlorides, sulfates, iron, and aluminum. Not only is it in the interest of public health, but
clean water also facilitates the production process and maintains consistency in flavor, color, and
body. Microbiological and other testing occur regularly.
Equipment and machinery for carbonated beverage
a) Carbon filter: - this type of filter is used to remove chlorine, sediment and volatile organic
compounds from water. This filter is made up of sand and gravles and in the middle of the
filter an activated carbon layer of 24 inches is provide. This carbon is generally activated with
a positive charge and is designed to attract –ve charge water contamination.
b) Micro filter: - This is a candle type filter and it is used to remove microorganism from
soft water.

c) Synchronmeter:- it is metering device in which flavouring syrup containing all the
ingredients except the remaining water and co2 is pumped. Treated and deareated water
is also pumped to the synchronmeter. This device then meters the syrups and water in
the fix proportion and mixes them thoroughly. This mixer is then delivered to carbon
cooler. It is fully automatic in operation. Starting and stopping an the demand and
requirement of carbo-cooler and filler.
d) Sand filter: - remove any flow particlew or may other suspended particle. The sand
filter is charged with sand and gravels. The finest sand particle makes up the top layer.
e) Bottle washer: - it is a device which is used for washing of glass bottle. In the bottle
washing the bottles are wash by soaking with caustic soda solution for 10 minutes at 70
to 80 degree C and then wash with normal water or cold water.
f) Bottle filler: - Bottle filler is the heart of bottling line. It consists of filler bowl and
valves stir cups and liquid distribution system, lubrication system and centre coloumn
bearing.

g) Inspection unit: -
1. for empty bottle light:- it is the light present place in between washer and
filler. The main function of this light is to detect dirty bottle, other brands bottle and
broken bottle.
2. Final light: - it is the light
present after filler. The main
function of this light is to check
volume of the liquid in the
bottle i.e. half filled, over
filled, proper crowning etc.
h) Carbo-cooler: - As its name
indicates the carbo-cooler both
cool and carbonate the liquid
entering from the
synchronmeter. It contains
refrigerated plate and is under
co2 pressure.
i) Deaerator:- it is also an
important part of beverages
line. It supply deareated water
use of deareated water reducing foaming during the filling process and permit greater
co2 content in the final products.

Introduction to Tea:-
Tea is one of the true stimulants and satisfying the palate demands of human beings for
centuries. Teas can generally be divided into categories based on how they are processed. There are at
least six different types of tea: white, yellow, green, oolong (or wulong), black (called red tea in
China), and post-fermented tea. Tea contains a large number of possibly bioactive chemicals,
including flavonoids; amino acids, vitamins, caffeine and several polysaccharides, and a variety of
health effects have been proposed and investigated.
Tea has wide applications so it processed in many ways so as to get different products.Tea is
one of the most popular beverages in the world. It also provides valuable source of income to many tea
producer countries. It is a capital earning industry. To promote its development, the Govt. of India has
set up Tea Board under the Ministry of Commerc. Tea is a perennial plant having a lifespan extending
100 years. The popularity of tea is due to:
 Its sensory properties
 Relatively low retail price
 Apparent health benefits
 History:-The history of tea production in India spans more than 160 years. In 1838, the first
consignment of tea from Assam was shipped to England. The word ‘Chai’ is derived from a
Cantonese word ‘Chah’. Plantations in Darjeeling, Tarai and Dooars regions of northern
Bengal and Nilgiris and other regions of South India.
 Origin and Distribution Centre of origin – Southeast China Later it spread to Southern
portion of China, parts of India, Myanmar, Thailand, Laos and Vietnam Early part of 19th
Century – An unsuccessful attempt was made to establish Chinese tea in India. Only when the
native „wild tea plants found in Assam were used, the tea production in India became‟
successful. Tea industries in India are there in Assam, West Bengal, Kerala, Karnataka,
Tamilnadu and to some extent in Tripura and Himachal Pradesh.
Scientific name :Camellia sinensis.
Family : Camelliaceae.
Camellia Sinensis, an ever green shrub that grow to height of 30 feet, but is usually clipped to a
height of2-5 feet in cultivation for easy plucking purposes. Harvest of its leaves is by hand with
special shears, or by machines. It is cultivated as a plantation crop, like acidic soil and a warm climate
with at least 50 inches of rain per annum.tea from individual plantations has developed its own
character and taste, depending on the direction of the growing slopes and weather conditions at the
time of plucking leaf and manufacture from green leaf to black tea. Tea breaks down into three basic
types: black green and oolong.
Non-carbonated beverages-Technology, specification, equipment and machinery for instant and

