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TABLE OF CONTENTS

Section NO  Topics 

Section No 1   

  Introduction 

Section NO 2   

  Divisions of Shakarganj 

  Dairy division and its products 

  Juice division and its products 

Section NO 3   

  Production of FCOJ 

  Flow sheet of production 

  Detail of each step involved in production process 

Section NO 4   

  Quality Department at Shakarganj   Quality standards of fruit 

  Quality parameters of FCOJ 

  Sample preparation and holding of whole fruit and juice 

  Quality tests performed at SFPL 

  Measurement of juice contents 

  Measurement of TSS with refractometer 

  pH Measurement 

  Forecast analysis 

  Forecast analysis of concentrate 

  Measurement of %age pulp 

  Sodium determination with flame photometer 

  Measurement of citric acid 

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Welcome to Shakarganj Food Products

Introduction Shakarganj Food Products Limited (SFPL) is a subsidiary of Shakarganj Mills

Limited – a pioneer in sugar business in Pakistan. At present, SFPL is producing a whole

range of dairy products as well as fruit juice concentrates, and has a well-established and

diverse procurement, sales and marketing network in the country.

With combined experience of over 40 years in the sugar and food industry,

Shakarganj knows what it takes to deliver high-quality goods.

SFPL products include UHT milk; cream, flavored milk, pure Desi ghee, milk

powder, and fruit concentrate of mango and orange/kinnow.

From HACCP certification, ISO 9000 and Kosher Certification, SFPL products meet

customer’s demand in every sense of the word. Shakarganj customers know exactly

where its products are coming from and the suppliers know where their product is going.

The SFPL corporate office is located at Lahore, while the dairy and juice divisions

are in Jaranwala and Chiniot respectively.

For the efforts undertaken towards the community, Shakarganj received the 2008 Intel-

AIM Corporate Social Responsibility Award and was the first Pakistani company to

receive this

Divisions of Shakarganj

Dairy Division

Juice Division

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Dairy Division

An operational dairy plant located at Jaranwala, near Faisalabad, was acquired in 2006. Nearly 80

percent of the total raw milk is supplied from this part of the country. The plant packing capacity

at the time of acquisition was 75,000 liters per day of UHT liquid milk and 5 metric tons per day

of powder milk. 

 

Plant Line Capacity & Storage

Plant processing and filling capacity increased to 200,000 plus liters per day of UHT.

New Tetra Pak, Alfla Laval dairy equipment in operation.

A well-equipped laboratory and testing facilities at the plant and milk procurement

centers.

Skilled and well-trained staff with years of experience in the dairy industry.

Extensive storage and material handling facilities.

Research facility for new product development.

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Products of Dairy divison of shakarganj

Good Milk Shakarganj Food Products has developed an elaborate system of collecting milk directly from the

farmers on a daily basis, ensuring freshness of the product. The fresh milk thus collected is

processed using state of the art UHT (ultra-high temperature) technology and aseptically packed

in Tetra Pak filling machines. This process ensures zero microbial activation, while preserving

maximum flavor, taste, and nutritional value without the use of any preservatives. The product,

“good milk” is standardized at 3.5% fat and 8.9% SNF, and has a shelf life of 90 days without

refrigeration. It comes in convenient 1,000ml, 500ml and 250ml Tetra Brik packing.

 

 

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Good Milk Slim SLIM is Low-Fat High-Calcium milk. It contains less than 1% fat and has a

higher portion of calcium compared to regular milk. Two to three glasses

of SLIM help meet an adult's daily Calcium intake requirement.

SLIM has been introduced keeping in mind the need for a nutritional product for

adults. SLIM has high nutritional Value and is good in taste and after taste.

Tune in to better health with a low-fat, calcium enriched lifestyle. Move to the

rhythm of life with good milk SLIM.

 

Flavored Milk OOLALA

Flavored Milk OOLALAKids - we all love them. We love them

more as we see them grow. And who doesn't know that milk with all

its natural goodness and essential nutrients plays a pivotal role in the

child's physical and mental development. Without milk, a child's

daily diet plan is incomplete. The tough part, however, is to make

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the kids drink milk, particularly the school going ones. Somehow

they are always shying away. But now Shakarganj Foods has come

up with “Oolala”- a delicious blend of milk, available in four

exciting flavors i.e. Chocolate, Strawberry, Mango and Banana. And

kids just love it! Processed and aseptically packed in 200ml Tetra

Briks, Shakarganj ensures good quality nutritious milk with all the

essential nutrients needed for a child to grow and glow. OOLALA -

Drink more and have fun

 

Good Milk Cream

Milk that is collected from the farmers is rich in fat (over 5%).

