Therefore, there are no product losses, it is easier to maintain cleanliness and tank truck filling takes less time. The pasteurizer is designed to carry out pasteurization of the concentrate in order to preserve it. The pasteurization kills microorganisms that are harmful to life and health.
Once the pasteurization has been completed properly, our apple concentrate has a longer shelf life and preserved organoleptic properties. MONA aseptic filtration system Alicyclobacillus elimination allows eliminating ACB bacteria as well as improving the quality of concentrated juices, e.
The principle of MONA operation is based on three processes: heating, filtration, cooling. Application of the Mona system is the only effective way to eliminate ACB bacteria,. ADS XL adsorber is used for stabilisation and conditioning of apple juice. This device is applied for the production of high-quality concentrates, which have to meet high quality requirements regarding stability and colour. The adsorber is used any time the uf xl ultrafiltration system does not ensure the required quality elated to colour standardisation and does not guarantee long-term stability of juices and concentrates.
CIP clean in place station is used for washing installations, devices and pipelines in the production line in CIP system.
In the production process of juice and concentrates, washing station ensures cleanliness and hygiene in process tanks and storage tanks as well as in pipelines transporting raw material in pipelayers. Washing products are prepared in the station in the form of working solutions and pumped to the device or installation which is to be cleaned.
Then, they circulate in a closed circuit between CIP station and a given device within the time which ensures thorough cleaning at a set temperature. Washing temperature and solution concentration undergoes ongoing verification and automatic adjustment. A washing procedure consists of the following phases:. Closed circuit washing allows for cleaning agent economy and reduction of sewage discharged.
Working solutions are prepared in the CIP station in the concentrations recommended by the manufacturer and in adequate temperatures. Solutions are retained in three tanks insulated with a double coat and fed by a pump as needed. Below is a set of eight videos that show how apple concentrate is produced by one of Poland's leading concentrate manufacturers. ADS XL Adsorber is a technologically advanced, modern device designed for concentrate manufacturers, the use of which increases the competitiveness Before you go further, please read our Privacy policy that explains how we collect your personal data and how we process it.
The process of production of juices and concentrates in a nutshell! How fruit juice and concentrate is produced? Have you ever wondered how juice in your glass was made? Acceptance of raw material The production process of fruit juice and concentrates begins with raw material purchasing. Hydro-unloading system consists of: automatically controlled water cannon used for rinsing fruit from a car operator's rooms with control and pneumatic cabinet for system operation bucket conveyor for vertical transport of raw material and separating water floatable chute with draining devices which accepts raw material from bucket conveyor and the flap system directs it to respective silos The delivery scope of dry unloading system includes: hydraulic tipper for vehicles.
Raw material is unloaded from a car through lifting the front part of the platform and emptying fruit to the hopper operator's cabin spiral sorter - separates impurities such as: leaves, branches, sand and stones diagonal belt conveyor - takes raw material from the hopper unloading belt conveyor - located above silos, directs the accepted raw material to respective storage chambers Apples should be stored in small prisms.
Fruits are washed depending on the unloading method applied: in two or in three stages during hydro-transport from silos through water spraying in front of the vertical elevator which transports fruits to the inspection belt at the end of the inspection belt of tables through the system of spray nozzles Fruits taken from silos by a sorting unit are transferred to the pulp preparation section. Fruit pulp preparation and processing Raw materials from pre-production warehouse are transferred to the dosing units known as sorting units.
We can also help you create a product to take advantage of the latest fruit consumption recommendations. Incorporating a full serving of fruit into your product creates a marketable advantage. Why choose apple juice concentrate? Shelf Life and Storage Recommendations:. Nutritional Information. Nutrient Amount Moisture You may also like Click on images below for more information.
Finishing-Style Apple Juice Concentrate. Pear Juice Concentrate. If you conclude in your hazard analysis that metal fragments are a hazard that is reasonably likely to occur in your juice, you must establish controls for metal fragments in your HACCP plan.
Step 2 -- The second step of a hazard analysis is to evaluate each of the potential hazards from Step 1 by assessing the likelihood of occurrence and the severity of health consequences associated with the potential hazard.