Tea Processing
It is a method in which the leaves and flushes from camellia sinensis are transferred in to the dried
leaves for brewing tea. The types of tea are distinguished by the processing they undergo. In its most
general form, tea processing involves oxidising the leaves, stopping the oxidation, forming the tea and
drying it. Of these steps, the degree of oxidation plays a significant role of determining the final
flavour of the tea, with curing and leaf breakage contributing to flavour by a lesser amount. Although
each type of tea has different taste, smell and visual appearance, tea processing for all tea types
consists of a very similar set of methods with only minor variations:
1. Picking
Picking is done by hand when a higher quality tea is needed. Hand picking is done by pulling the flush
with a snap of the wrist and does not involve twisting or pinching the flush, since doing the latter
reduces the quality of the leaves tea flushes and leaves can also be picked by machine, though there
will be more broken leaves and partial flushes.
2. Withering
Withering is used to remove excess water from the leaves and allows a very slight amount of
oxidation. The leaves can be either put under the sun or left in a cool breezy room to pull moisture out
from the leaves.
3. Rolling/bruising
In order to promote and quicken oxidation, the leaves may be may be bruised by tumbling by baskets
or by being kneaded or by being kneaded or rolled over by heavy wheels. This also releases some of
the leaf juices, which may aid in oxidation and change the taste profile of the tea.
4. Fermentation
Fermentation is the most important stage in the manufacture tea. For this the leaves are left on
their own climate controlled room where they turn progressively darker. In this process the chlorophyll
in the leaves is enzymatically broken down, and its tannins are released or transformed. This process is
termed to as fermentation. The tea producer may choose when the oxidation should be stopped, which
depends on the desire qualities in the final tea as well as the weather conditions. For light oolong teas
this may be anywhere from 5-40% oxidation, in darker oolong teas 60-70% and in black teas 100%.
The mechanical aspect involves spreading out of the leaves macerated by rolling a layer 5-8 cms thick,
for 45 minutes to 3 hours, depending on the quality of the leaves. Fermenting machines make the
process continuous, that is, every unit of macerated leaf has to be spread out for individual treatment.
5. Fixation

This is done to stop the leaf oxidation at a oxidation at a desired level. This is followed by
moderatively heating the tea leaves, thus deactivating their oxidative enzymes, without destroying the
flavour of the tea.
6. Drying
After fermentation the tea is dried by passing through a drier .the objective of drying is to a) arrest
fermentation b) remove moisture and produce teas with good qualities. The mass of leaf is exposed to
hot air when it passes through a chamber is maintained at temperatures between 100-130C centigrade
as its base range. It takes 15 minutes to half an hour to dry the leaf, when the enzymes are fully
inactivated. After completion of the drying process the tea becomes fully black in colour.
7. Packaging
Tea is a markedly hygrospic material and while cooling and sorting it absorbs moisture. Before
packing tea the accumated series of daily batches of each grade are bulked and mixed to obtain the
highest possible degree of unity. Before packing tea is passed under powerful magnets to prevent
possible pieces of iron mixing with the tea. Packing is the process of preserving the product using the
cheapest but most appropriate material taking in to account the product
properties.
1. Green tea
Green tea is made from the leaves from Camellia sinensis that have
undergone minimal oxidation during processing. . Green tea has become
the raw material for extracts used in various beverages, health foods,
dietary supplements, and cosmetic items. Many varieties of green tea have
been created in the countries where it is grown. These varieties can differ
substantially due to variable growing conditions, horticulture, production
processing, and harvesting time. The main constituent of green tea leaves
belong to the polyphenol group accounting for 25-35% on a dry basis.
2. Oolong tea
The processing of oolong tea requires only a partial
oxidation of the leaves. After the leaves are plucked,
they are laid out to wither for about 8 to 24 hours. Then the
leaves are tossed in baskets in order to bruise the edges of the
leaves. This bruising only causes the leaves to partially oxidize
because only a portion of the enzymes are exposed to air. The
taste of the tea is very rich. It can be sweet and fruity, or woody
and thick, or green and fresh, all depends on the horticulture
and style of production. Here only 50% fermentation is done.
3. Black tea
Black tea is a type of tea that is more oxidized than oolong,
green and white teas. Black tea is generally stronger in flavour

than the less oxidized teas. Black tea retains its flavour for several years. Here 100% fermentation is
done.
Manufacturing process for instant tea
The processing in tea processing plant includes extraction, separation of waste, evaporation and spray
drying. The plant size varies from 5 kg/h to 1000 kg/h of instant tea. The processing steps are as
outlined below:
Instant tea is manufactured from black tea by extracting the brew from processed leaves, tea wastes or
undried fermented leaves.
The extract is concentrated under low pressure, and dried to a powder by any of the processes
including freezing, drying, spray-drying and vacuum-
drying.
Low temperature is used to minimize the loss of
flavor and aroma.
The flow chart for production of Instant tea
Instant Tea
The manufacture of instant tea is in several ways like
that of instant coffee. Instant tea processing begins
with
• Extraction of the selected tea leaf blend.
Generally, a fermented black tea type is used-
one chosen for reddish color, relative freedom
from haze, and strong flavor when brewed.
About 10 parts of water are combined with 1
part of tea leaves by weight in the extractors,
and extraction is carried out at temperatures
between about 60 and 100ºC for 10 min. The
final extract contains about 4% solids, which
represents approximately 85% of the soluble
solids in the leaves.
• Cooling the tea extract to about 10ºC to
encourage caffeine-tannin complex
formation. The complex, which gives a fine precipitate, can be removed by filtration or
centrifugation.

