Fruit Juice Concentrates

Aakash Gill
Abhishek Dwivedi
B.Tech DT 2nd Year

National Dairy Research Institute

Karnal, Haryana
 Introduction

Fruit Juice : 8 16 % TS

FJ Concentrate : a product obtained from partial

removal of moisture from fruit juice

Used in production of
(a) fruit juice,
(b) fruit juice beverages
(c) fruit juice powder
 Introduction

Advantages:

1. Microbiological stability
Reduced water activity (aw)
Increased shelf life
No undesirable changes

2. Ease of handling of Fruit Juice Powder

3. Economy in packaging,
transportation
and distribution of the finished
product
 Methods
Evaporative concentration under vacuum

Membrane concentration :
Nanofiltration
Ultrafiltration
Reverse osmosis
Microfiltration

Freeze concentration
 Thermal Evaporation

Multiple effect vacuum evaporators

High vacuum (29 inHg)
Low evaporation temperature (58-60C) much
lower than the boiling point of the juice
Economical method of fruit juice concentration
Types Of Evaporators Used

Concentration Specific type

method
Vacuum pan Tubular Climbing film
Falling film

Recirculation Single stage and one

pass
Five stages and single
pass

Plate Three stages and single

pass

Agitated film Single stage

Centrifugal Single stage

 Disadvantages

Loss of much volatile flavoring compounds as

well as nutrients
Requires use of fining agents, enzymes and
centrifugation for juice clarification
High temperature promotes oxidation of
compounds in the juice, which may result in
chemical alteration of the aroma and flavor
compounds.
 Conc. Of Pulpy or Cloudy Juice
FOULING
Formation of burnt
For such juices, layer
special evaporators Concentration
having agitators becomes difficult
are used Retardation of heat
Serum transfer
Overall Heat Transfer
Concentration
coefficient (U) reduces
Process :

ce ---------- > Pulp ( Solid Phase) + Serum (Liquid Ph

Centrifugation

Mixing Concentration
 Freeze Concentration

Cold, gentle and

selective
concentration
procedure

Two distinctive steps,

viz., I ) ice
crystallization and STAGE I
II) ice separation Direct contact crystallizer
from the concentrate Indirect contact crystallizer
phase are involved.
STAGE II
()Presses
()Filtering centrifuges,
() Wash columns
() any combination of the
 Advantages and Disadvantages
Less energy is needed to Major problem is the loss
freeze a unit of water. of soluble solids of the
The low process juice in the separated
temperature prevents ice.
undesirable chemical and The final concentration
biochemical reactions of the concentrated juice
(minimum color change, is as low as 40-55% dry
non enzymatic browning matter, due to steep
and vitamin losses). increase in the viscosity
As vacuum is not of ice concentrated
involved, the losses of mixture.
low boiling flavor and
aromatic esters are
completely avoided
Better flavour profile.
Multistage Freeze Concentration

As the juice concentrates, there is increase in

viscosity which retards water crystallization.
In such process, the ice crystals are separated out
at the end of each cycle .
The remaining concentrate after separation are
fed to the succeeding crystallizing compartments.
In theses compartments, ice crystals are
separated at different levels of concentration and
viscosity.
 Membrane Processing
Usage: ADVANTAGES OF UF
Clarification the juice Desirable quality
by means of Greater Speed
ultrafiltration and Single step clarification and
microfiltration refining
Concentration by Lower energy consumption
means of nanofiltration Increased flavor and aroma
and reverse osmosis. retention

Ultrafiltration :
performs clarification ADVANTAGES OF RO
and fractionation Considerable amount of
Reverse Osmosis : aroma retention at a cost
competitive with
performs concentration
evaporation
Papplied > Posmotic No undue loss of solids.
Pressure forces out the Concentration without
water from the juice phase change or thermal
damage
 Combined UF and RO

Initially, the fruit juice is passed through Ultrafiltration

system to remove suspended solids
The UF permeate is directed to an RO system to
simultaneously concentrate the flavor and aroma
compounds, sugars and amino acids for eventual
reconstitution to single strength juice.
This allows for concentration of orange juice to levels
of ~ 42oBrix. On commercial scale up to 45-55 Brix
can be achieved.
 Drying Of Fruit Juices
Almost complete removal of
moisture
Purpose:
-enhances storage stability,
-minimizes packaging
requirements -
-reduces transport weight