For instance:. Step 3 -- The third step of the written hazard analysis is to determine, based upon the information gathered in steps 1 and 2, whether each potential hazard will require controls in your HACCP plan pursuant to 21 CFR A hazard that will require control is referred to in the juice HACCP regulation as a hazard that is "reasonably likely to occur. A hazard that is "reasonably likely to occur" is one that presents an identifiable and significant food safety risk that you, acting as a responsible processor, would act to reduce to an acceptable level, prevent or eliminate, by establishing and carrying out control measures for that hazard.
Generally, you will carry out your control measures at CCPs which are specific points in the process for producing juice identified in your HACCP plan.
If a potential hazard has a severe, acute public health impact e. Hazards that require exposure over time to cause harm would need to occur over time at levels of concern in the juice to be classified as a hazard that is reasonably likely to occur. The mycotoxin, patulin, which can occur at high levels in apple juice, is an example of a hazard that could result over time from exposure to a contaminant and thus, may need to be controlled through your HACCP plan.
Your HACCP team may identify a potential hazard for your juice, that upon further evaluation is determined not to require control. For example, processors of carrot juice may identify lead as a potential hazard because high lead levels have recently occurred in some carrot products apparently due to the carrots being grown in soils contaminated with lead from the past application of a no longer permitted, lead-containing pesticide to orchards formerly on the land.
However, you may be able to establish that the land upon which your supplier grows carrots is not contaminated with lead, or that crops were never grown on that land that would have had lead-containing pesticides applied to them. Having established either of these premises, you could conclude appropriately that elevated levels of lead are not reasonably likely to occur in the carrots that you use to make juice.
However, if you acquire a new supplier of carrots, you should reassess the potential for elevated levels of lead to pose a hazard in your juice as part of the re-validation of your hazard analysis required in 21 CFR FDA recognizes that hazards controlled by most types of sanitation programs may be impractical to manage in a HACCP plan format because it is often difficult to determine appropriate critical limits and corrective actions for sanitation controls.
Therefore, when you conduct your hazard analysis, and identify hazards that derive from any of the eight areas listed in 21 CFR As provided in 21 CFR Examples of potential hazards that may be controlled under your SSOP program include substances used on juice processing equipment, such as lubricants and sanitizing chemicals, or substances applied to juice packaging materials under the provisions of a food additive regulation, such as hydrogen peroxide that is used to sterilize packaging materials on aseptic packaging lines for juice.
If you have SSOPs designed to ensure that the substance will be used in accord CGMPs or with the provisions of the applicable food additive regulation, you may, in your hazard analysis, cite the SSOP as a justification for determining that the hazard is not reasonably likely to occur. Examples of this approach are included in the Example Hazard Analyses in section VII A for pasteurized refrigerated apple juice the sanitizer used for cleaning the holding tank and for not-from-concentrate pasteurized orange juice the lubricant used on the extraction equipment.
In addition, the following partial hazard analysis summary table for an aseptic juice packaging operation illustrating only the aseptic filling and packaging step where hydrogen peroxide is used as a sterilant illustrates the same approach. As noted in the previous section, hazards that arise in juice processing from unsanitary food contact surfaces that can contaminate juice with residues of food allergens should be considered to be "reasonably likely to occur.
To be amenable to control at a CCP, the control measure must lend itself to validation and to the establishment of critical limits. We may question the adequacy of a HACCP plan to control hazards that may arise from unsanitary food contact surfaces when the plan does not include rigorous SSOP controls, or where applicable as discussed in the next paragraph , CCP controls for such hazards.
For example, if you produce juice on equipment that also is used to process milk, we recommend that you identify undeclared milk residues in your juice as a hazard that is "reasonably likely to occur. If it is not possible to validate control measures for cleaning food contact surfaces, and critical limits cannot be established, your control activity would not be amenable to incorporation into a CCP and you would have to control the hazard through a rigorous SSOP procedure.