However the processed and aseptically packed “good milk” is toned

at 3.5% fat (internationally accepted standard of full cream milk).

The extra cream from the milk is processed using state of the art

UHT (ultra high temperature) technology and aseptically packed in

Tetra Brik packages. The packed cream has a fat content of 40%.

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The rich cream, with a smooth texture, is ready for use in tea, coffee,

and desserts. It is also used as an ingredient in many traditional

recipes of cooking. It is available in packing of 200ml.

Pure Desi Ghee

Shakarganj Food Products specializes in offering high quality “Pure

Desi Ghee” (butter oil from buffalo milk) made from fresh cream.

With food connoisseur in almost every other house and culinary

heritage considered an important part of our culture, Desi ghee with

its typical rich aroma and smooth texture is used in nearly every

local cuisine and sweetmeats served especially during festivities.

Full of energy, it is also a rich source of Vitamins A, D, E and K.

Pure Desi Ghee is available in 1kg tin packing. 

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Juice Division of Shakarganj

The juice plant was acquired in October 2005 and is located in the

Punjab province, which is a fruit growing region and where citrus

fruit, mango and guava are grown in abundance. 

 

Plant Line Capacity & Storage

The plant produces juice concentrate, purée and pulp on its

Citrus and Tropical Lines.

Products are stored in refrigerated and frozen stores, which

have significant capacities.

 

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Operation Certification

ISO 9000

HACCP

Kosher

 

Production

The equipment is of Bertuzzi (Italy) and the plant is in

operation since 2006.

Consistent quality citrus concentrate and mango pulp is

produced.

Skilled and professionally trained manpower with

significant experience in the fruit industry is handling the

operations.

A well-equipped laboratory and testing facilities ensure

effective quality assurance according to the international

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standards. 

Products of Juice Division of Shakarganj

Mango Puree

More than 20 varieties of mango are found in South Asia, among

which Chaunsa is the best liked due to its nutritious value and a rich

succulent flavor. At Shakarganj, chaunsa's heavy pulp full of juice is

used for making puree that has a fibreless texture, deep golden color

and aromatic sweet taste. During peak summer, Shakarganj produces

puree from June-end till late August and the entire stock is exported. 

 

 

 

Frozen Concentrated Orange Juice (FCOJ):

Frozen Concentrated Orange Juice (FCOJ) is the most widely traded as a

commodity in the international market, normally at 65º Brix. FCOJ is

obtained by removing, through evaporation, the water from the orange juice

of fresh, ripe oranges that have been graded, sorted, washed and squeezed in

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extraction machines. It is then stored at 20ºF or lower until it is sold or

packaged for sale. FCOJ is seven-to-one strength ratio to normal single-

strength orange juice.

Consumers reconstitute the FCOJ at home by adding water to the

concentrate. At one time this used to be the dominant type of orange juice

sold in the United States. However, due to increasing consumer preference

for more convenient ready-to-drink orange juice, FCOJ has lost its

supremacy. FCOJ can be stored for several years at the adequate

temperature.

 

At Shakarganj, Kinnow concentrate is made from Kinnow Mandarin –a fruit

known for its bright orange color, high nutritional value and sweet tangy

taste. Kinnow concentrate's production begins at the plant in the last days of

December and ends by mid April. The product parameters are controlled and

maintained according to the USDA Standard guidelines and following GMP

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rules as per ISO 9001:2000 Quality Management System and HACCP

checklist.

The Production Process Of Frozen Orange Juice Concentrate

The production process comprise of number of unit operation for the

transformation of raw material into required product. These unit operations

are arranged in order to get specified product. The plant at Shakarganj for

production of juice concentrate was installed by a German company

“BERTUZZI “. The steps involved in the production of fresh orange

concentrate juice are:

FLOW SHEET OF THE PRODUCTION PROCESS OF FCOJ

WEIGHING (at scale)

↓

UNLOADING

↓

FEEDING CONVEYER

↓

CONVEYER BELT

↓

STORAGE BIN (for storage of fruit)

↓

SORTING & GRADING (manually, color, size, unripe & diseased)

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↓

WASHING TUB (immersion washing)