• The dearomatized extract is then concentrated in low-temperature evaporators to between 25%
and 55% solids for subsequent drying. Instant tea has grown in popularity largely because of its
convenience in making iced tea.
• The concentrate tea supplemented with essence distilled earlier and is ready for dehydration.
• Instant tea is dried primarily in spray driers and low-temperature vacuum belt driers. Tea flavor
and aroma is even more sensitive than that of coffee, and so the spray driers are operated under
milder heat conditions than those used for coffee, which cuts down on their capacity. Freeze-
dried tea appears to offer few advantages.
In recent years, bottled and canned teas and in some parts of the world coffees have become popular.
These products are often sweetened with sugars or reduced-calorie sweeteners and may have fruit flavor
essences added. Their manufacture is similar to other canned and bottled beverages except that they start
with a brewed product which may initially be in the form of a concentrate. If their pH is above 4.6, they
would require retort processing. Many are aseptically processed and packaged.
Components of tea
1. Tannin
Tannins are a class of compounds in tea, especially black tea, which tend to have a bitter flavour and
astringent properties. Teas high in tannins can be described as tannic. Tannins are naturally occurring
and common, and are an important component of red wine. They are also responsible for the dark
colour in some streams, as they are found in leaves and wood, and are released as organic matter
breaks down.
2. Phenolic compound
The phenolic content in tea refers to the phenols and polyphenols, natural plant compounds which are
found in tea. These chemical compounds affect the flavour and mouth feel and are speculated to
provide potential health benefits.
3. Amino acids
Aspartic, glutamic, serine, glutamine, tyrosine, valine, phenylalanine, leucine, isoleucine and thiamine
were found to be the principal amino acids present in tea leaf.Theanine alone contributed around 60%
of total amino acid content. The amino acid plays an important role in the development of tea aroma
during the processing of black tea.
4. Caffeine
Caffeine is a purine derivative, which is 1, 3, 7-tri-methl xanthine.it has stimulating property and
removes mental fatigue. The contribution of caffeine to the infusion is the briskness and creamy
property resulting from the complex formed by caffeine with polypenols.
5. Carotenoids
The four major carotenoids,β-carotene,lutein,violaxanthine and neoxanthine .all these carotids were
found to decrease appreciably during black tea manufacture.
6. Carbohydrates
The free sugars found in tea shoot are glucose, fructose, sucrose, raffinose and stachyose.

Equipments used in tea processing
1. CTC machine
Crush, Tear, and Curl (also Cut, Twist, Curl) is a method of processing black tea, Instead of the leaves
being rolled as a final stage, they are passed through a series of cylindrical rollers with hundreds of
small sharps “teeth” that crush, tear, and curl the tea.CTC was invented by William McKercher .CTC
teas generally produce a rich red-brown colour when they are boiled by the Indian method. The
drawback of the CTC method is that it tends by its nature, and unfortunately by adulteration, to
homogenize all black tea 11flavours.
In the process of crushing, tearing and pelletizing the tea leaves, large pressures and stresses
occur which break down the cells, releasing large amounts of the phytins that normally oxidize to
produce black tea’s mahogany colour. Since, regardless of origin, CTC teas in their dry form are
generically “tea-like” in aroma, very similar in pelletized form, it is very easy to adulterate a more
expensive CTC-type tea with inexpensive and generally mild lowland teas of the same process. Whole
and broken leaf teas by contrast are quite varied in appearance, making adulteration more difficult.
2. Orthodox machine
The term orthodox is used by the tea industry to designate methods that adhere to traditional
production guidelines. Orthodox processing calls for a wither of 18-24 hours, two to six rolling of one
half-hour each, and a fermentation of 3-4 hours. There are also specifications for firing and drying.
Primary objectives are;
1. To rapture the cell walls and exposes their contents.
2. To bring the contents of tea leaf cells in contact of air to start the process of oxidation
3. To break the larger twisted leaf in to smaller particles
Common grades of tea
All tea is graded according to leaf size. One of the most common terms is ‘Orange Pekoe’, and
is often mistaken for a type of tea. In actual fact it is a term that denotes a particular size of Black Leaf
Tea. Grading is not related to its quality, that’s down to the climate, location and the type of
processing. It is the leaf size that plays an important role in influencing the overall essence of a cup.
White Tea, Green Tea and Oolong Tea are generally not graded like most Black Teas. Here are the
most common grades for black tea leaves.
• F.O.P. Flowery Orange Pekoe - Refers to high quality whole leaf tea made from the first two leaves
and bud of the shoot. India produces large amounts of this grade.

