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The Changing Face of Beverage Processing
The Changing Face of Beverage Processing
B
everage processing’s primary goal a fresh-tasting refrigerated beverage that hotter the treatment is, the more shelf-sta-
is to ensure a safe product and shelf costs both creator and consumer a premi- ble the final beverage product becomes.
stability. That of course means elimi- um or a retorted, overcooked tasting juice The specific time and temperature re-
nating pathogens and greatly reducing that is economical to make and can last for quired to ensure commercial sterility and
or eliminating spoilage bacteria. Three years on the shelf. The beverage creator’s stability are directly related to the pH of
processing methods – thermal, pressure, choice of trend will dictate the optimal that product. If a product is above pH 4.6,
and chemical – offer almost unlimited op- processing method, packaging material, it must be retorted for shelf stability; with
tions for meeting the demands of today’s storage conditions, and final price for the a pH below 4.6, a hot fill is enough. Wa-
beverage trends and nutritional choices. product. ter activity – controlled products, usually
From creamy high-protein smoothies to very high in sugar and brix, have minimal
vitamin-infused energy drinks, beverage An Array of Options water available for bacteria to grow. If a
creators can “pick their poison.” It might be Beverage makers should consider all beverage has a water activity below 0.85
three major processing options when cre- and a high pH, it may not need any thermal
ating a product. processing, just some preservatives – that’s
the scenario for beverage concentrates
The Chemical Appeal: As clean label with a high sugar content.
products become the norm, a beverage Even so, spoilage can occur depending
brand may want to avoid ingredients like on the water activity. Most beverage crea-
potassium sorbate or sodium benzoate tors seek the lowest time and temperature
on the ingredient label. However, signifi- process possible as they aim to retain fla-
cant cost benefits of this shelf-stable proc- vor, color and vitamins. They often must
ess sometimes make it a viable option to compromise some of the product’s at-
consider. Products that are high in acid tributes, however, to achieve shelf stability.
and sugar (like soda) or that “contain less The FDA requires that a “processing
than 10%” juice are prime candidates for authority” make decisions about time and
chemical preservation methods. The low temperature for beverage processing.
nutrient environment, sugar, acidity, and Chapter 21 of the Code of Federal Regu-
preservatives are enough to ensure shelf lation (CFR) 113.83 defines the authority
stability for up to one year. Chemically as having “expert knowledge of thermal
processed beverages are inexpensive to processing requirements for low-acid and
manufacture, because they can be made acidified foods in hermetically sealed con-
on production lines that are not set up for tainers.”
thermal processing. Chemical processing
should be considered by manufacturers of High-Pressure Processing (HPP): HPP, oth-
inexpensive products that are marketed to erwise known as non-thermal pasteuri-
consumers who are not as concerned with zation, is the latest and fastest-growing
nutrition, clean labels and sugar content. beverage category. It’s not just a trend but
❯ Juice and smoothie producer Fruitapeel
a “new product segment,” according to
has opened a new HPP facility, which The Thermal Approach: All beverage Avure Technologies, a leading manufactur-
it claims will make it the only UK products are made with ingredients – like er of HPP products. The non-thermal proc-
manufacturer able to extract juice directly fruits, vegetables, nuts, and seeds – that ess complements current consumer tastes
from the citrus fruit, bottle it and apply can support both spoilage and pathogenic for juice smoothies, detox beverages, co-
the HPP process from a single site. bacteria. Bacteria growth is influenced by conut water, and functional beverages – all
of which rely on great flavor, clean labels, ucts often come in cartons, and the retort willingness to pay, and the ultimate goals
and nutrient retention to encourage sales. works well with special foil pouches, glass, for the deliverable product.
The HPP process applies high pressure and metal cans.
of 400 to 600 mPA for 1 to 10 minutes, The HPP process can be used only with The Fruits of High Pressure: Fresh fruit and
thereby reducing several log cycles of plastic containers because in order to cre- vegetable smoothies are showing up un-
spoilage microorganisms and pathogens. ate 87,000 psi of water pressure, the HPP der the HPP process because it delivers
Hiperbaric, another leading manufacturer equipment must also compress the water the best flavor and nutrient value that con-
of HPP products, explains the science: by 15%. That means the packaging mate- sumers are willing to pay for. However, en-
“HPP is able to break, or create, weak rial also must have a minimum of 15% flex- ergy drinks (with vitamins and caffeine) are
bonds (hydrophobic and electrostatic ibility. Glass has no flexibility – it breaks. often made via hot-fill or pasteurization be-
interactions), only present on macromol- If a plastic container is too rigid, it too cause consumers of those products gen-
ecules. It allows microorganism inactiva- can crack or at least be stressed, thereby erally focus less on fresh taste and flavor
tion without modifying the food nutritional changing the appearance of the package. than on the stimulating effects. Smoothies
quality and without significantly reducing The choice of processing does dictate are most flavorful when delivered via HPP,
the enzymatic activity.” packaging to some extent, but a compa- but the cost is prohibitive and if protein is
HPP produces safer products with a ny’s design and marketing plan also play the main attraction, then developers don’t
longer shelf life because it inactivates veg- a big role. mind cutting costs and opting for a more
etative microorganisms while retaining fla- Many artisan start-up companies want shelf-stable retorted product. Probiotic
vor and nutrients. to give the impression that they have a low beverages that involve dairy and yogurt
Thermal pasteurization degrades vita- carbon footprint and prefer to use light- are typically pre-pasteurized to eliminate
mins, antioxidants, and polyphenols, but weight recyclable plastics and cans rather pathogens and then re-inoculated with the
the HPP process retains them at levels al- than heavier glass bottles. Foil pouches, beneficial bacteria. Those products cannot
most as high as that of the fresh, unproc- such as those often used for baby food, be post-pasteurized (because that would
essed juice. are not recyclable but are very lightweight kill the probiotics) and must be refrigerat-
and, therefore, consume less energy relat- ed to ensure that the good bacteria thrive
It’s All in the Package: The most common ed to shipping. for the entire shelf life.
