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Produce plant small packaged food concentrates

Produce plant small packaged food concentrates

A general object of the invention is to provide a method of food preparation in which a concentrate of the natural product is packaged for individual servings, maintained at a proper temperature for maximum preservation of food values, and quickly converted from a food concentrate to a whole food product immediately prior to serving. One of the more particular objects of the invention is to provide a new and improved method of preparing a food product from a food concentrate in which the time lapse from opening of the package containing the concentrate to the completion of the food product is a minimum so as to preclude to the maximum extent possible the loss of food values normally occurring during the preparation. Another object is to provide a method of preparing a food product from a food concentrate in which discharge of the concentrate from its package is accompanied by a preliminary reduction thereof to small size pieces, and in which the addition of extraneous ingredients, the mixing thereof with the concentrate, and the final comminution of the concentrate progresses simultaneously. Another object is to provide a method of preparing a food product from a food concentrate in which the concentrate is frozen, is maintained at a temperature well below freezing until the time of use, and at the time of use is reduced to pieces of small size as an incident to.

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US2765234A - Method of preparing a food product from a frozen concentrate - Google Patents

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Juice packers process concentrate and NFC juice and fill the end product into consumer packages. Cost-efficient operation and gentle product treatment are essential. During raw material storage and handling, it is important to maintain conditions that prevent microbial growth in products. The quality of water used for concentrate reconstitution must be high. Water treatment methods aim to remove or destroy undesirable substances. Examples of these are organic matter, salts, chlorine and microorganisms.

Reconstitution involves diluting one or a mix of different concentrates with water to the right Brix level. Although NFC juice is not diluted, NFC juices of different origins may be blended to produce juice with the desired properties. The more accurate the blending process, the greater the cost-savings achieved.

In-line continuous blending offers advantages in certain respects compared with batch blending. Pasteurization, with either plate or tubular heat exchangers, is carried out to destroy microorganisms in juice before filling. A deaerator may be included in the system. An aseptic buffer placed between the pasteurizer and the filling machine s makes product filling smoother and increases production efficiency.

In the hot filling method, hot product kills microorganisms on the surface of the non-aseptic container after filling. Effective CIP is essential for the high standard of hygiene demanded at the juice packer.

The most suitable combination of temperature, time, type of detergent solution and flow rate is selected for a particular cleaning cycle. Quality control of the packaged product is determined by two prime factors, the properties of the juice and its microbiological status. Product sampling and analysis are regularly carried out, which also helps to define the processing conditions needed to maintain juice quality.

Zoom Figure 7. Sometimes the juice packer also carries out the distribution of packaged products. Typical operating steps at the juice packer are illustrated in Figure 7. This section discusses the processing steps that take place in a juice packing plant up to the filling machine.

The larger facilities feature multiple processing and filling lines. One line of processing equipment can feed several fillers. Conversely, one filler can be alternately connected to several processing lines handling different types of product. Unlike the seasonal yet non-stop operation of fruit processors, production at juice packers is year-round and typically involves shifts per day, days a week. Production throughput is not uniform throughout the year. Peak output occurs normally in the run-up to the summer months and the Christmas period.

Market pressure on juice packers is steadily increasing. They are required to supply a wider choice of products, higher quality and more convenient packaging at ever more competitive prices.

Increased product diversification means smaller volumes of each product. In turn, this demands greater equipment flexibility and plant designs that minimize product losses and downtime when products are changed. From a plant operation perspective, better product quality means avoiding over-processing. Gentler product treatment is promoted by process control, which allows close monitoring and control of operating parameters, and careful equipment design.

To supply products at competitive prices requires cost-effective operation. High energy recovery that reduces heating and cooling costs and decreased product losses in the plant are two major ways to reduce operating costs.

Together with reducing waste from cleaning procedures, these measures also minimize environmental impact. High-acid products put different demands on processing equipment compared to low-acid products like milk.

Consideration must be given to the fact that fruit juices differ in viscosity and often contain particles pulp. The juice packing plant is normally designed to process and package a range of fruit juices and juice-based still drinks. The equipment described in this section is not only used for processing orange juice.

However, comments made regarding equipment requirements and performance relate to orange juice. The process line, from raw material reception to product reaching the filler, involves a number of steps.

The steps required depend on the type of raw material and product to be produced. Figure 7. Ingredient preparation for the production of orange nectar and fruit drinks is also included. In lines 3 and 4, Figure 7. Concentrate received in road tankers is pumped into large storage tanks. The storage area is refrigerated or the tanks are fitted with cooling jackets. Concentrate received in drums is placed in frozen storage. From the storage tanks, concentrate is pumped directly to the blending area for reconstitution with water.

Alternatively, blending of concentrates from different origins or fruit types takes place in a separate tank prior to dilution with water. The treatment required for product water used to dilute concentrate to final product depends on the quality of the water supplied to the plant. Common treatment methods include sand filtration to remove insoluble solids, active carbon filtration to remove colour, and membrane filtration to reduce dissolved salts and organic matter.

Ion exchange techniques may be used to soften the water or reduce its alkalinity. Plants with high water consumption, for instance during start-up and cleaning cycles, route treated product water to a buffer tank to ensure sufficient supply. The reconstitution step, referred to as the blending step, is carried out batchwise in line 1.