• G.F.O.P. Golden Flowery Orange Pekoe - The golden refers to the colourful tips at the end of the top
bud.
• T.G.F.O.P. Tippy Golden Flowery Orange Pekoe - FOP with larger amount of tips
• F.T.G.F.O.P Finest Tippy Golden Flowery Orange Pekoe - An even higher quality with more tips
than FOP
• O.P. Orange Pekoe: Refers to a high quality thin, wiry leaf rolled more tightly than F.O.P. Picked
later in the year than F.O.P.
.
Health benefits of tea
Tea contains a large number of possibly bioactive chemicals, including flavonoids; amino acids,
vitamins, caffeine and several polysaccharides, and a variety of health effects have been proposed and
investigated.
1. Green and black tea may protect against cancer.
2. The catechins found in green tea are thought to be more effective in preventing certain obesity-
related cancers such as liver and colorectal cancer.
3. Green and black teas may protect against cardiovascular disease.
COFFEE
Types of Coffee
The birthplace of Indian coffee, Bababudangiris is named in honour of the legendary saint
Baba Budan1 – who brought coffee to India. With a peak altitude of 1500 metres, the region is
frequented by spotted deer. The coffee plantations here produce full bodied Arabicas, which ripen at a
relatively slower pace due to mild weather conditions. The coffee from these carefully selected beans,
which are processed through natural fermentation, has a full body, acidity, mild flavour and
unmistakeable aroma with a hint of chocolate.
There are basically two types of coffee consumed most commonly worldwide - Arabica and Robusta -
that grow from the two main species of coffee plants: Coffee Arabica and Coffee Robusta respectively.
Although there are numerous varieties of coffee plants, Arabica and Robusta are the most important
from a commercial standpoint.
Arabica Coffee
Arabica coffees (or Arabicas) have a delicate flavour and balanced aroma coupled with a sharp
and sweet taste. They have about half the amount of caffeine compared to Robustas. Arabicas are
harvested between November to January, and are typically grown on higher altitudes ranging from 600
to 2000 metres in cool, moisture-rich and subtropical weather conditions. They require nutrient-rich
soil to be able to conform to the highest international coffee standards.
Robusta Coffee
Robusta coffees (or Robustas) have twice the level of caffeine compared to Arabicas. Robusta
coffees have a very strong taste, a grainy essence and an aftertaste somewhat similar to that of peanuts.
It is possible to grow this variety at lower heights. Robusta coffee plants are harvested from December
to February, and can better withstand the onslaught of unfriendly weather and plant pests.
Robustas have a better yield and take less time to bear fruit than Arabicas. Although the
Arabica variety is preferred in international markets, high quality Robustas are also highly sought after
in espressos due to their strong taste and the crema1 that they help generate.
Important Coffee Varieties – By Region
13 different varieties of Indian coffee can be identified based on their origins.

• Major Arabica producing regions include Anamalais, Bababudangiris, Biligiris, Araku Valley,
Brahmaputra, Shevaroys, and Pulneys
Major Robusta producing regions include Wayanaad (largest producer of Robusta) and
Travancore.
In addition, Coorg, Chikmaglur, Nilgiris and Manjarabad are famous for both the Arabica and Robusta
varieties.
Coffee Growing Regions of India
India's coffee growing regions can be divided into three categories:
• Traditional coffee growing regions, such as Karnataka, Kerala and Tamil Nadu
• Non-traditional (i.e. relatively new) coffee growing regions, such as Andhra Pradesh and
Orissa on the Eastern Ghats
• North-Eastern coffee growing regions, such as Assam, Manipur, Meghalaya, Mizoram,
Tripura, Nagaland and Arunachal Pradesh
Coffee in India is grown in different geographies, under varying degrees of rainfall (ranging from 800
mm to 4500 mm) – and altitudes (ranging from 700 m at Chikmaglur to 2000 m at Pulneys). These
differences bring subtle but exciting variations to the flavour Indian coffee.
In many parts of the world, coffee is one of the most popular beverages. In the United States,
annual consumption in 1991 was approximately 28 gal per person per year, whereas annual per capita
consumption of tea was 5.5 gallons. Whereas consumption of tea in the United States is much less than
that of coffee, in England, China, Japan, the Soviet Union, and certain other countries, the picture is
reversed. The five layers are:
1. Skin / Pulp: On the outside, the two coffee seeds are covered by a cherry-like skin. With the
exception of dried-in-the-fruit or Natural Process coffee, this outer layer is removed within a
few hours of harvest. In an edible cherry (like a nice plumb and sweet Rainier cherry from
Eastern Washington), we might call this skin the “flesh”. In coffee, the skin is mostly
considered a by-product (some make tea out of it).That’s why it’s called “pulp” and the
machine to remove it is called a depulper.
2. Mucilage: Beyond the skin lies the mucilage, a
sticky, gluey substance surrounding each of the two
seeds. Since it is so sticky and sugary, it is
sometimes called Honey. (Mucilage is found in most
fruit. It’s not unique to coffee:
http://en.wikipedia.org/wiki/Mucilage)
3. Parchment: After the mucilage, a layer of cellulose
protects each of the coffee seeds. When dried, this
layer looks and feels like parchment paper, hence the name.
4. Silver skin / Chaff: Further inside, an even thinner layer coats the
seed. This layer is called the silver skin because of its somewhat
silverish sheen. This layer comes off during roasting. If you ever
notice flakes in ground coffee, that is usually bits of silver skin or
chaff that didn’t separate from the beans during the roast process.
5. Seed / Coffee Bean: As you’ve already discovered, basically the
coffee bean is one of the two seeds from inside the coffee cherry
(Peaberries are an anomaly in which only one small, round seed

