Processing of cashew apple beverages

report submitted towards partial fullfilment of the requirements for the

degree of

BACHELOR OF TECHNOLOGY
IN
FOOD TECHNOLOGY

Submitted to

AMITY UNIVERSITY, UTTAR PRADESH

BY
PURVA SHARMA

B.Tech Food Technology (2016-2020)

Enrolment no- A4312616068

Under the guidance of

DR. NEHA SHARMA

Professor, AIFT

AMITY INSTITUTE OF FOOD TECHNOLOGY

I-1 BLOCK, 4TH FLOOR, AMITY UNIVERSITY
SECTOR-125, NOIDA201303, U.P.

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 DECLARATION BY CANDIDATE

I here by declare that the project entiltled “PROCESSING OF CASHEW APPLE

BEVERAGES’’ submitted by me to Amity institute of food technology, in partial
fulfillment of the requirement for the award of the degree of B.TECH (Food Technology)
is a record of bonfide project work carried out by me under the guidance of DR. NEHA
SHARMA. I further declare that the work done in this report is not taken from any other
source. I shall be responsible for any kind of copyright violations in this regard.

Date:
Place:

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 ACKNOWLEDGEMENT

I would like to express my gratitude to my faculty guide DR.NEHA SHARMA for their
constant guidance & support in completing my project.

I would also like to express my gratitude to the head of institution DR.VK MODI for
providing me with all the facility & this opportunity to learn, I came to know about so
many things I am really thankful to them.

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 ABSTRACT

I have done this minor project on topic “Processing of cashew apple beverages”, where I
learned about the major producers of cashew apple, its nutritional benefits & medicinal
too. Also about the stages of processing of frozen pulp, cashew apple squash, its jam, its
pickle & many more industrial products.

& how India is constantly working to reduce the wastage of cashew apple with the help
of government & also other countries too.

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 TABLE OF CONTENTS

NO. TOPICS PAGE NO

1) Introduction of cashew apple 6

2) Major producers 7

3) Physico-chemical properties & Effect of ripening stages 8

4) Cashew the nut that is not a nut 9

5) Stages in processing frozen pulp 10-14

6) Preparation of cashew apple syrup, squash, jam, pickle 14-16

7) Cashew apple agricultural uses 17

8) Preparation of alcoholic beverages 17

9) Various industrial products 18

10) Limitations of cashew apple in product development 19

11) Cashew apple waste usage 20

12) India’s focus on cashew apple waste usage 21

13) Conclusion 22

14) Refrences 23

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 1) INTRODUCTION

CASHEW APPLE
Grow on the tree Anacardium occidentale L .It is a by-product of the cashew nut
industry. In most Spanish countries it is known as maranon , in Venezuela known as
Merey, & in Portugese it is known as the Caju. It is bushy, low-branched, & spreading
(10.6m in height & width) , leaves (10-20cm) long & (5-10cm) wide.

It is native to and northeast Brazil and, in the 16th Century. It’s the portugese leaders who
first took the cashew from brazil to India(Goa) & then to Mozambique(Africa) in 16th
century & from how this it spreads to others parts of east Africa & Angola & also to the
south-eastern asia & northern Australia. It is planted in warm regions and a few fruiting
specimens are found in experimental stations and private gardens in southern Florida.

Its production & processing is difficult as because of the toxic shell oil.Latin Americans
& west Indians are trying from so many years to obtain a tender ,juicy & tasty cahew
apple and then throw away& processed it on a limited scale but when it comes to brazil
they have a highly developed cashew nut processing industry. Apple has been dominant
for decades in Mozambique, then the nut .

When ripening occurs the apple & nut fall together. But in commercial nut plantations,
generally we twist off the nut & then leave the apple on the ground. Whereas in some
areas the apple are collected & taken to the market processing. Still in some area of India,
especially in Goa the apples are smashed by foot to obtain a juice for locally famous
distilled liquor, feni. In Goa, India, the apples are still trampled by foot to extract the
juice for the locally famous distilled liquor, feni.

It is attacked by yeast & fungi at room temperature which can cause spoilage. For 5
days it can be maintained at 32 ° to 35° F & relative humidity of 85% to 90% according
to food technologist. The juice is slightly acidic or bitter as due to 35% tannin content
and because of 3% oily substance. Before converting it into a jam or chutney or juice the
fruit is boiled for 5-15 minutes.

Food engineers in Costa-rica is able to develop a process for producing the candied, sun
dried cashew apples. Unable to remove the tannins from the juice leads to the nutritional
deficiency as tannin prevent the assimilation of proteins in body.

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2) MAJOR PRODUCERS

India comes in number one rank when it comes to the largest single producer of cashew
nuts , when it comes to regional producer West Africa-Ivory, coast, Benin, & guinea-
Bissau comes in list.The major sources for production are Vietnam, Brazil, & east Africa
The major producer & exporter in southeast Asia has become Indonesia.The countries
which grows cashew trees are Indonesia, Tanzania, Kenya, Mozambique, Benin. Guinea-
Bissau, Ivory Coast, Nigerai.

According to (Indian horticulture database, 2010) cashew is cultivated in india in an area

of 9,23,000 ha & production of 613,000 MT & productivity of 0.7 MT/HA. In cashew
production Maharasthra is leading in terms of production 198,000 MT having 32% share.
It is also grown in west coast, east coast & in some areas of Karnataka & Madhya
Pradesh. India ranks on number one position of cashew production with 25.52% share in
the world.