Step 4 -- The fourth step in a written hazard analysis is to identify control measures and critical control points for hazards determined in step 3 to be reasonably likely to occur, and to review your current process to identify needed modifications to the process control measures are discussed in section V. This NACMCF CCP decision tree may assist you in determining critical control points for controlling the hazards that were identified in your hazard analysis as reasonably likely to occur.
A CCP may be established at any process step where you can effectively apply controls. For instance, for a pasteurized apple juice process that includes controls for pathogens and for the mycotoxin patulin:. Examples of HACCP control measures used in the processing of juice include measures carried out at CCPs specified in a HACCP plan such as the pasteurization of juice for the elimination of microbial pathogens; the culling or trimming of apples after storage to eliminate moldy, damaged, bruised, or rotten apples to ensure that patulin will not be present at levels of concern in the finished apple juice; and periodically monitoring processing lines for evidence of glass breakage.
Some activities firms may undertake in processing juice and in related functions are not HACCP control measures. It does not apply to firms that conduct activities such as the growing, harvesting, and transporting of fruits and vegetables that will be processed into juice. C above. However, if a hazard originating from the agricultural environment is determined to be reasonably likely to occur on your incoming fruit, e.
If control of such a hazard involves actions that will be carried out by your grower, e. However, we encourage you to work with your suppliers to evaluate and modify agricultural practices in accordance with FDA's GAPs guidance document.
Therefore, you cannot use CGMP programs to control a specific hazard that, based upon your hazard analysis, you have concluded is reasonably likely to occur in your juice. The 5-log pathogen reduction requirement in 21 CFR Processing experts evaluate treatments intended to destroy or inactivate pathogens in food in terms of "logs" of kill, where the term "log" is a shorthand expression of the mathematical term logarithm.
A logarithm is "the exponent of the power to which a base number must be raised to equal a given number. Again, if the base number is ten, it must be raised to the third power to equal , so the exponent is 3, i. The HACCP regulation requires you to use treatments capable of consistently achieving at least a 5-log reduction using ten as the base number in the level of the pertinent microorganism in your juice.
The important thing to understand is that each log of kill is capable of causing a tenfold reduction in the number of organisms of the pathogen that the treatment is designed to kill, i. A 2-log process further reduces the level of the target pathogen by another factor of 10, i. The initial number of pathogens present in your untreated juice is likely to be far less than 10 5 organisms per gram, i. Applying a 5-log treatment to juice that may contain such levels of pathogens achieves a tolerable level of risk by ensuring that the process is adequate to destroy microorganisms of public health significance or to prevent their growth.
Thus, if you use pasteurization as your pathogen control measure, that treatment must be carried out to achieve consistently at least a 5-log reduction in the "pertinent microorganism.
Multiple processing steps, such as a series of surface sanitization treatments for citrus fruit, may be used to achieve the 5-log reduction. However, under 21 CFR We recommend that all juice processors consult with a process authority see "Process Validation" in section V.
The "pertinent microorganism" is the most resistant microorganism of public health significance that is likely to occur in the juice and is the pathogen that you must target for the 5-log pathogen reduction treatment 21 CFR By choosing the most resistant pathogen as your target, you are also treating the product for all other pathogens that are less resistant to the means of treatment. One way to identify the pertinent microorganism for your juice is to consider whether there have been any illness outbreaks associated with this type of juice, and what microorganisms have caused the outbreaks.
If certain pathogens have been demonstrated, i. For example, Salmonella species have been the cause of several illness outbreaks related to orange juice and may be considered the "pertinent microorganism" for orange juice products. Which of these two pathogens is determined to be the pertinent microorganism will depend upon which of the two is most resistant to the means of treatment, e.
The pertinent microorganism for apple juice is discussed further in section V. Although Listeria monocytogenes has not been linked specifically to an illness outbreak from juice, it is ubiquitous in nature.