formed inside the cherry. Usually, about five percent of all coffee is graded as a peaberry.) It is
dried and infertile by time we receive it, ready to roast.
The Three Principal Processing Methods in Coffee
We know of three principal categories of processing methods. These three processes differ in the
number of layers that are removed before drying. Here is the short list:
1. Natural or Dried in the Fruit Process – no layers are removed.
2. Honey Process – skin and pulp are removed, but some or all of the mucilage (Honey) remains.
3. Washed Process – skin, pulp, and mucilage are removed using water and fermentation. Also
called Fully Washed. This is the conventional form of Arabica coffee processing used in most
parts of the world. It is possible to skip the fermentation step by using a high-tech pressure
washing machine to remove the skin, pulp and some or all of the mucilage. This process is
called Pulped Natural.
Production Practices
Coffee trees are started in nurseries as seedlings that are later transferred to the plantation. After
about 5 years, the trees bear fruit that turns red as it ripens and is referred to as cherries. When ripe, the
cherries are hand-picked. One coffee tree yields about 2000-4000 cherries per year. Each cherry
contains only two coffee beans; some 3000 beans yield only about 454 g (1 lb) of finished ground
coffee.
The two coffee beans are covered by a thin parchment like hull, which is further surrounded by
pulp.
1. Both the, pulp and hull are removed before the coffee beans are roasted for use. Ripe coffee
cherries are first passed through pulping machines that break and separate the pulp from the
rest of the bean. Separation of the pulp leaves a mucilaginous coating on the beans, which must
be removed. This is done by various methods including microbial fermentation of beans
heaped in large piles, use of commercial pectin-digesting enzymes, and various washing
treatments. After mucilage removal, the beans still contain an outer hull.
2. The coffee beans are now partially dried either by being spread out in the sun or by machine
driers. The object is to decrease the moisture level from about 53% down to about 12%.
Drying must be uniform throughout; when sun drying is used, beans must be turned frequently.
Drying by this method may take 5 days but is dependent on the weather. During drying, color
and flavor attributes are modified within the beans; overdrying or wide fluctuations in
temperature give variable coffee bean quality. Machine drying permits good control of
temperature and has several other advantages.
3. After the beans are dried to about 12% moisture, hulls are removed by machines that apply
friction to the hulls and then remove them in a current of air. Hulling is followed by sorting of
the beans for color and defects. Hand sorting of beans moving along a belt is still practiced to
some extent, but modern electronic sorting is less costly and gives better quality control.

4. The sorted beans are graded for size and color, and cup-tested to determine their potential
brewing quality. Up to this point, the beans are still green; that is, they have not yet been
roasted. For cup testing, small samples are roasted, ground, and brewed. For the most part,
though, graded coffee beans are shipped as green beans for further processing by coffee
manufacturers.
Coffee Processing
Blending- Different manufacturers favor various coffee blends and buy their beans from countries
producing the required coffee types. The manufacturer then custom-blends products for special market
outlets.
Roasting- During roasting, the characteristic flavor of coffee is developed. Both batch- and
continuous-roasting equipment is available. Newer types of continuous roasters can automatically
control temperature and humidity, recirculate roaster gases, and control residence time of beans in the
roaster.
Current roasting practices employ gas temperatures of about 260C for about 5 min. The bean
temperature rises to about 200C during roasting. All of the free moisture is removed from beans during
roasting; in addition, beans lose about 5% more of their green bean weight as volatile chemical
substances. One of the newer roasting processes employs heated nitrogen under pressure; among the
advantages claimed is improved flavor due in part to removal of oxygen.
Grinding
Following roasting, the beans are cooled and ground. The size to which coffee is ground depends on
its intended end use: home use in a vacuum, drip, or percolator brewer; restaurant use in a larger urn;
vending machine use where extremely fast brewing may be required; or use in the manufacture of
instant coffee. In each case, average particle size and particle size distribution affect the brewing time,
the degree of turbidity in the cup, and other properties of the brewed beverage.
Packing
The aroma and flavor properties of ground coffee are highly unstable to oxygen and to loss of
volatiles; coffee that is to be stored for long periods generally is packed in hermetic cans and jars
under vacuum or under inert gas.

