MANGO DRINK MANUFACTURING PROCESS

Nowadays, production and processing of fruit drink is a big industrial process called
beverage industry. Mango drink is one of the major and famous beverage.Other famous drinks
include litchi drink, apple drink, and guava drink and so on. These are famous for its natural
juice.

In our training we studied about the different processing steps involved in mango drink
manufacturing, important steps to control or minimize the load of the bacterial infections during
processing, minimum requirementas per the recipe and pros and cons in the process.

INTRODUCTION

Fruit plays an important role in human nutrition. Before the 20th century drinking of
squeezed fruit juices was the privilege of only a few. Welch was the first to preserve the grape
juice with heat treatment in America in 1869, followed by Muller-Thurgan in Switzerland in
1896. Thus began the production of preserved fruit juices. A wide range of drinks can be made
using extracted fruit juiceor fruit pulp or concentrate as the base material. The type of drink
made from fruit can be separated into two basic types: one those that are drunk straight after
opening and the other one is those that are used little by little from bottles which are stored
between used. The second one includes squashes and rail juice which needs to be diluted.
Classification

The different types of drinks are classified according to the following criteria:

1. Juices: Pure fruit juice with nothing added

2. Nectars: Normally contain 30% of fruit solids and are drunk immediately after opening. It is
one type of juice of paper fruit with a thick consultation.

3. Squashes: Normally contain at least 25% fruit pulp which is mixed with sugar syrup. They are
diluted for taste with water and may contain preservatives.

4. Cordials: Cordials are crystal clear squashes. Syrups are concentrated clear juices. They
normally have high sugar content and less pulp concentration. Examples include slice, maaza,
etc.

MANGO PROCESSING
 Process line starts from the farm, then to industries and finally to the end consumer. So
there requires two separate industries for production process – one for pulp processing and the
other for juice processing. Some juice industries have their own pulp processing line and others
having an approved pulp vendor for procuring their raw material. Raw mango is the base
material for pulp processing and mango pulp is the base material for juice industry

1. Pulp processing

Fruit washing

Sorting

Crushing

Jacketed kettle

Pulp
The first step in the pulp processing is the receiving of raw material. Inspection of
receiving raw material is an important stage in reception where overripe mango, mango with
black spots, infected mango from bacteria and fungi are rejected. Then it goes for fruit washing
where the raw material was washed with potable water. Then through elevator goes to fruit
sorter where the mango sorting was done based on color and size. Sorting is done either by
manual or by mechanical means. After the sorting process, the mango fruit goes to the crusher.
In the crusher there is a section for peeling purpose called peeler followed by crushing. After
crushing, the juice is taken into the jacketed vessel which maintains the minimum temperature
od 80°C for one hour. Then it is stored in a separate tank which sometimes uses citric acid for
longer shelf life. All these steps are for the preparation of pulp.

