HISTORY OF BEVERAGE

INDUSTRY

Worldwide –Beverage Industry

revolution
The types of beverages made so far

http://www.localhistories.org/drink.html
Early Drinks-

Young children drank milk. Water was often too dirty to drink. People only drank it if it came
fromm a pure source. So alcoholic drinks were popular due to safety.

• 3000 BC- In the Middle East wine was a common drink. In Egypt beer was popular.

•1200 AD- Vines were grown in England.

•Mead and cider also drunk but the most
•ale (beer brewed without hops).
16 century drinks

• 1600- Beer replaces ale as the most common drink in England. Cider became also very popular.

•1651 -The first coffee house in England was opened .

•Coffee was discovered in Ethiopia and it entered Europe in the 16th century through Italy.

•1657- Tea is first sold in England.

Tea was discovered by the Chinese in the earliest days

•Wine was still imported from Mediterranean belt

•Chocolate comes from Central America. The Spaniards brought it too Europe in the 16th century.
17th and 18th Century Drinks

1700 Gin (Gin is a distilled alcoholic drink that derives its

predominant flavour from juniper berries (Juniperus
communis) drinking becomes very popular among the
poor in England
1759 Guinness (Guinness is a dark Irish dry beer ) is first brewed
.
1772 Fizzy drinks were invented by Joseph Priestley, who
discovered how to trap carbon dioxide in water and made
carbonated water.
1789 Bourbon whiskey is first distilled, cider and perry (Perry is
an alcoholic beverage made from fermented pears, similar
to the way cider is made from apples) were also popular
18 century •Rum (an alcoholic liquor distilled from sugar-cane) was
first distilled in the Caribbean
•Vermouth -Vermouth is an aromatized, fortified wine
flavored with various botanicals was invented in Italy
18 century The Spaniards in Mexico also invented tequila. distilled
beverage made from the blue agave plant,
19th and 20th Century Drinks Safe water was available for drinking
For centuries ordinary people brewed their own beer and made their
own soft drinks like lemonade and cordials. In !9 and 20 century , they
become mass produced
1820 India Pale Ale (light-colored beer similar to bitter, typically with a higher than average alcohol and hop content.)

1839 Indian Tea is first sold in Britain

1842 Golden lager( often referred to as a Pale Lager, is pale-to-golden coloured beer with a varying degree of hop
bitterness) is invented
1858 Erasmus Bond patents tonic water

1883 Horlicks ( sweet malted milk hot drink) is invented

1884 Evaporated milk is patented by John Meyenberg

1885 Dr Pepper ( carbonated soft drink) is invented

1886 Coca Cola is invented

1888 Paper drinking straws are invented by Marvin Stone

1889 The screw bottle top is invented by Dan Rylands. The modern coffee percolator is invented by Hanson Goodrich in
1889,
Instant cofee in 1901 and cofee filter 1908

Tizer 1924 Vimto (is a soft drink sold in the United Kingdom), tizer, Tizer is a red-coloured, citrus-flavoured
Vimto 1908 soft drink , pimms ( Pimm's is a brand of gin-based fruit cup) were 20 th century drinks
20 century Iced tea in USA and Ovaltine is invented

•1935 Canned beer is first sold

•1985 The widget for beer cans is invented
Tea and Cofee
2737 BC Teais discovered by the Chinese emperor Shen Nung
1000AD According to legend coffee is discovered around this time

1450 Coffee is drunk in the Yemen

1550 Coffee is drunk in Turkey and Persia
1610 The Dutch introduce tea into Europe
•1651 A coffee house opens in Oxford
•1652 A coffee house opens in London

1657 Tea is first sold in England

1839 Tea from India is first sold in Britain

1865 The first American coffee percolator is patented

1901 Instant coffee is invented

1903 Decaffeinated coffee is invented
1938 Freeze dried coffee is invented
1946 The modern espresso machine is invented
1952 Tea rationing ends in Britain
1960 The first pump driven espresso machine is made
 21 century
• In 21 century , along with different
technologies, variety of products are
developed.
• Cans, glass bottles, PET bottles, nitro filling,
ozone filling, RTS and Nectars, herbal drinks,
fortified drinks, mixed drinks, flavor red milk,
almond milk, barley extract milk, soy milk etc
 Beverage Industry- Scope, status and
Importance
List of Top Companies in India
■ Ace Continental Exports -The company has been involved in the export activities of brewery
products in the overseas market.
■ Vinbros & Co.- the largest and oldest liquor manufacturing facility situated in the coastal region of
Pondicherry
■ Apple Valley Group- Apple Valley Group is involved in the manufacturing of tea products.
■ Karnataka-PlantationCoffee
■ LochanTea
■ Tata Tea
■ SABMiller- ABMiller plc was a multinational brewing and beverage company headquartered in
Woking, England
■ Coca Cola
■ PepsiCo.
■ McDowell & Company
■ Nestle
■ ShawWallace - SWC, was an Indian liquor manufacturer headquartered in the Wallace House in Kolkata
■ South Seas Distilleries & Breweries
■ UB Groups
ECONOMIC IMPORTANCE

• The beverage industry has a unique role in expanding economy .

•It employs several millions of people world wide and each type of beverage grosses
billions of dollars in revenue each year.

• Indeed, in several small, developing countries, the production of coffee is a major

support of the entire economy.
Amongst all the beverages, Tea and Coffee are manufactured as well as exported
heavily in the international markets from India

Beverage industry in India constitutes around USD230 million .

The major sectors in beverage industry in India are Tea and Coffee

Cont.
•The beverage Industry is growing at 6%-7% annually. 2. It employs around
1,25,000 people. 3. Supports growth of industries like glass, refrigeration,
transportation, paper and sugar. 4. Industry contributes exports goods worth Rs 2
billion. 5. 91% soft drink sales are made to the lower, middle and upper middle
classes.

•It has obviously attracted one of the highest FDI in the country.