Drying preserves the fruit juice as

water activity (aw) reduces
drastically and thus microorganisms
will not be able to proliferate.
 Methods of Drying

Sun/Solar Drying
Fluidized bed dryers
Spray dryers
Contact dryers
Foam drying
Vacuum and freeze
drying
 Sun/Solar Drying
It involves drying of fruit and
fruit juices by utilizing the
heat energy radiated by sun

Using solar drying techniques

can lead to poor quality and
product contamination

It takes more drying time

Gives low economy

More nutrition loss due to

heat damage to heat
sensitive constituents in the
product
 Spray Drying

Some fruit or vegetable powders are produced

from juices, concentrates, or pulps by
using a spray drying technique.
Dry powders can be directly used as important
constituents of dry soups, yogurt, etc.
The drying is achieved by spraying of the
slurry into an airstream at a temperature of
138C to 150C and introducing cold dry air
either into the outlet end of the dryer or to the
dryer walls to cool them to 38C 50C.
The most commonly used atomizers are rotary
wheel and single fluid pressure nozzle
 Spray Dryer

Simplified Diagram of a Spray Dryer

 Spray Drying (contd.)

A wide range of fruit and vegetable powders can be dried,

agglomerated, and instantized in spray drying units
These dryers are specially equipped with an internal static
fluidized bed, integral filter, or external vibrofluidizer
Bananas, peaches, apricots, and to a lesser extent citrus
powders are examples of products dried by such
techniques.
Spray drying of soluble fruit powders and convective drying
of fruit and vegetables reduces the thermoplasticity of
particles and product hygroscopicity.
They also eliminate the need for adding stabilizers which
may adversely affect the sensory properties of the final
product.
 Foam Drying

Foam mat and foam spray drying are two foam drying
methods.
Foam mat dried fruit or vegetable powders have fewer heat
induced changes in color and flavor than conventional
spray dried or drum dried products.
It yields product with lower density than that of a
conventional dryer.
The product density is about equal to the density of
instantized or agglomerated powder.
A stable gas-liquid foam is a prerequisite.
Glycerol monostearate, solubilized soya protein, and
propylene glycol monostearate are the typical additives for
the fruit and vegetable foam formulation from juice or pulp.
 Foam Drying

Foam mat drying involves drying a thin layer (0.10.5

mm) of the stabilized foam in air at 65C70C for a
few minutes, as the foam structure decreases drying
time to about one-third.
The foam is spread on perforated floor craters as the
airstream is forced through the bed.
A continuous belt tray dryer or a modified spray dryer
can be used.
Good quality tomato, apple, grape, orange, and
pineapple powders can be produced by this technique.
Optimal initial concentration of feed solids is in the
range of 30% for tomato and 55% for orange.
 Freeze Drying

There are two main stages in the freeze drying

process:
(a) freezing of the food, when most of the water is
converted into ice
(b) sublimation, when the bulk or all of the ice is
transferred into vapor under very low pressure or
high vacuum.

In some cases, additional final drying, in the same

or other equipment, is necessary.
Cabinet or tunnel batch type dryers are typically
used with pressures in the range 13.5270 Pa.
 Freeze Drying

Juice

and Powder formatio

 Freeze Drying (contd.)

Bananas, oranges, strawberries, peaches, plums,

tomato fruit juices are processed by freeze drying.
The advantage of freeze drying over other methods
of drying is the superior quality of the product.
Little or no shrinkage occurs.
The dry product has a porous structure and a color
almost as fresh as that of the raw material.
The only disadvantage of this process is the high
equipment and operational cost.
The dried fruits can be powdered for the purpose of
juice making
 Preservation of Concentrates

Especially for low pH fruit juices (like lime, lemon juices)

mild pasteurization is sufficient to have the desired shelf
life.
However, for higher pH fruit juices over and above
stringent pasteurization, chemical preservatives (i.e. salts of
sorbic acid or benzoic acids) may be used, where permitted
by laws.
The main purpose is to prevent fermentation from occurring
during the refrigerated or even ambient temperature
storage.
Sterilization of the fruit juice by Incan (retort) or by Ultra
high treatment (UHT) followed by aseptic packaging can
help in extending the shelf life for months even under
ambient storage conditions
Thank You