↓

BRUSH WASHER (unwanted dust & unwanted material removal)

↓

ELEVATOR

↓

CITRORASP

↓

CITROTALL (extraction of juice, peel and wastages are release by conveyer belt)

↓

FINISHER (to remove floating pulp)

↓

BALANCE TANK

↓

HOLDING TANK (A-19)

↓

PRE-HEATER (55-65˚C)

↓

DE-AERATOR (650 -760 mmHg)

↓

DECANTER (filter size 0.5mm)

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↓

BATCH TANK (A-25)

↓

EVAPOURATOR (2 effect evaporator, at 95˚c under vacuum) (65 Brix)

↓

CHILLER (for reducing temp of concentrate)

↓

BATCH TANK (A-22, A-27) (for holding and cooling)

↓

FILTRATION

↓

Chiller (cooling agent is glycol)

↓

Blend tank (for storage of concentrate at refrigeration temperature before filling)

↓

Filling (270Kg per drum)

↓

Storage (-18˚C)

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Detail of Each Step Involved in the Production Process:

Weighing:

 

The industry has a fruit procurement center whose duty is to ensure the

continuous flow fruit to the industry. Shakarganj has different centers in

orange grown areas mainly in

Sargodha

Bhalwal

Ajnala and

Kotmomin

The fruit reach in industry through truck, trolley and Mazda. As vehicle

enter industry it is send to scale for weighing.

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Unloading:

After weighing the vehicle move to the unloading area it is an inclined area

where the vehicles are parked. The inclined surface facilitates the unloading

process. Unloading is done manually.

Roughly It takes 60 min to unload truck

45 min to unload trolley and

About 35 min to unload Mazda.

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Feeding Conveyer:

After unloading the feeding conveyer takes the fruit. This belt either takes

the fruit into the plant or towards the storage bin depending upon the

condition.

Conveyer Belt:

From feeding conveyer the fruit move to conveyer belt. The fruit is sorted

manually at this position.

Sorting and Grading:

Sorting and grading is done manually as the fruit pass through conveyer belt.

It is done on bases of size and color. Unripe overripe, damage and disease

fruits are discarded.

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Washing Tub:

The fruit through conveyer belt comes to the washing tub. The water wet the

dirt dust stick to the surface of fruit. During tub washing the loosely stick

matter is removed. During this process stones, leaves straw and other foreign

matter are also removed. There are two valves present in washing tub one

inlet valve and one outlet valve. Through inlet valve fresh water comes in

washing tub and dirty water removes through outlet valve. In this way level

of water is maintain in washing tub.

Brush Washing:

 

Any foreign matter which is present on the fruit and cannot remove by

simple immersion washing is removed from the fruit by the help of

mechanical brushes during this step.

A number of brushes are present in series, the fruit pass over the brushes.

The hairs of the brushes loosen the sickly attach matter. Water is showered

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from the top to clean the fruit. After washer an elevator is present to lift up

the fruit for further processing.

Elevator:

 

After washer inclined conveyer is present to lift up the fruit. Washers are

present two feet above the ground to inspect properly.

Cirtorasp and citrotall are present 10 to 12 feet above the ground for this

purpose an elevator is required.

Citrorasp:

The orange peel has oil saps on it. citrorasp is used to rasp the oil saps for

the production of oil. In citrorasp scraper are present which rasp the oil saps.

As the orange pass through the citrorasp the oil saps are scraped. Fresh water

is showered from top the oil saps come in water and move toward the oil

production plant. The rasped orange move towards citrotall for crushing.

Citrotall:

Its purpose is to crush the orange. It has two counter rotating rollers. The

rollers have holding hooks on it to hold the fruit the hook strictly hold the

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fruit. A blade is present in between these rollers. As the orange pass through

the roller it cut the orange into two pieces. As these pieces move further

along roller orange is crushed, juice is extracted and waste is removed by

screw conveyer.

Finisher:

The juice coming from the citrotall contains a large amount of pulp in it. In

finisher floating pulp is removed. The finisher contains screws which create

the pressure. Increase the residence time of juice.

A gate prevents the juice from moving back. The juice passes through

sieves. The screw conveyer removes the pulp and it is wasted along with

peel.

Balance Tank:

After finisher a balance tank is present to balance the juice level. A mono

pump pushes the juice towards the holding tank (A-19).

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Holding Tank (A-19):

Due to time gap between crushing of fruit the juice flow is not uniform.