Coffee for restaurants, which is consumed more rapidly, may be packed in sealed bags. Storage
stability in each case also is affected by grind size. Ground coffee gives off considerable CO2, and so
must be allowed to outgas before packaging or the CO2, will accumulate and distend the package.
Decaffeinated Coffee
Coffee is a major source of caffeine and related stimulants in the diet, although it is present in several
other beverages and foods, including tea leaves, cacao beans, and kola nuts. Products made from these
materials have different levels of caffeine depending on the method of processing, kind of brewing in
the case of coffee and tea, and other factors. Brewed coffee generally contains about 75-150 mg
caffeine per 150 ml; brewed tea about 30-45 mg per 150-ml cup; cola beverages about 3065 mg per
360 ml; and milk chocolate about 6 mg per 28 g. Since caffeine, in addition to its stimulating effect,
may produce insomnia, nervousness, and other physiological responses in some persons, coffee and
tea may be decaffeinated. Decaffeinated coffee contains about 3 mg caffeine per cup.
Decaffeination involves steaming of green coffee beans followed by water extraction prior to
the usual roasting step. In some cases, organic solvents are used to extract the caffeine from the bean.
This leaves the problem of removing the residual solvent and of recovery of the solvent vapors. A
recent advanced process utilizes high-pressure CO, and is known as supercritical CO, extraction.
Under the proper conditions of high-pressure and reduced temperature, CO, (and other gases) has the
solvent power of a liquid and the penetrating ability of a gas. This means that lower temperatures can
be used and there is no worry about leaving behind traces of solvent in the coffee.

Instant Coffee
Instant coffee, or as it is technically known "solubilized" coffee, is made by dehydrating the brewed
coffee; manufacture of this product is carried out in plants that incorporate the most advanced
extraction, dehydration, and essence-recovery equipment to be found anywhere in the food industry.
1. Extraction- Extraction of roasted ground beans is accomplished in an extraction battery that
may consist of as many as six to eight percolators connected to be operated as a single unit.
Percolators are run at different temperatures, and extract is pumped from one to another at
various stages of the brewing operation. Conditions are set to obtain maximum extraction
without heat damage or over extraction of bitter constituents.
Efficient extraction using a temperature profile decreasing from about 150 to 70'C
removes most of the readily soluble solids and hydrolyzes less soluble coffee bean
carbohydrates resulting in a total extraction of about 40% of the weight of the roasted and

ground bean. Without high-temperature hydrolysis (150ºC), only about 20% of the bean weight
would be extracted,
2. The extract from the percolators is rapidly cooled and dehydrated immediately, since coffee
aroma and flavor can deteriorate in as little as 6 h even when cooled to 4'C.
3. Dehydration-The principal method of dehydrating the extract is spray drying, and spray driers
have been designed especially for coffee. As in spray drying of other products, the size, shape,
density, moisture content, solubility, and flavor properties of the dried particles depend on the
droplet size sprayed into the drier, the time required for the particle to descend, the temperature
exposure, the trajectory of the droplet to prevent sticking to the drier wall, and so on.
Since the late 1960s, increasing quantities of coffee extract have been dehydrated by freeze-
drying to retain maximum flavor and aroma. This has included the use of freeze concentration to
produce very high quality concentrated extracts for the freeze drying process. Currently, a significant
portion of all instant coffee produced in the United States is freeze-dried. Freeze-drying is a milder
treatment than spray drying and produces a higher quality instant coffee but at a higher price due to the
expense of the process.
Aromatization-Even the best instant coffee from the drier lacks the full flavor and aroma. To improve
flavor and aroma generally adding back flavor and aroma constituents recovered during processing to
the dry state. These flavor and aroma constituents have been trapped and recovered during roasting,
grinding, and extraction and have been obtained from oils pressed from the coffee bean.
FRUIT JUICE
In India, a little over 60 per cent of fruit produced is used in fruit based beverages. Fruit juice means
the unfermented and un-concentrated liquid expressed from sound, ripe fresh fruit and with or without:
• sugar, dextrose, invert sugar, or liquid glucose, either singly or in combination;
Non-carbonated beverages-Technology, specification, equipment and machinery for instant and