Its processing & agrarian sector gives employment to 3 lakh persons in which women
share 95% or more than that. In Asia, Africa, Latin America it is basically cultivated.
Vietnam is the first largest exporter after that India comes having 34% of the world’s
export of kernels. it was seen in 2009, that India exported 446 of cashew kernels.

Apart from all of these the cashew tree helps in many other work such as it supplies
timber, Firewood, medicines, fooder, etc.

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 3) PHYSICO-CHEMICAL PROPERTIES OF CASHEW
APPLE

The different species of cashew were grown & analyses of the juice was done in which it
was found 10 mineral in which seven were macro-minerals & three were trace elements.
It was in order of K>P>MG>S>NA>SI>CL, whereas the arrangement of trace elements
was not in order.
It was also noticed that minerals were not in free state but in a oxidized state containing
oxide contents in the apple. A analyze was done in Ghana, where the juice from red &
yellow cashew apple were taken & it was noticed that it contains potassium-76.0 which
was highest, then calcium-43.0, then magnesium- 10.92, then phosphorous-0.79 & then
sodium-0.41.
Whereas the other minerals like Zinc, Copper, & Iron were in less concentration ranging
from 0.05 to 0.08 mg/100 ml. It is due to the soil conditions, Cultural practices, &
Climatic conditions like temperature, humidity etc that the variations in the physico-
chemical properties of cashew apple were noticed.
Various tests were done like Vitamin C, Total sugars, glucose, fructose concentrations,
tartaric acid, citric acid, etc showed that expect PH the colors of apple influenced the
parameters that, more red elongated variety shows higher carotenoid levels as compared
to yellow one.
During the interval of 15 days randomly physical-chemical tests were done in cashew
apple. Through chemical tests we can determine the total acidity,Vitamin C, Phenolic
Compunds, PH, Soluble solids, moisture,Ash, Protein, Fiber, Iron, & phosphorous etc.

3.1) EFFECT OF RIPENING STAGES

Cashew apple have 3 different maturity stages:

1). Unripe fruits grow for 33 to 36 days.
2). Medium-ripe fruits grow for 45 to 50 days
3). Ripe fruits grow for 52 days
It was examined according to the phenolic content,ascorbic acid content & antioxidant.
It was found out that quantities of phenolic compounds are higher in immature cashews
& in ripening process it decreases. The main flavonoid present in them were 3-

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ogalactoside quercetin, Myricetin-3-o-rhamnoside Myricetin-3-O-rhamnoside in all
phases.
As the ripening increases its anti-oxidant capacity & ascorbic acid concentration
increases. The ascorbic acid influence the anti-oxidant activity more than the phenolic
content. It was noticed that Yellow flavonoid content was higher in ripe. The polyphenol
content is mainly responsible for the antioxidant activity of cashew apple.

4) CASHEWS : THE NUT THAT IS NOT A NUT

The cashew is basically a seed which is harvested from the cashew apple , basically it is a
fruit which grows on cashew tress, so we can say that it is technically not a nut.
It also grows outside the fruit , not inside in a kidney shaped drupe & it hangs on end of
cashew apple’s base.

Toxicity- You will be surprised to know that raw cashews has urushiol which is basically
a resin & if we ingest it, it can cause rashes & burns if it comes in contact with the skin.

So in industries, to remove this toxicity it goes through a rigorous roasting or steaming sp

that it can become safe to eat. Only due to this reason you have always seen cashews
shelled at a grocery store. & it will very surprised to know that also before this roasting
process cashews have a beautiful green shade color.

The family to which magoes, poison ivy, & pistachios belongs, cashews belongs to the
same.

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5) STAGES IN PROCESSING FROZEN PULP

HARVESTING

TRANSPORTING

RECEIVING & WEIGHING

WASHING & SORTING

EXTRACTING NUTS

SHREDDING

EXTRACTING JUICE

CLARIFYING

FILTERING

PREPARING FORMULATION

HEATING

PACKAGING

STORING

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1). HARVESTING – Harvesting time can be noticed by color, firmness & its
composition. Or we can also say that it take place when apples are fully grown.
When they attain their maximum size & become firm & attain desirable color.

Also we need to make sure that apple should be fully riped as cashew’s have climacteric
ripening in which ripening does not continue after harvesting, when they are fully riped
they have their best taste & aroma, less acidic, its sugar content.

Therefore harvester should daily observe the apples as apples will detach from its tree as
it becomes ripe

2). TRANSPORTING - Cashews has to transported in a crates which should not be

deep much to prevent from smashed fruits, damaged texture, & loss of juice. Such crates
can hold up to 17.6 L, measuring 0.5m×0.22m.

Then it should be carefully placed into a vehicle while stacking, ventilation should be
there between them & one crate should never touch the fruits placed in other crates which
is below them as it could lead to the damage of fruits.

Also make sure not to expose cashew to too much sunlight or high temperatures as it
could lead to loss of water due to transpiration & increased respiration rate.

3).RECEIVING & WEIGHING - Apples are received & then weighing is done in pre-
washing zone & calculation & payment is done. Crates should be washed & dried
adequately before going back to field to avoid deterioration of fruits in next process.

4).WASHING – Now washing is done to remove impurities as it carry from field, during
transportation , handling etc. Also to remove the heat which it absorbs from the moment
it has been harvested & taken to the factory. It carries a lot of microbial load, so to
remove this, fruits are sink in sodium hypochlorite solution for 15 to 20 min in a
concentration of 200 PPM.