• Strong forward and backward linkages with glass, plastic, refrigeration, sugar and
transportation industry further strengthens the portion of the industry. Soft drink
segment has a huge potential in the Indian market, as a vast portion of the market
it still to cover.
•At present, the Indian packaged juices market is valued at INR 1100 crore (~USD
200 million) and is projected to grow at a CAGR of ~15% over the next three years.

•The packaged fruit juices market can be divided into three subcategories, viz. fruit
drinks, juices, and nectar drinks. Fruit drinks, which have a maximum of 30% fruit
content, are the highest-selling category, with a 60% share of the market. Frooti,
Jumpin, Maaza, etc. are the most popular products in this category. Fruit Juices,
on the other hand, are 100% composed of fruit content, and claim a 30% market
share at present. In contrast, nectar drinks have between 25-90% fruit content,
but account for only about 10% of the market.

•The rising number of health-conscious consumers is giving a boost to fruit juices; it

has been observed that consumers are shifting from fruit-based drinks to fruit
juices as they consider the latter a healthier breakfast/snack option.
Status

•Fruit juices, pulp and concentrates and sauces or ketchups are doing well
in the beverage market in India for the past few years.

•Various milk products, health beverages, beer and country liquors have
also been contributing largely in the rising demand of beverages in India.

• Coca cola has accounted for a thriving growth since its inception.
• It occupies around 60% of the carbonated drinks sector in the Indian
beverage industry.
•Another predominant brand is Nestle India Limited which occupies 61.85%
of the total Nestle SA, Switzerland.

• The Nestle products are hugely exported to Russia apart from selling in
domestic markets.

Cont.
•Alcoholic beverages in India is considered to be the 3rd largest market for alcoholic
beverages in the world.

•The domestic beer and alcoholic beverages market is largely dominated by United
Breweries, Mohan Meakins and Radio Khaitan.

• The demand for beer and spirits is estimated to be around 373 million cases per year.

• There are 12 joint venture companies having a licensed capacity of 33,919 kilolitres
per annum for production of grain based alcoholic beverages.

• Around 56 units are manufacturing beer under license from the government of India.

• Country liquor and Indian made foreign liquor are the two segments in liquor, both
cater to different sections of society. The former is very much consumed in rural
areas and by low income groups, while the middle class and high-income groups
consume the latter.
•The soft drink segment is considered to be the 3rd largest in the packaged foods
industry.

•Over 100 plants are engaged in the aerated soft drinks industry and provide huge
employment.

•Although many of these beverages, including beer, wine and have been around for
thousands of years, the industry has developed only over the past few centuries.

•The soft drink industry is the exception to the rule, as its quite concentrated.
•Opportunities

•At the same time, the packaged juices market throws up many opportunities. Some of them are outlined below:
•
•Shift towards 100% juices from sweetened juices:-This offers a wide opportunity to existing and upcoming juices
manufacturing companies to spruce up their existing business and plan as needed for business or capacity
expansion.
•
• Healthy proposition: it has been observed that consumers are making healthy choices in their beverage
consumption; therefore, fiber-enriched juices and no sugar juices are more in demand. Some new juice variants
claim to have no added sugar; this can be positioned as a health attribute, e.g. “Dry Fruit Apple Juice” by Balan
Natural Foods
•
•Unique offering: Consumers are seeking unique fruit flavors apart from the usual mango, orange, or lime-based
fruit juices. Companies intentioned to identify some of the unique fruit juices that can be offered - “Dry Fruit
Apple Juice” for instance, which is much sought after due to the nutritive benefits provided by the combination of
dates, figs, raisins, almonds, and apple concentrate.
•
•Wider Options: Companies need to offer wider varieties and options for the consumer to choose from, ranging
from “mixed” fruit juices to pure, single fruit juices to dry fruit juices. Thanks to higher incomes, consumers are
willing to experiment with variety and pay a premium for such value-added products.
•
• Product extension: There has been some recent product extension, e.g. Tropicana launched Tropicana Fruit
Powder with no preservatives or artificial flavors, which will be available in single-serve sachets and can be made
into a full glass of juice simply by adding water.
•
•It is appropriate to say that the packaged juices market in India is still evolving. As there are many national and
international brands on the verge of succeeding and expanding further into the field, new entrants can also cash
in on this opportunity by positioning/promoting packaged and bottled fruit juices as part of the consumers’ daily
diet. Simultaneously, it is critical to ensure affordability for consumers, while maintaining the hygienic aspects
and quality of products throughout the year.
Water treatment Treatment/ process for improving the quality of water
for specific end use

•removes contaminants and undesirable/ impurities components

•drinking,
•beverage preparation
•industrial water supply,
• irrigation,
• river flow maintenance
•many other uses

Microbiological

•Pathogens
Chemical •Living organisms
•Total dissoved soilds/ turbidity
•Colour
Physical- •odour
•Total Dissolved Solids
•pH
 TDS, (total dissolved solids) inorganic compounds

the total concentration of dissolved substances in water

smaller than 2 microns (average filter size) is
considered a dissolved solid ✔ Ca, Mg, K, Na ( cation)
✔ Carbonates, nitrates,
organic matter chlorides, sulfates (anion)
High TSS effect?
Low TSS effect? ✔ Heavy metals
✔ Pesticide residue

✔ Bacteria and viruses

500 ppm
(optimum causes
limit)

•Natural 1
Optimizing TDS? At •Human Activities 2
Home and Industrial
level

1 Mineral springs contain water with high levels of dissolved solids because the water has
flown through a region where the rocks have a high salt content

2
Agricultural and urban run off, Water waste discharges ,Industrial waste water (may contain heavy metals and salts)
pH ✔Chemical pollution from industrial operations
✔Chemical pollution from vehicles
✔Inadequate water waste treatment
is a measure of its acidity or alkalinity ?

Can we consume high or low pH water?

6.5-8.5
Taste of water with (optimum
limit)
pH < 6.5: provides bitter, metallic taste and
corrosion
pH > 8.5: Soda like taste and deposits

How can we alter the pH ( if its not in range)?