• water, peel-oil, fruit essences and flavour, common salt, ascorbic acid, citric acid, and
preservatives.
The acidity of the finished product calculated as citric acid shall not be less than 4% in the case of pure
lemon juice or pulp and not less than 5% in the case of pure lime juice but shall not exceed 3.5%t in
the case of other juices. The total soluble solids for sweetened fruit juice (except tomato juice) shall
not be less than 10%. There are different types of fruit beverages:
Fruit juice: This is a natural juice pressed out of a fresh fruit. This is unaltered in its composition
during preparation and preservation, e.g., fresh juice and canned natural fruit juice.
Fruit drink: This is made by liquefying the whole fruit. At least 10 per cent of the volume of
undiluted drink must be whole fruit about and about 0.3 per cent acid. e.g. grape juice, apple juice and
mango juice.
Fruit squash: This is made from strained fruit juice, sugar and preservative. This contains 25 per cent
fruit juice, 45 per cent sugar, e.g., mango squash.
Crush-This type of fruit beverage contains at least 25 per cent fruit juice or pulp and 55 per cent total
soluble solids. It is more or less similar to squash, contains about 1.0 per cent acid and is diluted
before serving.
Fruit cordial: It is a sparkling, clear, sweetened fruit juice from which pulp and other insoluble.
Substances have been completely removed. It contains at least 25 per cent juice and 30 per cent TSS.
It also contains about 1.5 per cent acid and 350 ppm of sulphur dioxide. This is very suitable for
blending with wines. Lime and lemon are suitable for making cordial.
Nectar: This type of fruit beverage contains at least 20 per cent fruit juice/pulp and 15 per cent total
soluble solids and also about 0.3 per cent acid. It is not diluted before serving.
Fruit punch: Fruit punches are made by mixing the desired fruit juices. This contains 25 per cent of
total fruit juice and 65 per cent of sugar.
Fruit syrups: In fruit syrup only one type of fruit is used. This type of fruit beverage contains at least
25 per cent fruit juice or pulp and 65 per cent total soluble solids. It also contains 1.3-1.5 per cent acid
and is diluted before serving.
Fruit juice concentrates: This is the fruit juice which has been concentrated by the removal of water
either by heat or freezing or by reverse osmosis.
There are no guidelines or specification that particular equipment is dedicated to extraction of
juice or pulp of a particular fruit. It entirely depends on the equipment that gives the best juice or pulp
of high quality. Generally, crushing and pressing extract juice from fresh fruits. There are various
types of equipment used in extraction of fruit juices and pulp. Freshly extracted juices and pulps are
highly attractive in colour and excellent in flavor, but deteriorate very rapidly if they are not preserved
immediately, various factors influence and/or accelerate the loss of quality both internally and

externally. Preservation of pulp and juices by chemical preservatives, heat processing and freezing are
very popular.
Preparation of Fruit Juice
Fruit juices must be prepared from sound, mature fruits only. Soft fruit varieties such as grapes,
tomatoes and peaches should only be transported in clean boxes, which are free from mould and bits
of rotten fruit.
Fruits
↓
Receiving the material
↓
Washing
↓
Sorting
↓
Crushing/Grinding/Disintegration
↓
Enzyme treatment
↓
Extraction/ Expression
↓
Straining/Filtration
↓
Clarification (Optional)
↓
De-tartarisation (Optional)
↓
Preservation of fruit juice
↓
Filling in sterilized bottles
↓
Corking
↓
Pasteurization
↓
Labeling and Storage
Flow chart for fruit juice production
Washing: Fruit must be thoroughly washed. Generally, fruits are submitted to pre-washing before
sorting and a washing step just after sorting. Washing can be done either by water or by dilute
hydrochloric acid (1 part acid: 20 part water).
Sorting: Removal of partially or completely decayed fruit is the most important operation in the
preparation of fruit for production of first quality fruit juices; sorting is carried out on moving
inspection belts or sorting tables.