5).EXTRACTING NUTS – This can be done by two different ways. In first we use a
nylon string wrapped around the point to which nut is attached & it is pulled out in such a

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way that it does not tear apple. In second we use a small manually operated device by a
clear cut to point by which nut is attached to apple.

6).SHREDDING- After this apples are shredded, it is placed on a shredder which tears
the fruits without ripping their fibers. The juice which is extracted should be placed in a
clean container, it should not be a iron container. After that it is taken to a horizontal
pupler with stainless steel.

7).EXTRACTING JUICE - Before extracting the juice, what matters is the quality of
juice which also depends upon the type of crushing is used for crushing.

A crushing in which the fibers are totally torn apart basically a thorough crushing will
produce a slightly acidic or a bitter juice, but the juice extracted from the light crushing
will have a different taste as compared to last one. Therefore crushing should be done in a
appropriate way.

The most common method which is used for extracting juice in factories is expeller
presses which result in good yield. The expeller presses can be continous or non-
continous. Juice production generally ranges from 60 to 80%, while to obtain a good
quality the percentage should be around 70%. One thing which is important to take care
of is that whenever extraction of juice is taking place in expeller press, immediately filter
the juice after it’s production to remove big fibers.

8).CLARIFYING JUICE – The juice produced must be exposed to clarifying agents

then as to produce a flocculation in suspension when it comes in touch with a tannins.
The clarity of a juice is important factor as it determines the quality of a end product.

There are many clarifying agents available in market such as gelatin, albumen, casein, &
a mixture of gelatin & tannin are also used, but mostly in industries gelatin is used in
900ml of water , 100 g of gelatin is added, then heating is done at appropriate
temperature which ranges from 50 to 60°C as it dissolves the gelatin in water.

Now here comes the question what is gelatin, it is grainy powder, light yellow color,
tasteless & odourless. Basically a collagen (a protein which is extracted from the cow
skin), then it is purified, & marketed.

Now when the gelatin is added to juice its color changes to whitish or milky color, then
more gelatin is added to form a bigger floccules which make juice into just like solid or a
semi-solid milk.

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You can also know whether the clarification process is carried out successfully or not by
just looking out at the color, if the whitish color still is there, then it means that
clarification process is not done properly. maybe due to unable to reach the clarification
point or going past over it. If it is a case of clarification point has gone past, then add
more whole juice, stir it gently so that it can come in contact with gelatin.

If you are not sure what amount of gelatin should be added to obtain a desired quality of
juice, then you can go for pitcher test, this test is nothing but a very simple test in which
samples of juice are put in a glass containers, like a cone shaped with opening facing up,
then different ratio of gelatin is added to find out the appropriate amount.

9) FILTER THE JUICE- This process should be done in a careful way as this is the last
step which will determine the end product quality. In this process, filters are placed over
one another in which cotton pieces are installed , made up of a iron frame or wooden to
collect the juice. If all the steps are done carefully & as recommended then one can
obtain a good quality of 80% of juice.

10) PRESERVATION- Now the chemicals are added to preserve the cashew juice,
additives which are added should be the one which does not cause any harm to
consumers & does not change its properties also. It is very hard or impossible to preserve
the cashew juice without any preservatives at room temperature as shelf life of cashew
juice at room temperature is 48 hour & in refrigeration is max 1 week.

By adding preservatives & keeping it in a refrigeration at 5°C, one can keep it up for 2
months. The preservatives which are used are generally benzoic acid or sodium benzoate
(max-0.1%).

11) THERMAL THREATMENT – It is basically a preservation technique which

stabilizes the juice too. also applied to bottled juice. Make sure that the additives sulfur
dioxide should be only used for pasteurized juice.

12) PACKAGING – Packaging should be done immediately after thermal treatment. It is

packed in different type of containers basically 500 milliliter glass or plastic is used.
Semi-automatic filters are used or one can also hand fill them too, then closed with a
metal cap or screw cap.

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13) STORING – It should be stored in a optimum temperature before it is consumed.
The temperature ranges from 0 to 5°C.

6) PREPARATION OF CASHEW APPLE SYRUP:

Ingredients required for cashew apple syrup:

 Clarified cashew juice

 Sugar
 Citric acid
 Lemon yellow color

Method of preparation:

 Take clarified cashew juice & heat it on a medium flame

 Then add sugar into the clarified cashew juice
 Stir it continuously until sugar dissolves into it completely
 Add citric acid in a little amount of juice & stir it well
 Take out the solution from the flame, wait for some time until it become cool &
then add color
 To prevent the syrup from the spoilage, & preserve it for a long time, store it in a
sterilized glass bottles or PET bottles.
 Store it in a cool dry place
 To make a fresh drink for consumption, dilute it with a cool water five times as
recommended.

6.1) PREPARATION OF CASHEW APPLE SQUASH:

Ingredients required for cashew apple squash:

 Clarified cashew apple juice

 Sugar
 Citric acid
 Water
 Lemon yellow color

Method of preparation:

 Take water & add sugar & citric acid into it as per your required quantity & then
boil it
 Now when it starts boiling at the end, add clarified cashew juice immediately

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  Take out the from the flame, wait for some time until it become cool & then add
color & strain
 To prevent the syrup from the spoilage, & preserve it for a long time, store it in a
sterilized glass bottles or PET bottles.
 Store it in a cool dry place
 To make a fresh drink for consumption, dilute it with a cool water thrice as
recommended.