The concentrate is diluted with water in large agitated tanks. A batch is prepared in one tank while product is pumped from another tank to pasteurization after sampling to check Brix value. Pulp slurry and sugar solution for nectars and fruit drinks are added in the batch tank along with the concentrate.

Other ingredients may be added directly to the batch tank but are often prepared as a pre-blended mixture in the drink preparation area. In line 2, treated water and concentrate and other ingredients are fed continuously to the in-line blending system and mixed en route to the pasteurizer.

The critical parameter, usually Brix of the final product, is monitored constantly. The control system adjusts flow rates of the respective components to maintain the target Brix value.

The total flow of blended product, routed via a buffer tank, is adjusted to suit pasteurization capacity. A deaerator removes free air and dissolved oxygen from the juice. Most of the heat used is recovered from cooling pasteurized juice. Additional energy is supplied by circulating hot water heated by steam. During cleaning, start-up and any operating failure, the flow is recirculated over the pasteurizer.

In most cases, pasteurized product goes directly to the filler, from where any overflow is returned to the pasteurizer. A buffer tank between pasteurizer and filler ensures that variations in filler operation do not affect upstream processing and that continuous adjustment of pressure and flow can be made to suit the filling capacity.

Buffer capacity is required for certain filler types. The buffer tanks should be of aseptic design to avoid microbial recontamination of product. One pasteurizer system can feed product to one or several filling machines. The same type of pasteurizer yielding commercially sterile product is used for both aseptically filled juices and non-aseptic juices intended for long shelf life under chilled conditions.

A different pasteurizer design is used for hot filling. Sugar supplied to a plant in liquid form can go directly to on-site buffer storage, whereas granular sugar has to be dissolved in water to obtain a solution of specified Brix content.

Small quantities of ingredients for the production of nectars and fruit drinks may be premixed before routed to the blending section. Sugar dissolving and ingredient mixing are usually carried out batchwise.

Effective cleaning of all process line equipment is essential for good operational results. The cleaning unit supplies the required solutions and controls the cleaning sequences. A large central unit may clean the whole plant, or there may be locally placed units for cleaning different parts of the line.

Operators control individual processing units via panels located near the equipment or from a central control room where the whole process line is supervised. The automation system may supply online information to management along with regular reports and may be directly linked to the production scheduling department.

Processing lines using not-from-concentrate NFC as raw material are shown in lines 3 and 4. Solid frozen NFC is liquefied before processing. Rapid thawing is achieved by initial heating in a tunnel followed by tipping the drum contents into an ice-crusher. The ice slurry is then melted in a tubular heater.

Juice in tanks and aseptic bags is liquid and can be pumped directly to buffer tanks. Aseptic bags are emptied via a hose pump inserted into the top of the bag or using a pump connected to the emptying spout at the bottom of the bag.

Liquid NFC goes to buffer tanks. Here, juice of different origins may be blended and pulp added. Pasteurization and other downstream processing steps are carried out in the same way shown in lines 1 and 2 for reconstituted juice. A certain on-site stock of raw materials is required to ensure smooth production and avoid unplanned stops. Stocks are generally kept as small as possible to minimize storage space and inventory capital.

However, stocks are also used to take advantage of market conditions when changes in supply prices are forecast. Raw materials arrive in several different forms. Concentrate for high-volume production arrives by road tanker. Other raw materials may arrive in frozen drums and aseptic bag-in-box containers.

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Socioeconomic progress, diseases, and the constantly changing pace of life and lifestyles of consumers worldwide require food to be improved and tailored to meet the needs of purchasers. The produced food is functional, convenient, and enriched. This is achieved, i. Nowadays, food additives are very widespread in the human diet, but not all of them are synthetic and invasive on human health. All food additives, and their application and dosage, are subject to strict regulations.

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Juice packers process concentrate and NFC juice and fill the end product into consumer packages. Cost-efficient operation and gentle product treatment are essential.

Food processing is the transformation of agricultural products into food , or of one form of food into other forms. Food processing includes many forms of processing foods, from grinding grain to make raw flour to home cooking to complex industrial methods used to make convenience foods. Primary food processing is necessary to make most foods edible, and secondary food processing turns the ingredients into familiar foods, such as bread. Tertiary food processing has been criticized for promoting overnutrition and obesity, containing too much sugar and salt, too little fiber, and otherwise being unhealthful in respect to dietary needs of humans and farm animals. Primary food processing turns agricultural products, such as raw wheat kernels or livestock, into something that can eventually be eaten. This category includes ingredients that are produced by ancient processes such as drying , threshing , winnowing , and milling grain, shelling nuts , and butchering animals for meat. Contamination and spoilage problems in primary food processing can lead to significant public health threats, as the resulting foods are used so widely. Secondary food processing is the everyday process of creating food from ingredients that are ready to use. Baking bread , regardless of whether it is made at home, in a small bakery, or in a large factory, is an example of secondary food processing.

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Personal food, plant and animal product imports

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Fruit juice manufacturing process

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Processing at the juice packer

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Both common almond, soy, coconut, and rice nondairy milk alternatives as well as less common peanut, pea, oat, and other nondairy milk alternatives are described, as well as their manufacturing steps and quality control. History, Market, and Nutrition Plant-based milks have a long history in many cultures around the world. Of all the plant-based milks, coconut milk has the longest tradition of use. It originated in India and Southeast Asia and has been used as both a drink and an ingredient for nutrition and ceremonial offerings.

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