Extraction of juice-The method of extraction of pulp and juices depends upon the structure of fruit,
location and character of the tissues in which the juice is located. In fruits like aonla, apple, grapes etc
the juice is located throughout the fruit and is readily recovered by crushing and pressing. While in
case fruits like apricot, peaches, plum, mango, tomato etc. the raw or cooked fruits are passed through
a pulper or similar machine. In case of citrus fruits the juice is embedded in a sac and it requires
entirely different machine such as halving and burring machine halving and burring machine.
Requirements for extraction and preservation of pulps and juices are as follows:
Extraction
• Pulper
• Screw type juice extractor
• Citrus juice extractor
• Citrus halving machines
• Fruit mill/fruit grater
• Basket press/hydraulic press/rack and cloth press,
• Crown corking/pp cap sealing machine
Crushing/Grinding/Disintegration: This is applied in different ways and depends on fruit
types: Crushing for grapes and berries; Grinding for apples, pears; Disintegration for tomatoes,
peaches, mangoes, apricots etc. This processing step will need specific equipments, which
differs from one type of operation to another.
Enzyme treatment: The enzyme treatment of crushed fruit mass is applied to some fruits by
adding 0.2-0.8% pectolitic enzymes at about 50° C for 30 minutes. This optional step has the
following advantages:
• Extraction yield will be improved
• The juice colour is better fixed
• Taste of finished product is improved.
Expression/extraction: Generally juice is expressed from the crushed/disintegrated fruit pulp.
During expression, juices should not be unnecessarily exposed to air as it will spoil the colour,
taste and aroma and also reduce the vitamin content. The equipments used for the juice
extraction are screw type juice extractors, basket presses or fruit pulper. All equipments used in
the preparation of fruit juices and squashes should be rust and acid proof. Copper and iron
vessels should be strictly avoided as these metals react with fruit acids and cause blackening of
the product. Machines and equipments made of aluminium, stainless steel, etc can be used.
Straining/Filtration: The extracted juice contains some amount of suspended matter. The suspended
matter consists of broken fruit tissue, seed, skin, gums, pectic substances and protein in colloidal
suspension. These materials can be removed by straining through a thick cloth or sieve. Removal of all
suspended matter improves the appearance but often results in disappearance of fruity character and
flavour. The present practice is to let fruit juices and beverages retain a cloudy or pulpy appearance to
some extent.
Clarification: It is the process of complete removal of all suspended material from the juice. This can
be performed by many methods viz. centrifugation, enzyme treatment, settling, filtration, freezing (-
18oC), use of high temperature (nearly 82o
C) and low temperature (-2 to –3o
C). The chemical
treatments like addition of gelatin, albumin, casein, or a mixture of tannin and gelatin are also used for
the removal of suspended particles. Centrifugation is carried out in centrifugal separators with a speed
of 6000 to 6500 rpm. Enzyme clarifying is based on pectic substance hydrolysis; this will decrease the
viscosity of juice and facilitate their filtration. The treatment is the addition of pecolitic enzyme
preparations in a quantity of 0.5 to 2 g/l. This will last for 2 to 6 hours at room temperature, or less
than 2 hours at 50° C, a temperature that must not be exceeded.

De-tartarisation is applied only to raisin juice and is aimed to eliminate potassium bi-tartrate from
solution. This step can be performed by the addition of 1% calcium lactate or 0.4% calcium carbonate.
Preservation of Fruit Juices
Fruit juice is preserved to prevent the decay/spoilage and to extend the shelf life of the juice in a good
condition for future use. This is generally done by the use of high temperature (pasteurization and
flash pasteurization), use of low temperature (refrigeration and freezing), preservation with chemicals
(sulphur dioxide and benzoic acid), drying, filtration, carbonation, and by using sugar. The methods
used for the preservation are follows:
Pasteurization
Preservation by heat is the most common method. The juice is hermetically sealed in
containers before being pasteurized. Usually the fruit juices are pasteurized at about 85°C for
25 to 30 minutes according to the nature of the juice and size of the container.
Flash Pasteurization
In this method, fruit juice is heated for a short time at a temperature higher than the
pasteurization temperature and held at that temperature for about a minute and then filled into
containers which are sealed air tight under cover of steam to sterilize the seal and then, cooled.
This method has many advantages viz., minimum loss of flavour, preservation of vitamins,
economy of time and space, uniformity in body of juice, and minimum cooked flavour.
Preservation by Chemicals
Pasteurized fruit beverages undergo spoilage once opened. To avoid this it is necessary to use
chemical preservatives. Chemically preserved beverages can be kept for a fairly long time even
after opening the seal of the bottle. The two important chemical preservatives permitted in our
country by FPO are sulphur dioxide (including sulphites) and benzoic acid (include benzoates).
Sulfur dioxide: It is widely used throughout the world in the preservation of fruit juice
and other beverages. It has good preserving action against bacteria, moulds and inhibits
enzymes. In addition, it acts as an antioxidant and bleaching agent. It is generally used
in the form of it’s salts such as sulphite, bisulphite and metabisulphite.
The limitations of sulphur dioxide are:
• It can’t be used in some coloured juices like those of jamun, strawberry etc on
account of its bleaching action.
• It corrodes the tin containers.
• Some consumers may be sensitive to sulphur dioxide.
Benzoic acid: It is only partially soluble in water and hence its salt, namely sodium
benzoate is used as preservative. Pure sodium benzoate is tasteless and odorless. The
antibacterial action of benzoic acid is increased in the presence of CO2
and acid.
Benzoic acid is more effective against yeast than against moulds. The quantity of
benzoic acid depends on the acidity of the products. In case of fruit juices with pH of
3.5-4, addition of 0.06% of sodium benzoate is recommended.
By Addition of Sugar- Syrups containing 66 % or more of sugar do not ferment. Sugar
absorbs most of the available water with the result that there is very little water for the
growth of microorganisms. This reduction in water will inhibit the multiplication of
microorganisms and gradually they die out from the product.
By Freezing- Microbial growth and enzymatic reactions are retarded in juice stored at low
temperatures. This method is particularly useful in case of juices whose flavour is adversely
affected by heating. Preservation by freezing is carried out at about −30° C, after a preliminary
de-aeration. Then storage is done at −15 to −20° C.
By Drying

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