6.2) PREPARATION OF CASHEW APPLE JAM:

Ingredients required for cashew apple Jam:

 De-tanned cashew apple pulp

 Sugar
 Citric acid

Method of preparation:

 Take sugar & citric acid & add it to a pulp & then heat it continuously with
continuous stirring
 Measure the end point
 Pour the hot jam into a sterilized glass bottles when the end point is reached

6.3) PREPARATION OF CASHEW APPLE PICKLE

Ingredients required for cashew apple Jam:

 De-tanned raw green fruit

 Chili powder
 Fenugreek powder
 Turmeric powder
 Mustard powder
 Green chili paste & ginger paste
 Sodium benzoate
 Citric acid

Method of preparation:

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  Take gingili oil, boil it & put mustard & green chili paste & ginger paste into a
gingili oil
 Add fenugreek powder, turmeric powder, chili powder, mustard powder,
 Add sodium benzoate, vinegar, citric acid & sliced raw green fruit when the color
of chili powder starts changing
 As per required amount add water & salt while doing stirring
 Cover the utensil & allow it to cool
 Then pour it into a dry glass jar & add half tea spoon of gingili oil above it
 Seal the container
 Don’t use it immediately, keep it for one week at least.

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 7) CASHEW APPLE AGRICULTURAL USES:
IN SITU & EX-SITU BIOCOMPOST

Generally what we have seen is that cashew apples are thrown away in plants after taking
out the nut. When it comes to biodiversity sites, the rate of decomposition can be
improved by the soil microorganisms which can further on improve the biological &
physical properties of soil.

In situ & ex situ biocompost can be implemented by using leftover cashew apple with
the recyclable cashew biomass.

8) ALCOHOLIC BEVERAGES:
8.1) CASHEW APPLE FENI:

8.11) PREPARATION-

 It is made by fermentation & distillation process

 Good quality of cashew apples are taken, make sure that they are matured & ripe
 Then juice is extracted or cashew apples are crushed then fermented & then
passed to a distillation process.
 The concentration of alcohol can be adjust according to the requirement through
distillation process.

8.2) CASHEW APPLE WINE:

8.21) PREPARATION-

 First cashew apple are taken then they are washed by passing through a running
water to remove the dirt & debris, then it is immersed in 5% salt solution for 3-4
days
 Then steam is given for 15 min of 15 lb by autoclave
 After that steamed apples are crushed to take out the juice then filter by muslin
cloth
 After that preservatives are added to control or retard microbial growth
 Fermentation process is carried out at room temperature for 6 days at 28-31°C
then (the culture saccharomyces cerevisiae & bayanus is added to the mixture)
 Brix should lie between 2-3°C.
 Then wine is clarified by adding bentonite

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 9) VARIOUS INDUSTRIAL PRODUCTS:
As you know that cashew apple contain many nutrients & polysaccharides which make it
a suitable product for developing different beverages be its alcoholic or non-alcoholic at
industrial stage.

The various product which can be made by cashew apple are shown in flow chart &
various micro-organisms used for making that product are also listed:

CASHEW APPLE

WINE & BIOETHANOL BIOSURFACTANTS PROBIOTICS & LACTIC ACID

TANNASE & PECTINASE EMULSAN SURFACTIN

 For wine & bio-ethanol the micro-organisms used is saccharomyces cerevisiae

 For bio-surfactants the micro-organism used is bacillus subtilis
 For probiotic & lactic acid the micro-organism used is lactobacillus casei
 For tannase & pectinase the micro-organism used is pseudomonas aeruginosa
 For emulsan the micro-organism used is aspergillus spp
 For surfactin the micro-organism used is leuconostac spp.

9.1) BIO-FORTIFIED CASHEW APPLE JUICE:

As you know cashew apple is very nutritious, so if we blend it with other fruit juice it
will improves its nutritional quality. Cashew apple juice can be mixed with other fruit
juices according to the seasons & locations.

Even a new product was developed called “Cashlime” which is made by cashew apple &
lemon juice blending by ICAR. This nutrient rich beverage can be preserved by keeping
it in a refrigerator for 5 months without losing of nutrients. To look upon the cashew
apple juice sustainability & utility Pepsico has tied up with a Clinton foundation.

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10).LIMIATATION OF CASHEW APPLE IN PRODUCT
DEVELOPMENT:
1) Pest infestation – with the cashew apple there has been always a controversy attached
with it that the pest & disease after its so many uses. There are some pests which
attack either cashew apple or its nut or evn both cashew apple & its nut bore. People
have noticed that too sometimes there is crack over the surface on cashew apple it is
due to the attack of fruit flies & microbes.

2) Cashew apple cracking- It has been found that in some reports that cashew apple
which have orientation more towards southern & western sides are more exposed to
cracking between 70 to 80% as compared to the northern & eastern sides. It was also
found in a report that apples borne in upper branches is more prone to cracking as
they are exposed to sunlight more as compared to apples attached in inner branches.

3) Drying of cashew apple & its nut – Still today what are the attributes or reasons
which contribute to the drying of cashew apple & its nut are unknown. There are
many factors which can contribute like genetic inheritance, its toxicity or its nutrient
deficiency which leads to the drying of cashew apple & its nut.

4) Microbial infection – The delicate skin of cashew apple gives entry to the pathogens.