For this reason, we recommend that Listeria monocytogenes be considered as a possible "pertinent microorganism" for juices that have not been associated with illness outbreaks caused by Salmonella species, E. Alternatively, for juices other than apple juice, you may generically designate "vegetative bacterial pathogens" as your pertinent microorganism if your juice is an acidic juice, i. Low-acid juices, such as carrot juice, that are distributed under refrigeration, and are not subject to the Low Acid Canned Foods regulation 21 CFR Part may pose hazards associated with spore forming pathogens, specifically, toxins of non-proteolytic and proteolytic strains of Clostridium botulinum.
Control measures for such juices are likely to involve multiple measures, e. Destruction of spores of the non-proteolytic strains requires a less severe heat treatment, but these spores can germinate and produce toxin even under refrigerated storage conditions. The 5-log pathogen reduction treatment must last through the normal shelf life of the product when held under moderate temperature abuse conditions 21 CFR This requirement is intended to ensure the effectiveness of the treatment if any microorganisms that may be injured in processing, might be capable of surviving if held under optimal growing conditions.
Normal handling of juice includes the movement of the juice from the plant to retail e. Moderate abuse may occur when unusual circumstances occur during customary handling. For example, unloading a truck on a hot day where the product may sit on a loading dock for a short period of time could constitute moderate abuse. In addition, moderate abuse could occur if consumers purchase a product on a warm day, place it in their car, and run errands before refrigerating the product.
Moderate abuse does not include exposure to warm temperatures for extended periods of time. Your "process authority" see "Process Validation" in section V. You must meet the 5-log pathogen reduction requirement by treating the juice directly, i. However, for citrus juices, you may meet this requirement by applying pathogen reduction treatments to the surface of the citrus fruit prior to extracting the juice. Such treatments usually are carried out through a series of washing, brushing, and sanitizing steps.
If you use such treatments to meet the 5-log pathogen reduction requirement, you must also adhere to certain specific requirements in 21 CFR Pursuant to 21 CFR There are two potential exceptions discussed in the following paragraphs.
If you do treat your juice at a different facility than the one in which the final packaging is carried out, the treatments applied at the first facility cannot be counted towards meeting the 5-log pathogen reduction requirement. The first exception noted in the previous paragraph applies to producers and users of high degree Brix juice concentrate.
In a letter dated January 22, and a January 25, letter of correction , FDA stated that it would consider the exercise of enforcement discretion with respect to the "single facility" requirement as applied to producers and users of high degree Brix concentrate 6 where the following three conditions are satisfied: 1 the producer and user establish appropriate prerequisite programs and SSOPs for the transport of high Brix juice concentrate; 2 the producer and user designate as a CCP in their respective HACCP plans the transport of high Brix concentrate from the production facility to a second facility for formulation and final packaging of concentrates; and 3 the producer and user establish control measures to prevent, reduce, or eliminate the risk of recontamination of the concentrate during transport The January 22, , letter and a correction to that letter dated January 25, , are available at the website listed in section I.
The second exception applies to the bulk transport and packaging of shelf-stable single strength juice that is transported in aseptic packaging.
FDA also stated in the January 22, , letter that it would consider using its enforcement discretion with respect to processors that transport in bulk and package shelf-stable single strength juice that is transported in aseptic packaging.
FDA also stated in the January 22, , letter that it intended to develop and issue guidance that will contain FDA's basic recommendations for appropriate control measures for several transport modalities modes of transportations , including tankers, mobile tank farms within cargo ships, single-use sanitary containers e. B above. You may extract juice from the fruit in one location and ship the untreated juice to a second location for processing i. If you do this, we recommend that you obtain assurance, e.
We also recommend that the label of the untreated juice, or if transported in bulk, the invoice or other shipping documents, state that the juice has not received a treatment sufficient to yield a 5 log pathogen reduction. If you produce a citrus juice and you choose to meet the 5-log pathogen reduction requirement by surface treatment of the fruit, the following additional requirements apply:.
If you produce a citrus juice using surface treatments to meet the 5-log pathogen reduction requirement, FDA recommends that you do the following to meet the requirement that you use tree-picked and culled fruit:. If your verification testing yields a single positive for E. We recommend that you conduct these activities as quickly as possible. You also must look at results for the preceding six tests for that product; under 21 CFR In the juice HACCP final rule, we also suggested that if you get a single positive test result, you should review your test results over a larger window of tests more than just the last 7 tests to see if these test results are an early warning that the process may be approaching failure.