Suspended solids particles that are larger than 2 microns
Cloudiness or haziness/ turbidity

Inorganic 5 NTU
sand, gravel, clay (optimum
Organic
limit)
Algae colloidal

Overall effect ?
Humans/ aqua

Suspended
solids

NTU- Nephalometric turbidity units

Water Treatments commonly used for physical/ chemical/ microbial
contaminants

✔ Pressure Sand Filter

✔ Activated Carbon Filter
✔ Micron Cartridge Filter
✔ RO system
✔ UV Sterilization
✔ Aeration
✔ Ozonation
✔ Membrane filtration
Pressure Sand Filter

✔PSF is a depth filter that makes use of coarse

and fine media (sand) mixed together in fixed
proportion creating a filter bed.

✔Water is passed through multilayers of filter

bed

✔The contaminants in the water are captured in

the media bed and filtered water passes through
the discharge at the bottom of the tanks
Pressure Carbon Filters

✔ACF consists of activated carbon granules

supported by very fine quartz filter media.

✔The carbon granules have high surface area due

to high degree of porosity.

✔A granular activated carbon is charged on

the supporting media of coarse and Fine
silex.

✔Activated carbon filter operates through

adsorption. Adsorption is directly related to the
surface area of the media. This huge surface
area furnishes a huge adsorption area for
organic as well as chlorine molecules to attach
themselves.
 ✔Used for removal of micro contaminants
(including bacteria) from foods.
✔Removes particles in the range of 20 to 0.2
microns.

Micron cartridge filters

✔Only simple filtrations through filters of pore

size not finer than 0.5 microns which do not
change the composition of source water are
permitted.
Membrane Filters
 ✔ Removes dissolved gases such as CO2
✔Also oxidizes organic matter and dissolved
metals such as Fe.
✔Fe (Ferrous) +O2----Ferric oxide FEOx

Aeration Filter

✔Deactivate bacteria, viruses and other

pathogens
✔More effective than chlorination
✔No residues
✔No chemicals added to water supply
✔No alteration of color, odor, pH, conductivity
of water
✔Economical
UV Sterilization
 ✔Ozone is a strong disinfectant compared tpo
UV rays.
✔Destroys all pathogens and help to remove
iron, manganese, sulfur, color, odor.
✔Ozone oxidize iron, manganese, sulfur in
water to form insoluble metal oxides which
can be removed.

Ozonation
Ozonation is a type of advanced oxidation process , involving the production of very reactive oxygen
species able to attack a wide range of organic compounds and all microorganisms.

✔Osmosis (water flows from a region of low

conc to high conc).
✔Reverse osmosis (water flows from a region
of high conc to low conc region by applied
external pressure).
✔Removes 90-97% dissolved solids.
Reverse Osmosis ✔Two streams are obtained i.e reject stream
and product stream.
an applied pressure is used to overcome osmotic pressure
 Effluent Treatment Plant (ETP)

Is it different
Waste water Which waste from water
treatment water ? treatment?
plant

-Treatment which purifies industrial waste water for its reuse and aims to release safe
water to environment from the harmful effect caused by the effluent

Treatment Clean water

Effluent/
waste water Sludge

Sludge is the residual, semi-solid material that

is produced as a by-product during waste
water treatment.
Types and levels of treatments

Physical

•Use of screens to filter or settling of

larger impurities/ primary or
preliminary treatment so that they
don’t hinder further
Chemical •Includes grit removal, breaking larger
parts into smaller ones
•remove 50-60 % of
•Use of chemicals tothe suspended
precipitate the
solids
impurities / secondary treatment
•Oil and grease, organic nitrogen,
organic phosphorus and heavy metals
Biological associated with solids are also removed
during primary sedimentation
•Use of microbes to digest the organic
matter/ secondary treatment ( aerobic/
anaerobic)
•Some industries also use tertiary form of treatments
•It involves disinfection process (using chlorine, UV light, ozone)
 How to check purity of water?

BOD- Biological Oxygen demand

BOD is the amount of dissolved oxygen needed (i.e. demanded) by aerobic biological
organisms to break down organic material present in a given water sample at certain
temperature over a specific time period.

The BOD value is most commonly expressed in milligrams of oxygen consumed per
litre of sample during 5 days of incubation at 20 °C and is often used as a surrogate of
the degree of organic pollution of water O2.

Dissolved oxygen
O2 O 2 O 2 O 2 O 2 = BOD
Organic matter in waste O2 O2 O2 O2
 COD- Chemical Oxygen demand

•the chemical oxygen demand (COD) is an indicative measure of the amount of oxygen
that can be consumed by reactions in a measured solution.

•It is commonly expressed in mass of oxygen consumed over volume of solution which
in SI units is milligrams per litre (mg/L).
 Suspended Growth
Activated Sludge treatment

Using active mass of microbes

to clean water

Reactivated sludge sent back

to aeration tank for further
treatment

Aerated Lagoon

The treatment consists of using mixed culture of microbes which are suspended in a liquid.
Oxygen is flushed inside and a secondary settling tank allows the biological flocs (the sludge blanket) to settle and separate from waste water
 Attached Film Growth
Trickling Filter
Micro-organisms are attached to an inert material like wood, stone tc and form a
biofilm.

Micro-organisms are attached to an inert material and form a biofilm.

When air is applied, oxidation of organic waste occurs, which results in
reduction of BOD and COD
Rotating biological contractor (RBC)

•Consists of a series of closely placed circular

discs of polystyrene or polyvinyl chloride
submerged in waste water.
•Micro-organisms are fixed to these discs.
•The discs are rotated through the waste water
biodegradation takes place during the rotation.
An extended-aeration system includes capabilities for aeration & mixing,
settling, return of activated sludge and solids removal, this last in the form
of a biomass known as waste-activated sludge.

An activated sludge process re-circulates part of the biomass as an integral

part of the process
Anaerobic process is applicable to both:

•Waste water treatment

•Sludge digestion

The process involves facultative and anaerobic micro-organisms, which in the

absence of air convert organic material to gaseous Carbon dioxide and methane.