There is need of uniform flow after this as the juice is to pass through the

pre-heater. Holding talk holds 3000L of juice and supply a continuous

stream of juice toward the pre heater.

Pre-heater:

Plate heat exchangers are used to heat the juice, pre-heater heat the juice up

to 65Co.

Pre heating is done to facilitate the de-aeration process. De aerator only de-

aerates the heated juice not the cool juice.

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De-aerator:

After pre-heating of juice it moves toward de-aerator. In de-aerator air is

removed by creating vacuum of 650 – 740mmHg. Smell and off odors are

also removed due to vacuum. De-aerator is actually a centrifuge present in

vertical form. It rotates at a speed of 7000 rpm.

Decanter:

Decanter is centrifuge present is horizontal form which rotates at the speed

of 3000 rpm.

It removes the bottom pulp from juice with the help of centrifugal force after

removing bottom pulp juice is filter through filters having filter size 0.5mm

the purpose of filtration is to remove unwanted particles from the juice.

After filtration juice moves back to pre-heater. Filter juice exchange its heat

with fresh juice by counter action. The temperature of filter juice reduces to

30 ͦC on the other hand the temperature of fresh juice increased to 30 ͦC. if

this is not done more steam is required to heat the fresh juice.

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Batch tank (A-25):

Filter juice after moving through pre heater comes in batch tank (A-25). Its

capacity is 5000L its purpose is only holding of juice. As after this juice has

to pass through evaporator. So it should be move in continuous flow. That’s

why a tank is present before evaporator.

Evaporator:

 

A mono pump push the juice in the evaporator, double effect evaporator is

used to evaporate the juice. In the first effect juice is only heated by hot

water. In 2nd effect juice is evaporated under vacuum by using steam. The

steam used for evaporation has a pressure of 10 Bar. The Brix of concentrate

is adjusted up to 65 by controlling steam temperature and pressure.

Evaporation is done at 95 ͦC under vacuum. After evaporation the vapors of

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juice move to condenser, in condenser cooling water coming from the

cooling tower circulates which condense the juice vapor.

Chiller:

It is used to cool the concentrated juice. Glycol is used as a cooling agent. It

lowers the temperature of concentrate from about 80 ͦC to about 50 ͦC after

cooling the juice moves to the batch tanks (A-22 & A-27).

Batch Tank (A-22 & A-27):

 

The purpose of these tanks is to hold and cool the concentrate. For cooling

the stirring and agitation of juice is done. The °Brix of concentrate is

checked. If it is not accurate the concentrate is again passes through

evaporator to adjust the °Brix.

Filtration:

Before moving juice into the blend tank the juice is filtered again to

eliminate chances of any foreign matter present in the concentrate.

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Blend Tank:

Before filling of concentrate in final containers it is stored in blend tank. It

has capacity of storing 94 drum (1 drum = 270 kg concentrate). The blend

room has temperature of -18 °C to prevent microbial growth.

Filling:

When the blend tank fill up to 100 drums filling is start. In a batch 94 drums

are filled. Each drum contains 270 kg concentrate. Digital weighing balance

is used, when the drum fill up to 270 kg the filling valve closed

automatically. After filling the drum is sealed

Storage:

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After filling of 270 kg concentrate in large metal drums of 18 kg weight

which are coated with FDA approved paint and have two sheets of

polyethylene certain specifications are pasted over the containers which are

Product name

Product type

Production date

Best before

Ratio

Brix

Batch number

Drum number

Net weight

Gross weight

Each drum is manually checked to insure that exact specifications are

present on all the drums to avoid mixing of drums in storage area and ease in

shipment process.

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After checking of specifications it is insured they are same as written on the

quality sheet issued by quality department four drums at a time are stacked

on an electric lifter and are moved to storage area

Storage area is a large ware house in which -18 degree centigrade

temperature is always kept maintained to insure the proper shelf life of

finally packed product

Full batch of 94 drums is placed on a one selected place in a specific order

as described on drums in the form of drum number along with each batch 2

sample cups from 1st and last drum and 3 sample bottles from randomly

selected drums and 7 kg stainless steel container of concentrate is also

placed in the storage area product remains in the freeze storage zone till it is

to be send to the consumer on demand as no additional preservative is added

in the orange concentrate it requires special attention with regard to

packaging, storage and storage temperature maintains

Shipment:

Shipment refers to the process of sending the finally prepared product to the

customer

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In Shakarganj food products private Ltd according to the order of the

customer drums are removed from the freeze storage area. Drums are

commonly removed on the basis of their manufacturing date i.e. first come

first go.

