SUS304 BIB Filler Syrup Production Line For Cocktail Preparation

SUS304 BIB Filler Syrup Production Line For Cocktail Preparation

Process overview
Fruit and Vegetable Syrup
Fruit and vegetable syrup
Fruit syrups sold in stores are usually made with a concentrated sugar solution with flavors and colors, not real fruit syrup.
Natural products like maple syrup and honey contain syrup-like ingredients.
The food industry often produces fruit syrups to save weight and cost in shipping, and such syrups become juices when they are used or after being rinsed with water in the retail department. For example, the orange juice sold in restaurants and bars is almost completely made with fruit syrup. In addition, in the food industry, syrup is often made from corn, potato or wheat, rather than more expensive sugar cane.
Syrup is also added to some cocktails.

Generalize
In industrial production, starch sugar is divided into several types according to the glucose conversion value (DE).
According to the liquid glucose value, it can also be divided into high invert syrup (DE60-70), medium invert syrup (DE38-42), and low inversion syrup (below DE20). Product varieties are:

Maltose
It is a disaccharide composed of two monomolecular glucose, which has low sweetness and higher thermal stability than glucose. Glucose and other oligosaccharides can be obtained through oxidation reaction, and can also be converted into maltitol, glucitol, etc. Maltose is boiled at a temperature of 155°C. The temperature is higher than that of ordinary sugar.

Oligosaccharides
It refers to maltotriose and tetrasaccharide with low DE value, high viscosity and poor hygroscopicity. It is suitable for making hard candies, ice cream, cakes, etc.

Low invert sugar
The DE value is below 20, and the main component is dextrin, which is soluble in water, non-sweet, easy to digest, and does not absorb moisture. It is suitable for thickening. Both the acid method and the acid enzyme method can be used for low invert sugar. Acid filtration is difficult, the product has low solubility, and is easy to turbid or coagulate. It is best to use the staged liquefaction method.

High fructose syrup
This is a newly developed starch syrup whose sweetness is equal to or more than sucrose, because the sugar of fructose is divided into fructose and glucose, so it is called fruit grape syrup. It is D-glucose partially converted to fructose under the action of isomerase and catalyst. The principle of isomerization is very simple. Glucose syrup with high DE value is decolorized by activated carbon, desalted and degassed by ion exchange, and then corresponding catalysts and stabilizers are added, such as magnesium salts, cobalt salts, etc., at pH value. 6.5～8.5, the temperature is 60～70 ℃ to complete the isomerization reaction. Each enzyme is specific to pH and cannot be chosen arbitrarily.

The advantage of high fructose syrup is that any kind of starch can be used as a raw material, regardless of regional and seasonal conditions, the factory can produce all year round, the raw material resources are abundant, the price is cheap, and it is produced by enzymatic method. The conditions are general, the equipment is simple, and the investment is low. Therefore, the production of high fructose syrup has developed rapidly.

MAIN EQUIPMENTS

High-shear lysis system

The high shear lysis system is used for the dissolution of all powder components and mainly consists of parts such as a high shear dissolution tank, rotor pump and double filter.Pour hot water into the high shear dissolution tank into the tank according to the formula ratio, and then open the high-speed mixer dissolution material. After all raw materials are dissolved, pump into the double filter to separate the solid, and then sent into the mixing tank for deployment.

Blending Tank

The blending process is the core process of syrup seasoning processing, as after mixing, we obtained a semi-automatic syrup product.Hybrid process is also a thermal mixing process and can improve production efficiency.The temperature was controlled at about 6O-65℃ and the mixing time at about 15 – 30 minutes according to the composition.
The mixing pool is mixed by three layers of SUS304/316 material 2B plates and a paddle mixer at a mixing speed of 0-65rpm.It is the ideal device for mixing diluted water into ​syrup.The tank is equipped with material inlet, outlet, PT100 thermometer, steam valve set, liquid level sensor, CIP cleaning ball, sanitary valve, etc.

Homogenizer

The syrup in the syrup homogenized by the homogenizer has a smaller particle size and a higher viscosity. Under the action of shearing and impact, the ketchup is thinner and tastes smoother.
The high pressure homogenizer is mainly composed of a high pressure pump and a homogeneous valve.The uniform pressure of the material is between 25-40mpa.

Tubular sterilization machine

After mixing the syrup evenly, pump it into the sterilization machine for sterilization treatment, which can extend the shelf life of the product.The sterilization temperature was 55℃-105℃, sterilization time for 120 seconds.Material outlet temperature was set at 85℃, for hot filling.Due to the high viscosity of syrup, we generally use a tube pasteurizer.

Syrup filling machine

The most common syrup filling on the market is glass bottle filling. Syrup is a product with a relatively high viscosity. Therefore, the requirements for shelf life in filling are relatively low, and aseptic filling is not necessarily required. Ordinary linear filling machine/BIB filling machine can also be realized.

Water bath sterilization / spray cooling

The final product needs to be secondary pasteurized to better extend the shelf life.There are two kinds of secondary sterilization equipment, and we can choose according to the different packaging methods of the finished product.For tin cans or bottled syrup we use spray pasteurization, cooling channels spray hot water on the finished surface, then use cooling water to room temperature; for dose packs or self-reliance bags we use a water bath pasteurized .Soak dose packs or self-reliance bags in hot water for pasteurization, then cool with cold water, and finally blow off the droplets on the bag surface with compressor air.The secondary sterilization process was to preheat with 95℃ of hot water, then precooled with warm water to 65℃, and finally cooled to room temperature.The whole process takes about 40-60 minutes.