5) Physiology of cashew apple – As you know that cashew apple has a high respiration
rate & have a non-climacteric respiration & ethylene expression rate increases
constantly. If there will be a drastic drop in a ethylene expression rate & sudden
emission of volatile compounds, then it will be a unique stage of cashew apple.

6) Post-harvest spoilage- As I discussed above in microbial infection, that cashew apple

has a very delicate skin which gives entry to pathogens, so basically we can say that
cashew apples are prone to pre-harvest & post-harvest spoilage done by fruit flies
which leads to entry of fungal inoculums.

To prevent the cashew apple from it, it is recommended to dip the apple in citric
acid(0.25%) or use ascorbic acid(0.3%).

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7) Tannin present in cashew apple – You will be surprised to know that tannins are also
known as anti-nutritional factor, which means it interfere in process of protein
assimilation which lead to loss of nutrients. Some people complaint too that when
they consume cashew apple or its juice it gives them a unpleasant bitter or pungent
feeling, it is only due to tannin present in cashew apple. Tannin content present in
cashew apple is 35%.

11). CASHEW APPLE WASTE USAGE

 Brazil agricultural research corporation(EMBRAPA) is doing experiments by

mixing fermented cashew apple & manioc powder together to make it for or use
for animal feed.
 Even you will be surprised to know that it has also registered patent for process of
extracting pigments to use as a natural color.
 Even we can make bread, snack bars, & meat based products from cashew apple
fibers it has also made a natural colorant from cashew apple.

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12). INDIA’S FOCUS ON USAGE OF CASHEW APPLE
WASTE –
Prime minister of India Mr Narendra Modi has challenged in one of its event which was
held in IIT Bombay to utilize the cashew apple better for better future for industries &
farmers which can contribute to the economy too if properly done.

The KCMA(Karnataka cashew manufacturers association) has accepted the challenge &
requested prime minister to appoint a team from various industries & researchers to find
out how cashew apple wastage can be utilized in a better way.

According to president of KCMA our country produce 40 lakh tones of cashew apple, out
of which 98% goes to waste. Even requesting government to implement laws as due to
the certain laws only Goa is able to produce cashew feni by distillation process whereas
others states are not.

He also even said that their organization buys cashew apple from farmers & are ready to
buy even more.

It is right time to focus on utilization of cashew apple waste in a better way now, because
ultimately cashew apple industry will expand & more jobs will be developed in rural
areas, it will also increase the demand for farmers & their increase in salary.

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13).CONCULUSION
Through this project “processing of cashew apple beverages” I get to know more about
cashew apple in depth, its physical & chemical properties , it is highly nutritious product
with many medicinal properties which can be utilized more.

If properly utilized then there is a potential market for cashew apple & its products at
national & international level. No doubt that cashew apples comes with many limitations
too but if we are able to cover all that through certain physical & chemical steps then we
will be able to bring out the excellent cashew apple in terms of quality & palatability.

We also found out that where we are lacking is that we are not utilizing cashew apple for
its economic production of by-products expect in Goa which made cashew feni by
distillation process. So basically we can say too that it is exploitation of effective source
of revenue for cashew growers

It has a economical potential for farmers, consumers, industrialist too

So cashew apple is one of major topic for which food technologist , industrialist &
farmers should develop a strong desire for research.

There are the various products which can be made by cashew apple such as cashew apple
squash, cashew apple syrup , cashew apple pickle, cashew apple jam, cashew apple wine
& cashew apple feni etc.

Thorough this project we also get to know about EMBRAPA(Brazil) is continuously

trying or experimenting to find out the alternatives about the usage of cashew apple waste
& India is trying too how to reduce the 98% loss of cashew apple.

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14) REFRENCES
1) www.actahort.org
2) https://edias.ifas.ufl.edu
3) Indianresearchjournals.com
4) www.thepharmajournal.com
5) https://www.africancashewalliance.com
6) https://Cashew.icar.gov.in
7) https://www.researchgate.net

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mesh(0.5 millimeter opening) as to remove fibers from pulp

7).EXTRACTING THE JUICE- Another point to be taken into account in what

concerns the quality of clear juice is the

type of crushing applied to extract juice. A thorough crushing, in which fibers are torn
will
produce more astringent juice, thus resulting in a product with different taste as
compared to the one obtained through light crushing. Nonetheless, crushing must
be
done in a rationalized way, aiming at producing good yields and satisfactory juice
quality,
free of excessive amounts of tannins.

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WATER TREATMENT PLANT
Water treatment plant is one of the important part of beverage industry as it is used for
carbonated soft drink (92%) water. Before it goes into the production area, raw water is
treated in WTP, hard water is converted to soft water . the main chemical which is used
in water treatment plant are HYPERSPERSE MDC220, calcium hypochloride , KLEEN
MCT515.

Flowchart
BOREWELL

U.G TANK (550KL)

CHLORINE (2-4ppm)

PUMP

PRESSURESAND FILTER
PRE-RO SYSTEM

ACTIVATED CHARCOAL
PURIFIERFFILTERFILTER

ANTI-SCALING DOSING TANK TO PROCESS

MICRON CARTIDGE FILTER TREATED WATER

HIGH PRESURE PUMP U.V STERLIZER

R.O MEMBRANE MICRON CARTRIDGE FILTER

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 PER WATER STORAGE TANK
POST-RO SYSTEM

Water treatment plant process :

1) BOREWELL- The plant has overall three borewell located at different location of
plant, having depth of 400 Ft & capacity of 60 m3/h each.