Anaerobic contact beds

Upward anaerobic sludge blanket
Anaerobic process forming a blanket of granular sludge which suspends in
the tank
 ACCEPTABLE LIMITS
PARAMETERS PUNJAB POLLUTION
CONTROL BOARD
pH 6.4-8.5
TDS <2000
TSS <50
OIL AND GREASE <30
COD 90% reduction in effluent
RESIDUAL FREE <0.1
CHLORINE
DO >1
TEMPERATURE <5℃ from the environment
Waste water treatment system- potato plant
Waste water treatment system- Coca cola

KORE
PARAMETERS PPCB
PH 6 -9 6.5-8.5

BOD <50 <30

COD 90% Reduction

as in influent
D.O >1
 TEA
India being largest producer, Composition
consumer and exporter.
1197.18 million kg Carbohydrates- 30 percent
Proteins -20 percent
Very big employment
Lipids-2 percent
Minerals- 7 percent
Polyphenols ( 33-40 percent)
Caffeine 7 percent

Assam, West
Bengal, Kerala, States in Camellia sinensis Flavour Theaflavin,
India Native of India Thearubins
Tamil Nadu and
Karnataka Essential Oils
Caffeine

Growing
countries Teas from other
species are called
Total- 32 countries, India, China, Sri lanka, Japan and Kenya herbal teas
In India, British stated Tea cultivation
Important constituents of Tea Leaves

•Flavonoids i.e catechins, epicatechin, Flavor of tea is due to

epigallocatechin (65%)
•Gallocatechin phenols , caffeine and
essential oils.
•Caffiene-2.5-5.5 percent and it is stimulant.

•Amino acids- in tea leaves

•Pigments-Chlorohyll, beta carotene, lutein,
neoxanthin.

•Few others are Aroma compounds i.e. carbonyl,

alcohals, acids and lactones

•Enzymes- polyphenol oxidase, peroxidase,

chrophylase

•Lipids- about 2 percent

•Carbohydrates- glucose, fructose, Arabinose,

cellulose, hemicellulose

•Vitamins-carotene, riboflavin, nicotinic acid,

pantothenic acid, ascosrbic acid

•Minerals- Flourine
Process -
Rolling to open cells and
1. Plucking 3. Rolling juice and enzymes.
5-6 pluckings, gap of week

2 Withering or losing moisture (

Spreading Tea Leaves) Spreading of leaves to 4. Fermentation 2-6 h at 21-27
dry mc of 40%
Why its imp?
deg C Polyphenols i.e.
what happens during catechins are
withering oxidised here to
by polyphenol
oxidase to
theaflavins and
thearubigins ,
colour and
flavour
5. Drying ( hot air/ steam etc)- To 6. Grading and Packing- in components
reduce enzyme activity for 0-40 min at 93 detail further discussed
deg C . MC reduced to 2.5 percent
• Wither is to prepare the leaves for further
processing by reducing their moisture
content. This allows for the development of
aroma and flavor compounds in the leaves.
Controlling the withering process means
closely monitoring humidity, temperature and
air-flow over time
Two methods for Tea Processing
CTC
Withering It is carried out for 10-15 h
Rolling Withered Leaves are
macerated in shredder and
then passed through CTC
machine which consists of
rollers moving in opposite
direction
Fermentation Macerated tea is fermented
in revolving drum for 60-90
min with conditioned air.
During rotation, every bit of
tea is fermented and exposed
to fresh air
Orthodox
It is done for 18-24 h
Rolling is done in rollers like
leaf is rolled in hands. During
rolling twisting of leaves and
some ampunt of maceration
occurs. Then after 45 min of
rolling, leaf is passed on sifter
to remove rolled leaf. A
process known as roll
breaking. After roll breaking
fines are taken for
fermentation while residue is
left and put back for rolling
It is done by spreadng rolled
leaf in a layer of 2.5 to 7.5 cm
for 2-3 h. During
fermentation, low
temperature ( 20 deg C) and
high humidity are desirable (
95%)
 Types of Tea

Fermented
Non fermented
tea
Tea

Black Tea
Green Tea
Oolong Tea,
Yellow Tea
White Tea
Non fermented Tea- Green Tea/ yellow tea/ white tea

Plucking
Drying
Rolling
Drying to 6% mc by steam or pan drying
Grading/ refining ( sifting, cutting, polishing, blending
etc)
Packing

Oolong Tea

Plucking
Slight Withering
Rolling
Partial Fermentation
Drying
Grading
Black tea explained already Packing
 White Tea Black Tea

Fresh Leaves Fresh Leaves

Withered (develop flavour) Withered
Air dried Rolled
Fully Fermented
Air dried
Graded
Packed
Yellow Tea

Fresh Leaves
Rolled
Yellowed
Air dried

Gentle fruity, floral aroma. Yellow tea has a

medium body, which means flavor is neither
too strong or too weak
Grading of Black Tea

Whole Leaf Grade- Flowery orange

pekoe( FOP), golden flowey orange
Flower orange pekoe pekoe ( gFOP), Golden flowery
orange pekoe, trippy golden flowery
orange pekoe, finest trippy golden
pekoe flowery orange pekoe, flowery
pekoe, pekoe souchong
Brokens- Flowery broken orange
souchong pekoe, golden Flowery broken
orange pekoe , trippy golden golden
flowery
Fannings- Orange Fannings ( OF),
broken orange Pekoe Fannings
(BOPF), Pekoe Fannings ( PF),
broken mixed fannings ( BMF)
Dusts- Pekoe Dusts ( PD), Red Dust (
RD), Fine dust , golden dust, super
red dust, super fine dust
•pekoe grades consist of only the leaf buds, which are picked using fingertips
• souchang -a tea made from the larger older leaves of the shoot
•Fannings are small pieces of tea that are left over after higher grades of teas are gathered to be sold
Orange pekoe Souchang