We stated that review should be sufficiently extensive to allow you to spot a trend towards loss of process control. Here, we provide how far back we recommend you review your records. As the window gets larger i. Therefore, looking at results over a larger window is not required and finding two positive results in the larger window does not impose any additional regulatory requirements.
However, as noted above, looking at test results over an extended time period may allow you to spot a trend towards loss of process control and take appropriate action before your system fails.
How far back you choose to look may depend on a number of factors, including production volume, testing frequency, and experience. We recommend that you start by considering 2 positives in any series of 17 tests or 3 positives in any series of 52 tests as a potential warning. Thus, a finding of 2 positives in 17 tests, or 3 positives in 52 tests, could be an indication that your controls are not functioning as intended and that they may fail at some point.
You would then be able to investigate the operation of your control measures and take any necessary action to ensure that they are functioning as intended before a failure occurs. As window width increases to 20, 25, and 30 tests, the probabilities of finding two positives when the system is functioning correctly are 9. Our recommendations for factors to consider when establishing control measures for heat treated shelf stable juices and concentrates, and other non heat- treated juices are discussed in 4.
If you use a single thermal processing step to produce a shelf stable juice, or a thermal concentration process that includes all of the ingredients of a juice, you are not required to include control measures in your HACCP plan for achieving the 5-log pathogen reduction.
Based upon research it conducted for E. See reference to publication by Mazzotta in section V. To obtain the exemption from the requirement to include controls in your HACCP plan to achieve the 5-log pathogen reduction, the juice HACCP regulation requires a copy of the process used to produce the thermally processed juice concentrate to be included in your hazard analysis.
The thermal process must be applied to the concentrate and all of its ingredients. We recommend that the copy of the thermal process used to achieve concentration describe the steps in the process, such as the pre-evaporation heat treatment and the evaporation steps. We also recommend that it describe the type of equipment used in each process step such as a "continuous flow tubular heat exchanger" for the pre-evaporation step and a "X effect high temperature short time evaporator" X-representing the number of effects for the evaporation steps.
In addition, we recommend that it describe the product temperature and exposure time for the pre-treatment step, the product temperature for each of the evaporation effects, and the process time and temperature for the thermal process for any ingredient of the concentrate that is processed separately and then added to the concentrate. To ensure the safety of a "thermally processed concentrate" we recommend all of the juice receive a pretreatment consisting of a thermal treatment of at least 80 degrees Centigrade for thirty seconds.
Such a process delivers a degree of thermal inactivation of pathogens that is extraordinarily beyond the required 5-log reduction see Reference 68 in the juice HACCP final rule.
FDA is not likely to question whether a product processed in such a manner is a "thermal concentrate" and thus, qualifies for the exemption from a process control to achieve the 5-log performance standard for pathogen reduction. However concentrates produced using unconventional processes that involve low temperatures might not receive enough heat to ensure a comparable level of inactivation of potentially harmful microorganisms that might be present in the juice. If we encounter a concentrate that is processed in such an unconventional manner, we may ask for additional data demonstrating that the process delivers a level of thermal inactivation of microorganisms that is comparable to that delivered by a conventional thermal concentration process.
Absent providing such data, we may advise you of our view that the exemption from a process control to achieve the 5-log performance standard for pathogen reduction is not available for the product and that you should include control s CCP s in your HACCP plan for achieving the 5-log reduction.
If you produce a juice that is subject to the requirements of 21 CFR Parts or , i. You may identify such hazards as potential hazards in the hazard identification phase of your hazard analysis, but in the hazard evaluation phase, you may conclude that such hazards are not reasonably likely to occur because they are controlled through compliance with the requirements of 21 CFR Parts or However, the hazard analysis and HACCP plan should completely address any other hazards associated with such juices, i.