2). STORAGE TANK – The Raw water is stored into this. it has a capacity of 550KL.

3). ADDITION OF CHLORINE OR CHLORINE TREATMENT (2-4 PPM) - The

Raw water is treated with chorine or chlorine compounds such as calcium hypochloride .
it kills certain bacteria & other microorganisms , it act as a disinfectant .

4). PRESSURE SAND FILTER – With the help of multiple layers of sand , it filters the
water. Generally it is cleaned monthly by water & sand is changed in a year for efficient
function . In this, raw water is passed to an equipment or a tank which contains the
multiple layers of sand to remove the suspended particles from water . particles & the
larger parcticles present in raw water is not able to pass the filter.

5). ACTIVATED CHARCOAL PURIFIER – In this, a bed of a granulated carbon is

there which absorbs the chlorine & off odour from water , as we know that activated
carbon is good porous material. Generally, it is cleaned by steam monthly & changed
yearly.

6). ANTI-SCALING DOSING TANK- Hypersperse Mdc22o chemical is used for

anti-scaling tank. Removal of chlorine take place in dosing system. It is developed to
control scale preciptates & reduce particulate fouling.

7). MICRON CARTRIDGE FILTER – In this, 5 micron filter is used to remove

micro- size particles.

8). R.O MEMBRANE – It works on principle of reverse osmosis process & hence
water is cleaned.

9). U.V LIGHT (1-1.2 Sec) – It removes or kill all harmful bacteria with the help of
Ultra-voilet light.

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 SYRUP SECTION
A Syrup is thick, viscous solution of sugar, water, & flavor/concentrate. One of the
important step in beverages process & sensitive too.

INGREDIENT FOR SYRUP MAKING :

1). Water

2). Sugar

3) Concentrate

4) Natural colour

5) Carbon dioxide

FLOWCHART:

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 PRE-COATING TO
FILTER PRESS &
SUGAR P.H.E

CONCENTRATE
MIXING TANK

CARBON & HYFLOW

DUMPING ADDITION

ROTATORY
RAW SYRUP TANK READY SYRUP TANK
SYSTEM

SYRUP PREPARATION :

 Sugar storage & Dumping– The sugar is stored in sugar godown in a dry,
sanitary & secure area which is free from insect & rodent infestation. The
temperature maintained is less than 38 degree Celsius & relative humidity should
be less than 60 degree Celsius. The sugar storage room should be clean & empty
sugar bags should be kept at a suitable place.

 Raw Syrup Tank–The temperature maintained is 60-70 degree Celsius which is

warm. Treated water is added .

 Carbon &Hyflow addition - it is used as a filteration aid in sugar treatment with

carbon. It removes suspended solids & foreign matter. Carbon contact time – 30
min each batch, it also absorbs the impurities from sugar.

 Filter press - It separates the liquid-solid particles by working on the principle of

pressure feeding. The unfiltered particles or solid particles get blocked while clear
liquid get passed through the filter.

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  Plate heat exchanger – it has three stages. In the first stage water flow take place
, in the second stage syrup & cooling tower water is there, in the third stage glycol
is added which act as a coolant , it brings down the temperature to less than 25
degree Celsius, then it is passed through the 0.45 micron filter.

 Concentrate addition – Generally citric acid anhydrous , intermediate liquids

cloud component (6 units) , intermediate liquids(12 units)-citrus flavor ,
preservatives- sodium benzoate , sodium citrate , potassium solvate , caffeine
anhydrous, sodium hexameta-phosphate are added.

 Ready syrup tank – Temperature is less than 25 degree Celsius.

 1 batch – 24 units. For flavour & desirable changes maturation time for Pepsi is
24 hr, & no maturation time is required for Mountain Dew & Mirinda Orange.

QUALITY CONTROL

Test for sugar:

1). Procedure for colour –

 Take 50gm distilled water & add 50gm sugar

 Mix it well properly
 Filtered it half through Vacuum pump
 With the help of distilled water tare it (0) on device spectrometer
 Keep the filtered one on device spectrometer
 Note down the reading of color
 The unit is ICUMSA & It should be less than 150.

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 COLOUR READING

SIMBALI 50.62 ICUMSA

UTTAM 90.11 ICUMSA

2). Procedure for Turbidity-

 Take 50gm distilled water & add 50gm sugar

 Mix it well properly
 Filtered it half through Vacuum pump
 With the help of filtered sample tare it (0) on device spectrometer
 Keep the Unfiltered one on device spectrometer
 Note down the reading of turbidity
 The unit is NTU& It should be less than 125.

TURBIDITY READING

SIMBALI 27.616 NTU

UTTAM 76.101 NTU

3). Procedure for Floc test:

 Take 600g of sugar & 500ml of distilled water (it should have a brix of 54.5%
approx)
 Stir until dissolved
 Place electrode in solution
 Add phosphoric acid (or until PH -1.5 is reached)
 Place solution on hot plate & heat to boiling
 Cover with water glass(48hr stand)
 Observe it , if no floc observes, then keep it for more 8 days, if floc occurs it will
get failed & if not then it is passed.

