1. Process flow: raw material selection → cleaning and sorting → crushing → pressing → coarse filtration → clarification → fine filtration → adjustment of sugar acid → degassing → sterilization → packaging.
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2. Technical points:
(1) Incoming and intermediate storage of raw materials: It is usually purchased in bulk or large baskets. Use the company's internal warehouse for intermediate storage.
(2) Cleaning and selection: Before processing, the apple raw material must be cleaned and selected to remove dirt and decayed fruits. Juice processing companies generally use water-flow troughs for pre-washing of apples, which are typically done with jets of water on vertical or horizontal screw conveyors. Brush-type fruit washing machines also clean apples. Before or after washing, it is manually selected on the conveyor belt. Corrupted raw materials cannot be used to process apple juice.
(3) crushing and pulp processing: broken apple should meet the juice extraction process requirements. With a wrapper juicer, the particle size of the pulp should be fine, preferably 2 to 6 mm; and when using a chamber type, belt or spiral juicer, the size of the pulp should be larger. Keep the size of the pulp until the juice is started. The pulp is sent directly to the juice without intermediate storage.
The enzymatic treatment is to rapidly heat the pulp to 40-45°C, stir in the container for 15-20 minutes, ventilate (pre-oxidation), add 0.02%-0.03% high activity enzyme preparation, treat at 45°C for 3-4 hours and batch Stir slowly. The rate of juice production from apple juice with enzyme treatment was significantly increased.
(4) Juicing and leaching: There are many types of juicers suitable for apples. The pulp in the juicer is in motion, and the apple juice thus obtained contains a large amount of polymers. The juice yield of mature fresh raw materials ranges from 68% to 86%, with an average of 78% to 81%. Stored raw materials or over cooked raw materials, the juice yield dropped significantly. Add juice additives or enzyme treatment can increase juice yield. Apples contain 1.5% to 5% of water-soluble substances, in theory, the juice can reach 95% to 98.5%, but by the squeeze method, the apple's average juice yield can only reach 78% to 81%, apple residues still contain Part of apple juice. After juicing, the larger pulp particles in apple juice are usually removed by centrifugation.
(5) Clarification and Filtration: The clarification process of apple juice is very important. If it is handled improperly, turbidity and sedimentation will easily occur in the finished product. If it is stored apple raw material, using hydraulic juicer or screw juicer press, apple juice more likely to appear precipitate or turbidity. Enzymatic treatment not only completely decomposes macromolecules, pectins, pulp granules and cell debris, but also decomposes simple compounds fully dissolved in galacturonic acid or galacturonic acid. Therefore, the apple juice clarification must be carried out using enzyme preparations, clarifiers and their treatment processes. Clarifiers commonly used in apple juice are gelatin and gelatin-silica gel bentonite compound clarifiers. A pre-clarification test is performed prior to treatment to determine the optimum amount of clarifier added. The amount of clarifier used is generally gelatin: silica gel: bentonite=1:10:5. In the clarification treatment, the gelatin solution is first added, mixed uniformly and precipitated for 1 to 2 hours before the silica gel solution is added.
The clarification of apple juice must also consider whether apple juice contains starch. As long as there is residual starch in the apple raw material, it will greatly affect the clarifying effect. Heating the apple juice above 60-65°C before clarification will reduce the effect of starch on clarification. With a special amylase preparation or a pectin decomposing enzyme preparation with a certain amylase activity, the water-soluble starch in the juice can be decomposed, and the amylase preparation is usually added in an amount of 2 to 3 g/100 liters of juice, which can be used under special circumstances. Increase the amount until a satisfactory enzyme treatment effect is achieved. The amylase treatment temperature of the juice should not exceed 35°C. Both the amylase and the pectinase can be used simultaneously. Enzymatic treatment of 6 to 12 hours can completely decompose the starch in the juice. The clarified juice is filtered using a plate and frame filter or a diatomaceous earth filter.