If the treatment includes the use of a source of radiation, e. Both UV radiation and pulsed light have been approved by FDA for the control of microorganisms, and the regulations specifying the conditions under which they may be safely used are at 21 CFR If the treatment includes the use of a chemical anti-microbial agent, such as a sanitizer, to reduce pathogen levels on the surface of citrus fruit, the chemical agent must be approved by FDA for that use i. If you use sanitizing agents as surface treatments on fruit used in the production of citrus juice, you should secure documentation from your supplier that the sanitizing agent is either GRAS, or is approved by the FDA for this use.
Treatment technologies that do not involve the use of a source of radiation or a chemical agent, e. However you should verify any such assumption with your process authority see following section. Whether you use a form of radiation UV radiation or pulsed light , a chemical treatment, or some other type of treatment for pathogen reduction purposes, the process used for pathogen control must be validated for this purpose according to the validation requirements in 21 CFR You must ensure that the process you will use has been validated, i.
In order to ensure the validity of your process, FDA recommends that you employ or consult with a "process authority. Many different types of processes may be used to reduce the level of the organism of concern.
For each of these processes, the critical control points and critical limits must be identified. A process authority should know what critical limits, such as time and temperature, would be effective for treating juice. Other processing factors such as flow rate, turbulence, pressure, concentration, composition, intensity, penetration depth, and absorbance may also be important to a process.
Your process authority should be able to evaluate such other aspects of your processing system that could affect its performance. Although your process authority will likely be your source for information on the critical limits for your pathogen reduction process, you will have to know what those limits are, e.
You may employ a process authority as a member of your staff, or alternatively, you may be able to identify a process authority through your national or regional food processors trade association, or through educational institutions such as food science and technology departments in state universities. Some state government agencies, e.
Some processing equipment vendors employ or retain as consultants such experts who also have detailed knowledge about the performance capabilities of the vendor's equipment and can work with you to establish that the equipment will effectively control pathogens in your processing operation. At this time there are some published studies on pasteurization processes for controlling pathogens in juice that we can comment on to assist you in developing your HACCP plan. The efficacy of this process was measured using single strength apple, orange, and white grape juices adjusted to a pH of 3.
The authors noted that a pH in the range of 3. The authors also noted that the heat resistance of these vegetative bacterial pathogens might be considerably greater at pH values of 4. This process assumes that the pathogens will have increased thermal resistance due to their being acid-adapted.
Study 2 Summary: A study done at the University of Wisconsin 8 has shown that treatments of However, other validation studies may be needed for juices that have pH values greater than 4.
We also believe that either of the processes evaluated in the University of Wisconsin study is adequate to ensure a 5-log reduction of the three stated bacterial pathogens, E. Neither of these two studies evaluated thermal processes for achieving a 5-log reduction for oocysts of the protozoan parasite Cryptosporidium parvum that has been a cause of illness outbreaks associated with the consumption of apple juice. In fact, the thermal destruction of Cryptosporidium parvum oocysts has not been as widely studied in the published literature as it has for the vegetative bacterial pathogens; however, the available scientific literature suggests that Cryptosporidium parvum 9 oocysts may be more resistant to thermal processing than the three vegetative bacterial pathogens.
Therefore, we recommend that you consider Cryptosporidium parvum to be the pertinent microorganism when you are establishing a HACCP plan for apple juice. For apple juice at pH values of 4. The biggest challenge for cidermakers has always been the juice—it is heavy and takes up huge amounts of space. But in the 20th century, clever people figured a work-around: concentrate the juice, store it, and then rehydrate and ferment as needed throughout the year.
I had never really put a lot of thought into how juice is concentrated until I sat in on a session at CiderCon — an industry conference — with Terry Chambers, President and GM of FruitSmart , a company that prepares and sells apple juice and apple juice concentrate AJC in Yakima. When apples come to FruitSmart, the process for all products begins the same way: the fruit is inspected, washed, and milled or pulped.
The product lines then diverge, going toward unprocessed juicing or processing. For the unprocessed products, the milled apples are then pressed and either pasteurized or sold unpasteurized.
The latter product is new and offered on the request of cideries.
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