4). Procedure for Conductivity Ash:

 Take 28g sugar & 100ml water ( 28%brix solution will be formed)

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  Put it in a magnetic stirrer
 Take distilled water in another beaker. Measure the conductivity
 Reading of distilled water – 0.99 at 31.2 degree Celsius
 Reading of sugar syrup- 17.27 mg/L at temperature 32.2
 Formula for % conductivity of distilled water = CT/1+0.0026(T-20)
 Both conductivity will take place at 20 degree Celsius
 Formula for % conductivity ash = conductivity of sugar at 20 degree Celsius –
(0.35×Conducttivity of water at 20 degree Celsius/ 1666.7
 Standard –0.05%

Tests for syrup :

1). Procedure for color :

 Take 50gm distilled water & add 50gm syrup

 Mix it well properly
 Filtered it half through Vacuum pump
 With the help of distilled water tare it (0) on device spectrometer
 Keep the filtered one on device spectrometer
 Note down the reading of color
 The unit is ICUMSA & It should be less than 45.

Procedure for Turbidity-

 Take 50gm distilled water & add 50gm syrup

 Mix it well properly
 Filtered it half through Vacuum pump
 With the help of filtered sample tare it (0) on device spectrometer
 Keep the Unfiltered one on device spectrometer
 Note down the reading of turbidity
 The unit is NTU& It should be less than 25.

Procedure for Control drink -

 Agitate for 5 min before taking sample

 Rinse the one filled before, measure the refractometer brix
 In case of mountain dew, pepsi, 7U, make the ratio of 5:1 with water& in case of
miranda orange& sting, make the ratio of 4:1

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  Stir it for 2-3 min
 Check the brix , that will be the C.D.

Procedure for Inverted brix -

 Take 30mlsample & 0.1 HCL (whose normality should be 6)

 Keep it in a water bath for 40 min after it reaches the 100 degree celsuis
 After taking it out , check the brix at normal temperature

Procedure for T.A -

 Take a 100ml beverage sample

 Put it in a magnetic stirrer & measure its PH
 Titrate it with a NAOH solution , stop when the PH reaches the 8.75

Test for carbon in raw syrup

This test is done for detecting the presence of carbon in raw syrup. Carbon is an
undesirable susbstance and as soon as its purpose is served it needs to be completely
filtered out from the syrup. To check its presence we do the following test :

 Raw syrup is mixed with water in the ratio of 1:5.

 Then this solution is passed through a thin filter paper of 0.45 microns.
 The solution should then be filtered eight to twelve times.
 Filter paper is viewed for any carbon residue.
 This test can also be done via the method of candling. The syrup isviewed under
proper lighting and checked for carbon residue.

Test for carbon dioxide

The function of CO2 in beverages is to provide effervescence, some acidity and some
protection against microbiological growth without contributing any-off appearances, off-
odour,off-taste or undesirable level of trace impurities.

 Purity test
 AOT Test

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Purity test (Niel Zham Purity Tester):

Carbon dioxide gas is checked for its purity as soon as it is received. Beforeaccepting the
received carbon dioxide gas its purity is checked using Zham neglerco2 tester.

 Co2 is added to the Zham negler co2 tester along with NaOH solution.
 As soon as NaOH is added to the tester, a bubble is formed.
 The bubble should travel to the top of the instrument.(level 99-99.9)

AOT Test

 AOT stands for appearance, odor and taste.

 Dry CO 2 is collected from the sample truck and taken into a beaker.
 Water is added to the beaker containing dry CO2 and its appearance, odorand
taste is checked by the analyst using eyes, nose and tongue .

Test for soft & treated water:

Procedure for chlorine test:

 Take 10ml sample & add 1 sachet of DPD (pink colour will appear)
 Put it in a chlorine pocket colorimeter
 Note down the Reading.

Procedure for T.D.STest:

 Take 10ml sample

 Put it in a conductivity measuring device
 Note down the Reading.

Procedure for Hardness Test:

 Take 10ml sample & take hardness tablets (2), crush it & add it
 Add 2-3 drops of ammonia buffer solution
 Titrate it with N/50 EDTA , blue colour will appear
 Note down the Reading

Procedure for IronTest:

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  Tare it by putting 10ml distilled water sample in a pocket colorimeter machine
 Add one sachet of TPTZ in a sample water , put it in a pocket colorimeter machine.
 Note down the Reading.

Procedure for Manganese:

 Take two sample , one of distilled water & second sample water for testing (10ml each)
 Add 1 sachet of ascorbic acid in each. Dissolve it completely.
 Add 12 drops of alkaline cyanide in each
 Add 12 drops of pan indicator in each
 Keep it still for 2-3 min for color development
 Put distilled water in a pocket colorimeter for tare
 Then put sample water & note down the reading.

Procedure foralkalinity :

 Take 100ml sample

 Add 5-6 drops of phenolphthalein
 Add 5-6 drops of methyl orange, yellow color will developed
 Titrate it with N/50 H2S04
 Note down the reading.

Microbial testing-
In microbial testing of sugar we check the yeast & mold count present in 100ml sugar
solution. According to BU’s specification yeast & mold count should not be more than 15
CFU.

Other various tests performed in lab achieving a quality product :

1).GV LEVEL TEST: In this test gas volume of CO 2 is checked. Parameters like
pressure and temperature are recorded using a G.V test instrument and the values are seen
under the chart to obtain the volume of volume present in the finished beverage.

2). BRIX CALCULATION USING REFRACTOMETER:Brix test is done to check the

amount of sugar content present in the aqueous solution. Brix is 1 gram of sucrose in 100
grams of solution and represents the strength of the solution as percentage by mass. Brix

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value for mountain dew approximates to 11.69. Brix value for pepsi approximates to
10.60. Before initiating this test, it is important to degas the beverage, eliminationof CO2
is important to get an exact value of the sugar present in the beverage.