2. Juice processing

Pulp
 Pressing

Centrifugation

Clarification

Homogenization

Pasteurization

Blending tank

Ultra-temperature sterilization

Blow molding

Hot / Cold filling unit

Automatic plastic casing

Hot shrink machine

Stacking

Dispatch

In juice processing plant, pulp is the base material which comes in the solid form after
pulp processing. The received pulp should meet the required brix. The first step in juice
processing is pressing. During process if any fragment of masses is present should be smashed
out first. The juice that is taken for pressing should be clear. Then the juice is transferred into the
centrifuge by means of pump for proper mixing and helps to forms a clear solution. After
centrifugation, pulp is taken into the clarifier. The clarifier consists of three tanks: sugar syrup
tank, batch preparation tank and mango storage tank. Sugar syrup is separately prepared and
stored in sugar syrup tank. The mango pulp, prepared sugar syrup, emulsifiers, stabilizers and
color were taken into the batch preparation tank as per the formulations. Finally volume makeup
is done by using water. The batch preparation tank consists of an agitator, which rotates in a
normal speed at ambient temperature. It is then stored in storage tank till further process take
place. Next is the homogenizer which helps in the proper mixing of the material. The
homogenizer used for juice processing is a two-stage homogenizer, having 500 – 2500 bar
capacity and a piston arrangement, which helps in the fast movement of the juice into the
vacuum degassing. Vacuum degassing is uncommon and helps in the removal of oxygen
scavenger present in the juice by means of vacuum. This is not a mandatory step. After vacuum
degassing it is then transferred into the evaporator or pasteurizer. Pasteurization is maintained at
92ᵒC for 1-2 seconds for sterilization of the product. The holding time required is 1-2 minutes.
The main intention is to decrease the microbial load. After pasteurization the product goes to
ultra temperature sterilizer or simply sterilizer. In sterilizer the product is aseptically maintained
at 120ᵒC for 1-2 hours in a closed chamber. After sterilization the bacterial load should be
decreased to 99%. Then the product goes into filling section. There are two types of filling: hot
filling and cold filling. Before hot filling section, there is a blow molding room where bottles are
manufactured. Hot filling is done for glass bottles and PET bottles. Cold filling is used for tetra
Pak small packets. Hot filling section has three chambers include blow molding section, washing
section and filling section. Filled bottles are then transferred into automatic plastic casing where
a label is made above the bottle. The whole bottles will be properly covered with the label
information plastic packets. Then it comes to the hot shrink machine which helps the shrink wrap
per to stick into the bottle. The hot water produced in the hot shrink machine generates heat that
helps to shrink the laminate into the bottles. After completing of all processes the products will
go into the storage room where they are stacked. Finally the products are ready for dispatch.

PROCESS DESCRIPTION
Sl.No PROCESS TITILE
Receipt of raw material
1 and packaging material
2 Vehicle inspection
3 QC Inspection
4 Rejection
5 Unloading and storage
6 Melting of mango pulp
7 Straining
DESCRIPTION
RM & PM should source from approved vendor, at
receiving to manufacturing unit the inventory team shall
check the material received against raced PO, then
quality team shall inspect the material according to
specification , if quality parameters not comply can
reject the product.
It should be carried by inventory team before unloading
the raw material. Vehicle should appear with closed
condition and no foreign materials, dirt, free of debris
and free of undesirable odor, no objectionable goods
like hazardous chemicals, petroleum products, void of
cracks, and no seepage of oil into product bay.
Sample of received raw material and packaging
material shall collect by QC persons as per sampling
plan and evaluate the quality parameters. Materials
meets with desired standard will be accepted.
Received material if observed out of specification, the
material will be rejected and sent to vendor with
rejection note.
Quality accepted materials will be unloaded and sent
for storage section according to the product nature. Raw
material will be stored on pallet and kept away from
touching of wall with batch identification for
traceability to follow the FIFO program.
Put mango pulps in boiling vat for 3-5 mins, destroy the
polyphenols oxidase, and stabilize the color and
improve flavor. Preheating/ melting can also eliminate
the air in raw materials. In this way, we can prevent
oxidation of mango pulp.
Straining is one of the filtration processes .By the help
 of filter, fibrous material separated and smoothly pulp
get transfers to mixing tank.

8,9&10 Mixing Thorough mixing to ensure uniform suspension

Take the sample for checking of Brix & acidity. Brix

should be 14.5 ± 0.2 at 20ºC and acidity should be 0.28
11,11.1 Quality Check ± 0.02. If results not match, then required for
standardization. After that again check for quality and
allow for further process.

` The mix after filtration through filters is pasteurized at

12 & Pasteurization 92(±2) ᵒC for 15 sec followed by two stage
13 Homogenization homogenization at pressure 2500 psi and 500 psi
respectively and then transfer to the filling section.

Prepared mix filtered through duplex filter with attach

14&15 Filtration magnetic bar which helps to prevent the entry of any
physical contaminant.

Bottle transfer through the cooling tunnel and

16&17 Cooling & Labeling temperature drop to 42 ºc, after that label insertion done
by manually and bottle pass through shrinking section,
where label shrink with bottle.
18 Secondary Packing Products transfer into corrugated boxes and store
designated FG storage.