But batches can also send depending upon the specifications mentioned by

the customer because all the batches do not have same specifications

All the drums which are to be send are checked weather they belong to same

batch and have same specifications as per described by the customer listed in

quality sheet

After manual inspection of each drum for leakage and damage following

standard procedure is used to verify the accurate delivery of the product

Firstly the container on which batch is to be stacked is checked for

hygiene and cleanliness if the container is ok it is send to shipment

yard otherwise it is rejected and send for re-cleaning

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After cleaning inspection reefer of the vehicle is checked for

temperature maintains during transportation

All the drums are re-checked for cracks, damages, broken seals and

weigh again prior to loading on the container

Randomly selected 6 drums from each batch of 94 drums are opened

and all the quality tests are performed once again to insure the

delivery of the product having accurate specifications

After satisfactory results of quality tests drums are placed on the

container fitted on the vehicle and refer is set at -6 degree centigrade

3 sample bottles which were placed along with the batch in the storage

area and the drums start their journey to the customer

After sending of the shipment a report is prepared by the shipment

supervisor indicating the number of drums and batches remaining in the

stock and the whole shipment process is documented and signed by

Shipment supervisor

Store in charge

Quality supervisor

Production manager

Plant manager

And after this final report is send to the General Manager.

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Quality Department at Shakarganj Foods

Quality standards of citrus fruit and citrus concentrate

Sample preparation and handling of whole fruit and fruit juice

Quality tests performed at Shakarganj quality lab

Citrus Fruit Quality Standards

Consumers demand high quality for the food they consume and they are

increasingly demanding concerning the taste, appearance and shape of citrus

fruits (and produce in general), as well as the consistency, purity and

freshness of citrus juices. Food safety has become a very significant issue,

particularly after the food scares in Europe. Consumers want to be informed

about the food they are consuming through appropriate labeling and tracking

and traceability schemes. The quality requirements citrus fruit and products

have to comply with, would be determined by attributes such as maturity,

hygiene, presentation, absence of residues, blemishes and diseases and

environment protection.

International quality standards for citrus fruits and products are normally set

in Codex Alimentarius. According to UNECE Recommendation for Citrus

Fruit (UN Economic Commission for Europe, Agricultural Standards Unit,

Fresh Fruit and Vegetables), the citrus fruits must be:

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Intact

Free of bruising and/or extensive healed over cuts.

Produce affected by rotting or deterioration such as to make it unfit

for consumption is excluded.

Clean practically free of any visible foreign matter

Practically free from pests.

Practically free from damage caused by pests.

Free of signs of internal shriveling.

Free of damage caused by low temperature or frost.

Free of all abnormal external moisture.

Free of any foreign smell and/or taste.

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Quality Parameters of Concentrate

Parameter  Target value  Acceptable range  Remarks 

Brix corrected  64.7-64.9  64.5-65.5  - 

%age pulp  8.0  7.0-11.0  %age 

Sodium  <30  <50  PPM 

TPC  Zero  <1000 CFU  CFU/g 

Yeast  Zero  <100 CFU  CFU/g 

Mold  Zero  <50 CFU  CFU/g 

Coliform  Zero  Zero  CFU/g Pre-heater

temperature 60  55-65  Degree centigrade 

De-aeration  700  500-700  mmHg 

Pasteurization temperature 

98  97-100  Degree centigrade 

Sterilization temperature 

106  104-108  Degree centigrade 

Aseptic filling temperature 

20  <30  Degree centigrade 

Frozen filling temperature 

0  <4  Degree centigrade 

Packing 

Product in contact with two food

grade poly liners in steel drums 

Product in contact with two food

grade poly liners in steel drums 

- 

Net weight  270 ± 0.5  270 ± 0.1  Kg 

Gross weight  287.5± 0.5  287.5 ± 0.1  Kg 

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Sample Preparation and Handling Of Whole Fruit and Fruit Juice:

Collect fruit samples randomized including all loads, locations, sizes,

and exclude defective fruits.

Fruit must be sorted to the sizes for the particular extractor settings.

Handle fruit sample with care and avoid physical and temperature

abuses.

Make prompt analysis to avoid chemical and physical changes due to

respiration, evaporation, fermentation etc.