3). Pressure Gauge Tester

4). Bottle Burst Tester

5). Crown Gauge

6). Base Clearance Test

7). Bottle cutter test

Production Line

MS and SS “PET Bottle Line”

MS and SS line is a PET line, “PET” stands for polyethylene terephthalate, it is a type of
plastic polymer used for making bottles.

Flowchart:

130
 Blowing of PET Bottle goes to
bottles Capper put cap on
bottle. Filler- fills warmer
beverage

PET bottle goes to

the rinser
Filler- fills beverage
in rinsed bottles
Labeling and
Coding
After rinsing the
bottle goes to filler

Syrup comes to mix Mix processor mixes

water, syrup, and CO2 Packing and
processor palletizing
in fixed ratio

Flow diagram of production process in PET line

Blow Molding
This section makes PET bottle from blow molding machine.

 The preform of PET is ordered from an external source.

 Preform is subjected to high temperatures of 107°C in heating oven zone.
 Once it gets heated to ductile phase, it is then subjected to low pressure (10 bar)
and pre blowing is done
 Then a high pressure (36 bars) is applied for main blowing phase.
 Bottles are then fed to air conveyors which carry the bottles to filling area.

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Bottle Rinser
Treated water used for bottle rinsing, for proper sanitation from the point of food
safety.

Filler

Filing is next step after rinsing, by the help of vent tube we can maintain the net
content of bottle.

Maintaining GV in PET is a major concern in PET bottles.

The prime reason for loss of GV is the nature of bottle. It is made of polymer named as
polyethylene terephthalate. It loses CO2 due to its permeable nature.

Filling process followed by warming than labelling, coding, secondary packaging and
than product goes for warehousing.

GRB(Glass Recoverable Bottles) PROCESSING

There are one GRB lines used to produce glass bottle beverage product. A well equipped
quality laboratory is established to checkout all the quality parameters, beverage or any
other specifications.GRB line consists of the following path is in flow diagram.

Flowchart:

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 Empty loading Coding Final light inspection

Bottle washer
filler

Manual light Palletizer and

EBI warehousing
inspection

Primary Container Preparation CSD:

133
 Final rinse MB Test Caustic
Uncasing of bottles compartment carry over test

Pre final
Pre inspection compartment

Final rinse
compartment
Pre rinse Hydro wash
compartment.

Soak 1 Bottle washer in Washed sanitized

Compartment main soak bottles

Bottle washer(Bottle washing equipment)

Chamber of the Bottle washer.

 PRE RINSE
 SOAK 1
 RPE WASH
 SOAK 2
 HYDRO
 PRE FINAL
 FINAL

Equipment

1)-Pre-Rinse Tank
• From the pre-rinse, bottles are inverted and enter there-wash tanks.
• Bottles are immersed in a normal temperature water to soften soils and
contaminants.
• Gentle agitation aids in the label removal process.
• Lower jets and upper jets areused for cleaning.

134
2)-Hot Caustic Soak Tank-1-

Caustic spray section, fixed nozzles and intermittent

chain movement.

3)-Pre-Wash Tank

From the pre-wash, bottles are inverted and enter the wash tanks.Bottles are immersed in
a hot cleaning solution to soften soils and contaminants.Gentle agitation aids in the label
removal process.

4)-Hot Caustic Soak Tank-2. - Caustic spray section, fixed nozzles and intermittent
chain movement.

Empty bottle inspection (EBI)

After bottle washer empty washed bottle are inspect by EBI machine, defected bottle are
rejected, many defect are occur in the bottles.

 Foreign matter
 Chipped neck
 Min 5 ml of water/caustic solution.

Effluent treatment plant:

FLOW CHART

Screen Bar

135
 Oil& grease chamber
ccccvhiuiccccccccchambe
r
Equalization tank

Anaerobic Tank

Primary clarifier

Aeration Tank

Secondary clarifier

Activated carbon purifier

tank tank ttank

Chlorination

CONCLUSION

Soft drinks are generally sweetened, flavored, acidified, carbonated and sometime
chemically preserved drinks. A systematic quality control is essential to ensure their
quality production. At the end of overall processing of carbonated soft drinks an essential
point is that the quality of product should satisfy the national as well as international

136
standards. Because of food safety concerns purity and hygiene must be ensured at any
food or beverage plant.

To achieve this quality control department must focus on:

1. Improved quality of products

2. Achievement of greater consumer and customer satisfaction

3. Promotion of National and international trade

4. Raw material control
5. Inspection of finished products
6. Sensory evaluation
7. Packaging standards
8. Labelling, Coding and hygienic storage.

Quality concerns in food and beverage plants in India have recently attained great
importance owing to the introduction of new food safety act and 3D quality concepts (
trade quality, plant quality and food quality).With everyday increasing market demands, at times
it becomes quite difficult for the quality assurance departments to ensure 100 % quality along
with assisting great production. However, at the end of the day its quality control that not only
creates demand for the products but also maintains it.

The reason being simple: “IF YOU DON’T LIKE IT, YOU WONT BUY IT!

REFRENCES
1). Bottle Washer Lab Manual.
2). Quality Control Guidebook
3). https://varunpepsi.com/
4). https://www.goodreturns.in/company/varun-beverages/history.html

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