EXPLANATION

Receiving of RM and PM

RM means raw material and PM is the packaging material. Raw materials for mango
drink manufacturing are mango pulp, sugar, color, flavorings and other chemicals. PM include
primary packaging materials and secondary packaging materials. Primary package is the
laminate and secondary package is the corrugated boxes. After receiving, we need to check the
inspections of the material. The brix and acidity of the pulp must be checked. In case of sugar we
need to test the color concentration in ICUMSA level and moisture level. For coloring and
flavoring agents we need to ensure that these are received according to the order and for
chemicals we need to check the purity. Before receiving of RM, need to check the vehicle
condition. In QA inspection if all RM and PM meet the standard requirement then it goes to the
next process. If any material shows out of specification then it is rejected to the vendor. Accepted
materials will go for unloading and to the designated RM and PM storage area to prevent cross
contamination

Pulp melting vat

Mango pulp is transferred into PVC drum where pressing of mango takes place
Staining

Staining is done with the help of a filter .If staining is not done then fibrous material
will come into the product, the purpose of staining is to obtain crystal clear product. After
staining the product is transferred into the batch tank where the formulations used for the mango
drink processing is checked. After checking of the concentration we need to add the sugar syrup
as acidity regulator emulsifier and stabilizer. Sugar syrup is separately prepared in a sugar syrup
tank and it should maintain a concentration of 65ᵒ brix.

Mixing

After mixing of 20 – 30 mins as per the standard regulation of the company, color and
flavour is added. This is not added in batch mixing tank color and flavors are not added in the
batch tank because during agitation there is a chance of denaturation of the protein or the
denaturation of coloring and flavoring agents. Then we need to check the brix and acidity. If
those values don’t match then go for standardization. For this purpose, need to add more color
and flavor.

Pasteurization

If the brix and acidity meet the standard then go for pasteurization. This process is
maintained at 92ᵒC for 10-15 min. Then the product is transferred to the homogenizer.
Sometimes depending on industries homogenization is done prior to pasteurization. After
homogenization product passes through duplex filter which helps to remove metal contaminant.
After the metal detection, the product passes through bottling and capping section where the
temperature is maintained at 72ᵒC. Then it is cooled to 42ᵒC. After cooling shrink wrap
packaging and labeling is done. Finally the product is ready for dispatch.
FORMULATIONS

INGREDIENTS QUANTITY (%)

Mango pulp 16

Water 70

Sugar 13

Citric acid 0.22

Preservatives 0.002

Flavors 0.07

Color 0.0033

Stabilizer 0.04

The table shows the formulations used for the preparation of mango juice. For 16% of
mango pulp add 70% water, 13% sugar, 0.22% citric acid, 0.002% preservatives, 0.07% flavors,
0.0033% color and 0.04% stabilizers. Citric acid is added to maintain the acidity level of juice.
Industrially used preservatives include sorbic acid and sodium benzoate. Addition of artificial
flavour and color depends on the industry and is highly confidential. Pectin is used as stabilizer
which also increases the consistency of the product. Xanthum was banned by FSSAI and is not
recommended as a stabilizer.

QUALITY SPECIFICATIONS

QUALITY PARAMETERS RANGE

Brix at 20ºc 14.5+/-0.2

Acidity 0.28+/-0.02

Torque at 25ᵒ c -30ᵒ c 8-18 lbs-inch

MICROBIOLOGICAL SPECIFICATIONS

MICROBE COUNT

TPC at 37ᵒC <20/2ML

TPC at 22ᵒ C <100/2ML

Yeast and Mould Absent

Coliform Absent

E.coli Absent

Mango juice is rich in nutrients and the fruity is very strong. At the same time, mango
also has a lot of effect and functions can play a good role in the protection of the health of the
body. Mango also has a large amount of vitamin A, vitamin C and minerals. Vitamin A has a
very good anti-cancer, anti-cancer effect, vitamin C and minerals have the effect of cancer
prevention, prevention of arteriosclerosis and hypertension. A lot of vitamins can also beautify
the skin. What’s more, mango juice has a lot of fiber, it has the effect of emptying the stomach.
For people with carsick and seasickness, mango juice has some antiemetic effect. So mango
juice is very popular. Understanding mango juice production process is of great help to the
mango juice production