packaging options in today’s beverage In the HPP category, the most common
market are glass and plastic bottles, metal Entrepreneurial Trends offerings are functional smoothie blends,
cans, flexible pouches, and coated cartons. With the array of options for creating ei- detox drinks, and fresh fruit-plus-vege-
Pasteurized, ESL-, and UHT-processed bev- ther shelf-stable or refrigerated products, tables combinations. The HPP process is
erages are usually filled into cans, pouch- beverage makers have to consider the cost crucial when marketing drinks that include
es, glass bottles, or cartons. Aseptic prod- of making the product, the consumer’s heat-sensitive ingredients like vitamins
and enzymes. Even more important, HPP provide consumers with a variety of tastes. of the mainstream kombucha brands add
retains fresh flavors and creates a fresh- Most kombucha products are ferment- strong flavors like grape, ginger, vanilla,
tasting juice experience. ed in glass bottles, which several manu- and apple to appeal to the masses.
facturers tout as a benefit (contending
Fermented Kombucha Drinks: Kombucha, that fermentation in plastic bottles makes Herbs and Spices: The beverage market
a probiotic-fermented tea beverage, com- chemicals leach out of the plastic and into has begun to tap the known medicinal and
bines tea, water, sugar and kombucha the drink). It is a subject of debate whether antimicrobial properties of herbs and spic-
bacteria cultures (or “scoby,” a mixture of all the probiotic organisms can truly sur- es. Several HPP detox blends, such as Suja
bacteria and yeast). The bacteria and yeast vive the bottling process and maintain the and Blueprint, include cayenne, mint, cinna-
ferment the sugar, yielding an effervescent claimed health properties, which include mon, ginger, and red chili peppers. Tumeri-
drink that is low in sugar. The beverages greater vitality, digestion detox, immunity cALIVE has a line of HPP-processed sport
often incorporate herb and fruit flavors to protection, and weight-loss potential. Most beverages that contain turmeric in combi-
nation with other fruit and vegetable pu-
Table 2: Up and Coming Ingredients for Beverages rees. Popular vegetables in detox smooth-
ies include kale, spinach, cucumber and
Ingredient Types Claims celery. Lemons, limes, and ginger are used
to sweeten the beverages naturally and to
Cinnamon Lowers blood sugar, fiber source
improve overall flavor and palatability.
Turmeric Anti-inflammatory
Herbs and Spices Vinegar Drinks: For more than 50 years, Pa-
Mint Helps digestion and irritable bowel syndrome tricia and Paul Braggs have been promot-
ing the health attributes of raw vinegar and
Ginger Nausea remedy for pregnant women
encouraging their customers to drink their
Insects Ground-Up Cricket Flour Sustainable protein source 5% acid apple cider vinegar as a beverage.
Vinegar drinks are now becoming more
Vegan and allergen free protein with all 9 widely accepted as other companies begin
Hemp Protein
essential amino acids
Cannabis to market similar drinks. PokPok, based in
Hemp Oil Omega 3 and omega 6 Portland, Oregon, sells its vinegar drink as
a concentrate that can be added to water
Black Tea Energy, antioxidants or club soda. Another beverage company,
Tea Gravity, has a more mainstream approach
Matcha Green Tea Powder High in fiber, antioxidants, fat burner of combining a small amount of apple cider
vinegar with regular apple cider. The drink
Vinegar Apple Cider Vinegar Energy, vitality, digestion, well being is sweetened with honey and xylitol to make
Maple Phytonutrients it more palatable. Consumers who favor the
harsh vinegar acidity may prefer drinks like
Plant Waters Barley Digestion, well being Braggs or Kevita, which has 30 grams of ap-
ple cider vinegar per bottle.
Artichoke Vitamins, potassium