Dusting and
pekoe fanning
 7. Packing
• Tea is blended before it reaches the consumer.
• The blended tea is generally packed in plywood
boxes lined with aluminum foil and parchment
paper.
• Tea is also available in other packed forms such
as loose in paper containers within a cardboard
outer or in tea bags
Coffee Processing
a. Coffee cherry
b. Coffee beans ( separted from pulp)
c. Washed coffee beans
Coffee cherry structure
11. America
12. Australia
Best coffee beans in the world 2019

1) Tanzania Peaberry Coffee

2) Hawaii Kona Coffee
3) Nicaraguan Coffee
4) Sumatra Mandheling Coffee
5) Sulawesi Toraja Coffee
6) Mocha Java Coffee
7) Ethiopian Harrar Coffee
8) Ethiopian Yirgacheffe Coffee
9) Guatemalan Antigua Coffee

https://espressocoffeeguide.com/best-coffee-
beans/
 Some famous brands
Caribou-American
Dunkin Donuts-American
Kopi Luwak-Indoneshian
Folgers- California
Gloria Jean’s-Australia
Green Mountain Roaster
Nescafe- Switzerland.
Peet’s-San Fransisco
Seattle’s- seattle
Starbucks
Doughe egbert
Harrar-ethopia
Costa cofee
The Kopi Luwak from Indonesia is also known
as the Civet Coffee. The coffee cherries are
picked and eaten by the palm civet after which
they spend about a day or two in its digestive
tract. The undigested beans are passed out in
the animal droppings that are collected,
cleaned and roasted like conventional coffee.
The Coffee is pacaged with multiple names but
the brand in itself has been one of the most
sought out
History coffee -India
robusta

Bitter tasting with 50%

extra caffeine- Robusta
 Coffee Processing
Harvesting- It is done when coffee cherries are red . They are ready afyter
8-9 months of sowing

Harvesting

Manual Mechanical
1. Selective Harvesting 1. Hand held Harvesters
2. Stripping 2. Large harvesters

Unripe coffee beans have for instance citric

acid in them which will lead to more acidic
coffee. So maturation is very important to pick
the ripened coffee cherries.
 Processing of Coffee
Cofee Processing means the removal
of several layers of coffee to finally get
the coffee that we consume

1 Dry Processed
2 Wet Processed or
washed
3 Semi- dry processed
 Process Flow

Fermentation

Separation of unripe berries, extraneous matter by sieving or flotation

Pulping refers to separation of pulp from coffee bean and is done in pulpers
Graded beans are cup tested to determine their potential brewing quality.
For cup testing small samples are roasted, ground and brewed.
 Some common types of coffee/ Grades
• Instant coffee, also called soluble coffee, coffee crystals, and coffee powder, is
a beverage derived from brewed coffee beans that enables people to quickly prepare hot
coffee by adding hot water or milk to the powder or crystals and stirring. Instant coffee is
commercially prepared by either freeze-drying or spray drying, after which it can be
rehydrated.

• Ground or Filtered coffee is any coffee which is brewed

through some type of filter so the grounds don't end up in the drink

• Speciality speciality coffee is grown at high altitudes, with much care and
attention from the farmer. From there, it is sold at a premium to coffee traders, or
direct to roasters.

• Decaffienated- Solvent extraction or super critical carbon dioxide extraction can

also be done to remove caffeine
Cocoa Processing

What is cocoa?

Cocoa is a concentrated powder made from cocoa beans. It is a key ingredient in chocolate confectionary.

The cocoa bean or simply cocoa which is also called the cacao bean or cacao is the dried and fully
fermented seed of Theobroma cacao, from which cocoa solids (a mixture of nonfat substances) and cocoa
butter (the fat) can be extracted.

1
a) cocoa pods

b) Cocoa beans

c) cocoa beans in cocoa pod-A cocoa pod (fruit) has a rough, leathery rind about 2 to 3 cm (0.79 to
1.18 in) thick (this varies with the origin and variety of pod) filled with sweet, mucilaginous pulp (called
baba de cacao in South America) with a lemonade-like taste enclosing 30 to 50 large seeds that are fairly
soft and a pale lavender to dark brownish purple color.

d) cocoa powder- Made from grinding the cocoa beans

e) cocoa tree

f} Cocoa tree and its parts

2
American tropics i.e. Brazil, Amazon rain forest, Argentina, Columbia , Equador and Peru

3
Cocoa Varieties

Forastero, Criollo, Trinitario

1. Forastero is the most common type of cocoa . 80-90% of cocoa in orld is processed from
Forastero.
2. Criollo- Cocoa beans of the Criollo variety are rarer and considered a delicacy.
3. Trinitario- is a hybrid between Criollo and Forastero varieties. It is considered to be of much
higher quality than Forastero.

Harvesting of Cocoa pods

The pods on a tree do not ripen together;harvesting needs to be done periodically through the
year.Harvesting occurs between three and four times weekly during the harvest season.The ripe and near-
ripe pods, as judged by their colour, are harvested from the trunk and branches of the cocoa tree with a
curved knife on a long pole.

4
Composition of cocoa bean

5
Cocoa Processing

The Cocoa cake is further milled and sieved to get cocoa powder.

6
Process-

Step-1 The first step in cocoa processing begins with splitting of cocoa pods to obtain the seeds. After the
separation of husks or rind, the wet bean ( with pulp) is obtained.

Step-2 The fermentation is then carried out for 5-6 days and varies according to species. The pulp
surrounding the cocoa bean undergoes fermentation and not the bean. During fermentation process, a
simultaneous curing process is taking place inside the cocoa bean.

Fermentation has to be carried out within 24-48 hours after breaking the cocoa pod. It takes about 5-7
days on average and varies according to the species. Forastero - 5–7 days, Criollo- 1-3 days It is
responsible for the chocolate flavor and aroma in cocoa and also external browning of beans. Cocoa
beans do not themselves undergo a fermentation at all It is pulp ( sugar rich) surrounding the beans
which is fermented by microbes , while simultaneous ‘curing’ process takes place within the beans.

What happens during fermentation?