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Fruit Juice:

Always keep fruit under refrigeration until analyzed. If analysis is

delayed beyond a few hours the sample should be frozen.

Thaw frozen single strength juice and concentrate juice in sealed

containers in a water bath at less then 25°C. Make sure to avoid water

getting into the sample.

Analysis should take place right after thawing and warming.

Juice reconstituted from concentrate must be deaerated by vacuum to

remove air bubbles incorporated during reconstitution.

Make sure all juices are homogeneous by thoroughly shaking, stirring

before taking samples for analysis.

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Quality Tests Performed at SFPL

Measurement of Juice Content—Percentage Juice

Juice content is an important measurement of internal quality. Under or

over-ripe fruit tend to be less juicy, which directly affects the production of

FCOJ.

Procedure

Weigh your ten fruit and record the combined weight in grams.

Weigh the empty 1 or 2-litre jug and record the weight in grams.

Juice all ten fruit using the juicer.

Apply even force and try to remove all the juice.

Strain the juice into the jug

Weigh the juice and record the weight in grams, then subtract the

weight of the jug.

Calculate percentage juice content by dividing the juice weight by the

total fruit weight.

Multiply this by 100 to get the percentage.

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Note: Remember to subtract the weight of the jug from the weight of the

juice and jug. Alternatively place the empty jug on the scales and zero the

scales prior to adding the juice.

Total Soluble Solids by Refractometer:

Apparatus:

Refractometer

Tissue paper

Distilled water

Procedure:

Bring single strength or reconstituted juice to ambient temperature

and mix thoroughly.

Measure sample temperature if refractometer has no automatic

temperature compensation.

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Clean the prisms of the refractometer before each reading with

distilled water and soft tissue or non-abrasive materials.

Apply an aliquot of sample (3 drops) to the refractometer prism,

avoiding bubbles and large pulp particles.

If sample temperature differs from the refractometer allow time for

adjustment.

Cover the sample with the fogged glass and position the light beam to

the shine through the fogged glass.

Adjust the shadow to the cross hairs.

Read the °Brix.

pH Measurement:

Apparatus:

pH meter with ± 0.1 accuracy with ATC.

 

Magnetic stirrer and Teflon coated stirring bar

100 ml glass beaker

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Procedure:

Maintain sample temperature near 20 °C, especially if the pH meter

has no ATC.

Calibrate pH meter with standard buffer solutions of pH 7.0 and pH

4.0 according to pH meter manufactures procedure.

Place sample in a 100ml beaker and immerse electrodes. Use

sufficient sample so that the tips of the electrodes are covered.

Read pH to the nearest 0.05 after reading stabilizes.

Remove electrodes from sample, rinse with distilled water, and blot

with paper tissue.

After using, repeat step 5 and store probe in a pH 7.0 buffer or follow

manufacturer’s instructions.

Calculations:

For pH meter equipped with ATC, the pH values observed are used

directly; make temperature correction for readings from pH meter

without ATC

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Fore Cost Analysis

Principle

It is actually the determination of °Brix to acid ratio of citrus sample

Apparatus

Plastic basket

Distilled water

Volumetric cylinder

Refractometer

Electric weigh balance

Glass beakers

Stirrer

Titration assembly

Procedure

Take sample from unloading area on the basis of color, size and

maturity

Weigh the sample along with basket

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Weigh the empty basket to and subtract it from previous reading to get

the exact weight of fruit sample

Now thoroughly wash the fruits

Extract the juice from fruits

Weigh the juice with the help of electric weigh balance

Calculate the brix of juice using refractometer

Take 25 ml juice in volumetric cylinder and add 75 ml of distilled

water

Pour this 100 ml solution in 250 ml beaker

Put a magnetic tablet in the beaker and place it on the stirrer and shake

it well

Put the electrode of pH meter in the beaker and notice the reading

Titrate this solution against 0.3125 normal NaOH until the pH reaches

to 8.20

Note the amount of NaOH used

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Calculations

%age Acid = amount of NaOH used * (0.08)

