Beverage production line filling method
The hot filling of beverage production line is to fill the product into the bottle at a temperature of about 90 degrees after high temperature sterilization, and screw the cap, and use the temperature of the beverage itself to carry out the final sterilization of the bottle and cap. In this way, the product will remain in a high temperature state for a long time, but this process will have a certain impact on the taste and nutrition of the product.
The cold filling of the beverage production line is to first sterilize the product at ultra-high temperature, and then cool it to room temperature, and then fill the product into the bottle after sterilization with hydrogen peroxide in an artificially created sterile environment, and the bottle cap also needs to be tightened after sterilization with hydrogen peroxide.
Cold filling this way has a relatively small impact on the taste and nutritional quality of the product, and the amount of material used is relatively small, but the cost of cold filling is about 1 times more than that of hot filling.
Juice beverage production line
Step 1：Dilute
The first step in starting your juice production journey is dilution. We must first take out the defrosted concentrated juice, and then strictly refer to the requirements stipulated in the formula, add an appropriate amount of pure water into it, so that the concentrated juice can be better diluted, achieve the ideal concentration required by the subsequent process, and lay a good raw material foundation for the entire production process.
Step 2： Filter
In the diluted fruit juice, there are generally some suspended solids or impurities, so the mission of filtration is to remove these “uninvited guests” that affect the quality of the juice.
After careful filtration treatment, the juice can present a clear and transparent appearance, and the appearance is better.
Step 3：Uniformity
The filtered juice still needs to go through the homogenization process. As you can imagine, if the ingredients inside the juice are not uniform and stable, the taste and texture of the final product will definitely be greatly reduced.
We will homogenize the filtered diluted juice, so that the various ingredients in the juice are fully mixed and evenly distributed, and in this process, the homogenization pressure must be controlled within the specific range of 20-25MPa to ensure that the juice reaches an ideal state of uniformity and stability.
Step 4：Dissolve sugar and strain
This link is mainly carried out in the sugar dissolving tank, we first need to turn on the blender, add the right amount of water to the tank, and then according to the clear requirements of the formula of white sugar. The way of dissolving sugar is divided into two kinds, respectively, hot melt and cold melt, the specific choice of which, according to the specific needs of the actual production process to determine.
After the sugar is dissolved, we also have to filter the sugar liquid, generally speaking, the method of diatomaceous earth filtration will be used to ensure the purity of the sugar liquid.
The dissolution and filtration operation of other auxiliary materials is generally similar to the process of white sugar, which should be strictly implemented in accordance with the corresponding standards to prepare high-quality raw materials for the subsequent deployment process.
Step 5: Deploy
When all the above processes are completed in an orderly manner, we need to put the previously carefully diluted juice, properly dissolved and carefully filtered sugar liquid, as well as the equally processed auxiliary materials, all into the mixing tank, and then by fully mixing and stirring, so that they can better integrate together, and complete the constant volume operation. After that, add flavor, pigment, etc. in accordance with the amount specified in the formula, and stir well again.
At this point, the juice has basically completed the preliminary deployment work, and has taken an important step toward the final product.
Step 6: Filter
When the liquid is prepared, the liquid must be guided again through the filter bucket connected to the pipeline, and again a meticulous filtration operation, not to miss any point that may exist suspended matter and impurities, only after such a strict filtration operation, in order to make the beverage clear and transparent, uniform texture, and eliminate the phenomenon of precipitation
Step 7: Kill bacteria
The filtered beverage will be transported to the UHT sterilizer, where they have to undergo a “high temperature test”, the sterilization temperature will be controlled in the range of 130-135°C, and the duration must be maintained at 4-6 seconds, not only that, the steam pressure of the sterilizer must be no less than 0.8MPa.
Through the above operation, those harmful microorganisms that affect the quality of the beverage will be eliminated, ensuring the safety and quality of the product to meet high standards.
Step 8: Wash
After the beverage is processed, we have to carry out a comprehensive cleaning of the bottle to prepare it for filling.
The bottle waiting for filling will be sent into the bottle washing machine, and a variety of water washing and cleaning procedures will work in an orderly manner to remove the dust and dirt that may be hidden in the bottle. In order to ensure that it is no longer contaminated after cleaning, the cleaning link of the bottle is often combined with filling and packaging, which is jointly developed in the “three-in-one” filling machine.
Step 9: Filling and capping
There are two main ways of filling: aseptic cold filling and aseptic hot filling, but for our juice drink, after comprehensive consideration, aseptic hot filling is often chosen. Generally, the temperature during filling can not be lower than 90 ° C, and the temperature inside the bottle after filling can not be lower than 85 ° C. Only by reaching such a temperature standard can the product quality be better guaranteed. After the filling is completed, it can not be delayed, and the capping operation must be carried out immediately.
When the cap is closed, it is necessary to carefully adjust the appropriate torque of the cap head to ensure that the seal of each bottle is tightly sealed and there will be no leakage.
This link is also completed in the “three-in-one” hot filling machine, and the various steps are closely linked and completed in one go.
Step 10: Pour the bottle
After the filling and capping are completed, we should immediately put the bottle upside down after the hot filling of the product.
The purpose is using the temperature remaining after the filling of the beverage to sterilize the bottle and the cap again, which is equivalent to another insurance for the product quality.
Step 11: Light inspection
After the above series of processes, the product will accept the “physical examination”. The staff will check each bottle by themselves through the lamp inspection machine, check whether there is dirt, impurities, and whether the seal of the bottle is intact. This step is an important line of defense for good product quality.
Step12: Cool down
When the product successfully passes the lamp inspection, the final is the cooling link. We will let the product through the cooling tunnel, as if to blow a “cool wind”, the temperature of the product quickly reduced to (38 ± 2)℃, and the product to achieve the appropriate storage and subsequent transportation conditions, so that the entire production process is basically completed.