The Anaerobic yeast convert sugar to alcohol and carbon dioxide ( in first 24-48h) followed by aerobic
fermentation resulting in acetic acid ( alcohol is converted to acetic acid). The resultant temperature is
aroung 50 degree C. What happens during curing process/ formation of chocolate flavor precursors?

Due to the disruption, compounds in the beans mix and interact within themselves. Reactions between
storage proteins, enzymes (proteolytic, polyphenol oxidase, invertase) and polyphenols result in
formation of the crucial chocolate flavor precursors. Proteins are degraded by enzymes to polypeptides
and amino acids Reducing sugars (glucose/ fructose) are released. Reduction of astringent and bitter
taste. Part of polyphenols oxidized into large tannin molecules.

These compounds starts to penetrate the bean which results a bean death ( inactivity of enzymes or other
biological mechanisms). At the end of the fermentation process, bean changes its colour to brown,
becomes plump and filled with reddish brown exudate

Importance of Fermentation & Curing -There is no chocolate flavor in cocoa bean without

Step 3- Sundrying or firing is used to dry the beans (to 6% MC) which are filled with browning exudates.
The firing process generally is done at high temperatures. Dried beans are roasted at 200˚F to 250˚F for 1-
2 hours in order to develop the flavor of the beans. The beans become brown in color and friable (brittle).
The dried cocoa beans are bagged and shipped further. On receiving the bags are opened and inspected
and beans are cleaned and roasted.

Step4-Winnowing- The dried beans are cracked and a stream of air separates the shell from the nib, the
small pieces used to make chocolate.

7
Step 5- Roasting-The nibs are roasted in special ovens at temperatures between 105-120 degrees Celsius.
The actual roasting time depends on whether the end use is for cocoa or chocolate. During roasting, the
cocoa nibs darken to a rich, brown colour and acquire their characteristic chocolate flavour and aroma.
This flavour however, actually starts to develop during fermentation.

Step 6-Grinding The roasted nibs are ground in stone mills until the friction and heat of the milling
reduces them to a thick chocolate-coloured liquid, known as 'mass.' It contains 53-58% cocoa butter and
solidifies on cooling. This is the basis of all chocolate and cocoa products.

Step 7- Pressing- The mass is finally pressed (hydraulic press) to obtain cocoa butter and cocoa cake. The
butter separates as it gets melted during pressing. The cocoa cake is finally ground to get cocoa powder

Step 8- Sometimes cocoa powder is treated with alkali to make it more water soluble

8
Process outline for obtaining cocoa butter and cocoa powder

9
For understanding only-

10
 cocoa powder

chocolate

11
 PLANT
EXTRACTS IN
BEVERAGES
 INTRODUCTION
►Plantextracts are the chemicals extracted
from plants to incorporate them into other
materials or applications to improve the
process, quality of product.
►In food and beverages , consumers consider
‘ botanical ingredients’ as premium ones.
►They add authentic taste to product.
►In beverages most popular botanical profile
include mainly floral , herbs, spices etc.
►Softdrinks contain wide variety of natural
extracts.
►They provide specific health benefits like
boosting immune system, improve skin
health , provide relaxation etc.
IMPORTANCE OF SPICES AND HERBS IN
PRODUCTION OF BEVERAGES
► Herbs are flowering or sterile plants used in cooking and medication due to
their chemical compounds
► Spices in general are used for seasoning , flavouring or preserving of foods.

FLAVOR TYPICAL REPRESENTATIVE

Strong flavour without any Cumin seeds
bitter taste
Sweet Anise seed
Sharply hot flavour Cinnamon
Slightly bitter Orange peel
Slight flavour without any Coffee bean
special bitter taste
Most bitter drugs Cassia
Spices Allspice
PLANT EXTRACTS
USED IN BEVERAGES

LAVENDER
Lavender syrup is a brilliant way to
add the herb's floral flavor to a
variety of beverages.
It is used to add an aromatic
sweetness to cocktails like the
lavender martini, to sweeten tea or
lemonade,
Example: tea bags, Levander
lemonade
 PLANT EXTRACTS
USED IN BEVERAGES

ROSEMARY
Rosemary leaves are used as a
flavoring in beverages.
They have a bitter, astringent taste
and a characteristic aroma .
Herbal tea can be made from the
leaves.
It is used in Rosemary lemonade
 PLANT EXTRACTS
USED IN BEVERAGES

CHAMOMILE
Chamomile is a herb that comes from
the daisy-like flowers of the Asteraceae
plant family.
Chamomile tea is a herbal infusion
made from dried flowers and hot
water.
Chamomile tea is loaded with
antioxidants that may play a role in
lowering risk of several diseases,
including heart disease and cancer.
Chamomile may be used as a flavoring
agent in foods and beverages,
PLANT EXTRACTS
USED IN BEVERAGES

MINT( Mentha sp.)

Mint flavors — particularly
spearmint and peppermint — used
in beverages such as mojitos
They are strongly associated with
refreshment.
It is used for relieving stomach
,Improve energy level and sleep.
Example: Mojito mint syrup , lemon
and mint juice, Lipton mint ice tea
.
 PLANT EXTRACTS
USED IN BEVERAGES

CLOVES(Eugenia caryophyllata)
Clove is a delightful addition to sweet
and savory drinks.
It provide sharp flavor and fragrant
aroma.
Cloves can also be used in alcoholic
beverages.
Cloves can help the body as an
anti-inflammatory agent and are able
to provide multiple nutrients like
vitamin C, fiber, manganese and more
so it is used in clove tea.
Example: Hibiscus clove tea
PLANT EXTRACTS
USED IN BEVERAGES

VANILLA( Vanilla planifolia)

Vanilla is one of the world’s most
popular flavor profiles used in food
and drinks.
vanilla is always used as a
stand-alone flavor but also in
combination with other flavors.
Vanilla essence is extracted from
vanilla beans and is used to flavor
the beverages.
Example: Bolthouse vanilla chai,
French vanilla, vanilla pepsi.
OTHER PLANT EXTRACTS USED

► Allspice – used in non alcoholic beverages

► Anise – used in traditional alcoholic beverage
► Cassia – used in spiced tea and coffee
► Lemongrass- used in green tea
► Hibiscus- hibiscus tea
► Rose extract - used in herbal rose tea
Methods of
extraction and
production of
essential oils
from LAVENDER
1. Steam Distillation Process
► This process involves placing quantities of plant
materials in a large container of water.
► This water and plant mixture is then brought to a
boil and steam is produced.
► Then the essential volatile plant oils are carried by
the steam through a cooler (the coil) where it
condenses.
► This liquid made up of plant oils and water is
collected.
► The essential oil floats on top of the water in a thin
film and must be separated.
2.The Expression Method

This method is used for those plant materials that contain

essential oils in larger oil sacs.

The plant oils are squeezed from the plant materials and
collected for use and filtered.

Citrus fruit essential oils such as orange, lemon, lime are

examples of the types of plant materials where the
expression method is used as a means of extraction.
3.Maceration

► In this method, quantities of plant materials are collected and chopped.

► This plant material is placed into a container of another oil such as olive or
sunflower oil.
► This mixture is then allowed to sit for a period of time and agitated and
mixed periodically.
► After some time the macerated plant material is removed and the oil is
filtered and strained of any remaining plant particles.
► The resulting oil is now infused with and contains the plant's essential oil
molecules.
General plant extraction
Vanilla extract Stevia extract Ginger extract Hibiscus

Some commonly used beverages with

botanical extracts
Rose extract lemongrass Bael extract Cloves , cardamom
and cinnamon

Some commonly used beverages with

botanical extracts
THANK
YOU!
INTRODUCTION: PACKAGING MATERIAL FOR
BEVERAGES

• Definition
• Packaging- It is the technology of enclosing or protecting products for
distribution,storage,sale and use . Packaging also refers to the process of designing,
evaluating and producing packages. Packaging can be described as a coordinated system
of preparing goods for transport, warehousing,logistics,sale and end use.
• It protects the product from detrioration
NEED FOR PACKAGING

• There are 4 primary functions of packaging

1. Product protection: transportation, handling, distribution
2. Product safety: hazards, traceability
3. Product freshness: apperance,taste, freshness, quality
4. Brand identity: marketing,brand integrity
TYPES OF PACKAGING MATERIAL

1. Bottles:glass, plastic,more recently metals

2. Flexible:Cartons, pouches
3. Cans
4. Closures
BOTTLES- (A)GLASS

• Strong ,inert , odorless , good barrier ,suitable for both carbonated & non carbonated
beverages and alcohlic beverages
• Excellent decorative & closure options
• Many shapes
• 500ml , 250-300ml size for carbonated soft drinks
• Perceived as ‘quality’ & premium image for alcoholic beverages like beer , wine etc
• Limitations- easy to damage , high transport cost , other secondary processing
performance causing substantial reduction in usage
BOTTLES- (B) PLASTIC

• For non carbonated- have ribs to add strength, withstand vacuum on many filling
machines
• 1) polyvinyl chloride (PVC) & high density polyethylene (HDPE): for non carbonated
• For carbonated- pressure forces any shape out and therefore PET is used
2) POLYETHYLENE TEREPHTHALATE (PET) BOTTLES

• Light, strong, impact resistance, temperature stable

• Used for both carbonated (CO2 inflated) & still ones (ribs or liq. Nitrogen added before
capping)
• High flexibility, easy transportation & storage, low energy recycling, water resistant
• Limitations- CO, O2 permeability, non biodegradable, permeable to light, taste
deterioration,
FLEXIBLE – (A) CARTONS

• Drink cartons for non carbonated drinks are usually made with a square or rectangular cross
section
• These are manufactured by the well developed systems
• These are high technology packaging formats and whilst they are understood by the consumer
• Aseptic processing allows for the food to be properly sterilized outside the container and then
placed into a previously sterilized container, which is then sealed in a sterile environment.Most
systems use ultra-high temperature (UHT) sterilization to sterilize the food product before it is
packaged. 
• Tetra Pak cartons are primarily made from paper. 75% of the Tetra Pak carton
is made from paperboard, 20% of polyethylene and 5% of aluminium. These three
materials are layered together using heat and pressure to form a six layered armour
which protects the contents from light, oxygen, air, dirt and moisture.
FLEXIBLE- (B) POUCHES

• Flexible laminates can be made in to pouch packs for non carbonated drinks
• the product needs to be aseptically or hot filled ambient storage for fruit based drinks
• Consumer will see the unbreakable collapsed format as being suitably sports oriented
• Because the pouches are not normally self supporting the secondary packaging needs careful
consideration

• polyethylene is used as a barrier on the inner and outer sides of aseptic packaging. These
layers protect against moisture entering or exiting the container.
• Film foil helps preserve the product by keeping light and oxygen out.
CANS

• Highly developed to deliver a drink efficiently at low cost to consumers

• Robust, excellent product production, retention of carbonation, low O2 ingress
• Limited decorative capability due to cost increase
PACKAGING OF ALCOHLIC BEVERAGES

• Tin cans
• Glass bottles
SECONDARY PACKAGING

• Secondary packaging is defined as additional packaging ,which has no direct influence on primary
or original container or package that is ultimately bought and use by the consumer.

• It keep the primary packaging in best condition upto the point of purchase ans use
• Secondary packaging such as shrink wrapping, cardboard cartons, re-usable plastic crates
• The delivery driver takes the goods into the shop, arranges the display and collect. The empty
crates
• These crates are designed to nest inside one another and reduce the space on tge return
journey
SECONDARY PACKAGING

• In this way,the crates are sorted and returned efficiently to the correct factory for
washing,as necessary,and reuse
• Such crates are made from various poyolefine plastic and suitably protected with
stabilisers to prevent degradation by sunlight
THANK YOU
Flavored syrup
 Flavored syrup
• Concentrated sugar syrup.
• Contains natural/ artificial flavors.
• Does not contain fruit pulp/ juice.
 Ingredients
• Pure cane sugar
• Water
• Natural Flavor (may contain artificial flavors)
• Citric acid (As Acidulant)
• Sodium Benzoate (As preservative)
• Artificial colors
 Ingredients (Regular)
• Pure cane sugar
• Water
• Natural flavors
• Citric acid
• Sodium benzoate
• FD&C Red≠ 40
• Caramel color
 Ingredients (sugar free)
• Sucralose, Acesulfame K
• Water
• Natural flavor
• Citric acid
• Sodium benzoate,
Potassium sorbate
• Artificial colors
• Caramel color
 Ingredients (Coffee Syrup)
• Pure cane sugar
• Pure coffee extract
• Natural flavors
• Citric acid
• Sodium benzoate
• Potassium sorbate
(to preserve freshness)
 Ingredients (Tea Spice Syrup)
• Pure cane sugar
• Natural flavors (including Cinnamon, vanilla,
nutmeg)
• Tea extract
• Citric acid
• Sodium benzoate
• Potassium sorbate
 Ingredients (Monin)
• Pure cane sugar
• Water
• Natural and identical
flavors
• Mallic acid
• Potassium sorbate
• FD&C Blue≠ 1
Coconut based beverages
 Edible coconut products
Fresh Coconut Coconut water Copra Coconut sap
Dried Milk Oil Tender Mature Coconut Unferme Fermente
coconut coconut oil nted sap d sap
water water NEERA TODDY
Desiccated Coconut Coconut Margarine Coconut Arrack
coconut cream water jaggery
concentrate
Coconut Coconut Coconut
milk vinegar sugar
powder
Coconut
yoghurt
Coconut
syrup
and jam
 Coconut milk
Coconut Dehusking

Deshelling

Blanching by immersing in hot water at 80˚C/10min

Grinding in hammer mill

Pressing in continues screw press to extract milk

Filtration of coconut milk by passing through a vibratory scream

Pasteurization to eliminate micro-organisms

 Coconut cream
• Coconut cream is chiefly used as fat source.
• It is similar to coconut milk but has a thicker
paste like consistency.
• Can be used directly or diluted with water to
be used in curries, sweets, deserts, puddings,
cakes and ice cream.
 Coconut Cream
Coconut milk

Addition of food additives (emulsifiers, stabilizers to obtain stable consistency

and texture)

Emulsification mechanical impeller emulsifier

Thick coconut cream

Pasteurization at 95˚C for 10min in plate heat exchanger

Pasteurized coconut cream is hot filled in cans followed by exhausting,

seaming and processing in retort at 15PSI/20min

Cooling
 Packed tender coconut water
• Natural Isotonic beverage which balance
electrolyte in our blood.
• Passes therapeutic properties
• Contain significant amount of minerals (K, Na,
Ca, Mg, P, Fe) dietary fiber.
• Low in calories chlorides and cholesterol.
 Tender coconut water
• Tender coconut fruits(harvested at an age of 9
months from time of pollination, the period
before the solid endosperm or white meat
forms).
Processing of Coconut water(Pet
bottles)
Washing in portable water

Sanitizing with chlorinated water for 15mins

Cutting manually or mechanically

Filtration

Adjustment of pH, Total soluble sugars

Pasteurization

Cooling

Packaging in pre-sanitized pet bottles

Processing of Coconut water(Tetra
packs)
Washing in portable water

Sanitizing with chlorinated water for 15mins

Cutting manually or mechanically

Filtration

Adjustment of pH, Total soluble sugars

UHT sterilization

Cooling

Packaging in tetra packs

 Coconut water concentrate
Fresh coconut water

Removal of suspended solids and oils by centrifugation

Removal of minerals by passing through ionic resin packed

Colum to get a sweet taste

Concentrated coconut water

Can be frozen or preserved in cans

After dilution, can be used in production of carbonated and

non-carbonated coconut beverages
 Coconut vinegar
• Healthier alternative for synthetic vinegar(rich
in minerals and vitamins such as
beta-carotene).
• Can be prepared from coconut water or from
sap of coconut tree.
• Used as flavoring and preservative agent in
pickles, salad dressing and sauces.
• It is a resultant product of alcoholic and acetic
fermentation of sugar enriches coconut water.
 Preparation of coconut vinegar
Coconut water(Brix-15˚ by adding sugar)

Pasteurization

Cooling

Inoculation with active dry yeast(1.5gm/L)

Incubate at 28˚C (room temperature) for 5-7 days for alcoholic fermentation

Add mother vinegar for acetic fermentation

Again incubate at 28˚C (room temperature) for 7 days

Filter the residue part

 Neera
• Neera is unfermented sweet sap extracted
from coconut tree.
• Neera is suscepible to natural fermentation at
ambient temperature with in few hours of
extraction.
• Once fermented, Neera become toddy.
• Neera is rich in carbohydrates mainly sucrose,
Vitamins and have a nearly neutral pH.
• To extent the shelf life it is pasteurized.
 Toddy
• Toddy is obtained by natural fermentation of
sap(neera).
• Bacteria and fungi are responsible for
fermentation of coconut sap.
• Fully fermented in 6-8 hours with alcohol
content 4-6%.
 Process
The sap is collected from the cut flower of palm tree

Container is fastened to the flower stump to collect

the sap

As soon as it is collected natural yeast and bacteria

starts fermentation

With in 2 hours an aromatic wine up to 4% alcohol

content with sweet taste is developed
 Coconut Arrack
• Toddy may be distilled to make a stronger
alcoholic liquid.
• It is distilled between 33-50% alcohol by
volume.
 Coconut syrup
• It is syrup prepared from coconut milk.
• Used for topping of bakery products or may
be diluted with water and used in preparation
of cakes and other delicacies.
 Process
Equal amount of Coconut milk and sugar is
homogenized with addition of 0.05% citric
acid

Mixture is heated till TSS reaches 65-68%

Packing of hot syrup in lacquered tin cans