0.08 is a constant factor for single strength juice

For each value of %age acid, acid correction is measured from a

standard chart placed in Shakarganj laboratory

°Brix is calculated by using refractometer and °Brix corrected of the

sample is measure by adding acid correction of the sample in its °Brix

value

Ratio is calculated by the following formula

Ratio = °Brix corrected /percentage Acid

Forecast Analysis of Concentrate

Principle

It is actually the determination of brix to acid ratio of citrus sample

Apparatus

Sample cup containing concentrate sample

Distilled water

Volumetric cylinder

Refractometer

Electric weigh balance

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Glass beakers

Stirrer

Titration assembly

Plastic spoon

Procedure

Take sample from batch tank, blend tank or from anywhere in the

flow line

Check the brix using refractometer

Take 250 ml beaker rinse with distilled water and dry with tissue

paper

Now place the beaker on electric weigh balance and add exact 10g of

concentrate

Add 90ml distilled water

Now place shake it with the help of electromagnetic stirrer to

homogenize the juice

Put the electrode of pH meter in the beaker and notice the reading

Titrate this solution against 0.3125 normal NaOH until the pH reaches

to 8.20

Note the amount of NaOH used

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Calculations

%age Acid = amount of NaOH used * (0.2)

0.2 is a constant factor for concentrate

For each value of %age acid, acid correction is measured from a

standard chart placed in Shakarganj laboratory

°Brix is calculated by using refractometer and brix corrected of the

sample is measure by adding acid correction of the sample in its °Brix

value

Ratio is calculated by the following formula

Ratio = °Brix corrected /percentage Acid

Measurement of %age Pulp

Principle

Determination of pulp is actually the determination of heavier particles in

the juice by using centrifugation

Apparatus

Sample cup

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Distilled water

Centrifuge machine

Centrifuge tubes

Portable light source

Plastic spoon

Procedure

Take 2 sample cups rinse with distilled water and dry thoroughly with tissue

paper

Take juice sample in one sample cup from finisher

Take juice sample in 2nd sample cup from decenter

Eliminate foam from the surface of juice with the help of plastic spoon

Add 50 ml of sample in centrifuge tubes

Place tubes in centrifuge machine and set time (26 mints are sufficient)

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Centrifuge machine is set at 1500 rpm

After completion of set time removes the tubes from machine

Check the pulp in the bottom

It will show a zigzag pattern

With the help of light source measure the minimum level and maximum

level of pulp from the scale present on the centrifuge tube

Add both the values

This is the percentage pulp value

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Sodium Determination

Principle

Sodium is determined by using flame photometer. The light ray emitted by

flame photometer is converted into electric energy and is determined in the

form of current

This value is measured against the value of standard solution to measure the

quantity of sodium

Working of Flame Photometer

Flame photometer has a light source when solutions containing different

elements is sprinkled over it the electrons of elements goes into excited state

and so when they come back to normal state they emit light rays of different

colors. When these radiations are allow to pass through specific color filter

e.g. sodium filter it will allow only one type of radiations to pass through it

while all other radiations are retained by it

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When this radiation which passes through sodium filter is allow to fall on

photocell some amount of current is produced which is measured by

galvanometer

Firstly standard solution is used and then samples are run and the amount of

sodium is determined by comparison against standard solution

Measurement of Citric Acid Content

Citric acid gives citrus its tartness and is in highest concentrations early in

the season, decreasing as the fruit mature. Citric acid content can be

determined using two methods:

a) Using a chemical indicator called Phenolphthalein

b) Using a pH meter

Both methods involve titration, which means adding a solution of known

concentration to a solution of unknown concentration until a desired reaction

is achieved.

Procedure (a) Using Phenolphthalein

Draw 10 milliliters of juice into the pipette and transfer the juice to a

clean conical flask

Clean the pipette immediately after transferring the juice

Add three to four drops of phenolphthalein indicator to the conical

flask and carefully swish mixture.

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Squeeze the burette fill bottle, containing 0.1 Normal sodium

hydroxide (NaOH) to fill the burette

Open the burettes tap and allow a trickle of NaOH to run into an

empty beaker.

This is to ensure no air is trapped in the burette prior to use.

Squeeze the burette fill bottle again until the NaOH level in the

burette reads zero at the top of the scale.

Hold the conical flask containing the juice mix under the burette and

while swirling the flask slowly add the NaOH to the juice by opening

the burette’s tap.

Keep swirling the flask while adding NaOH, until the solution just

starts to turn pink

As soon as the solution turns pink close the burette’s tap.

Look at the scale on the burette and record how much sodium

hydroxide you have added to the flask.

Multiply the figure you have recorded by 0.064 to give you the citric

acid level of your sample.

Procedure (b) Using a pH Meter

Draw 10 milliliters of juice into the pipette and transfer to a clean

beaker

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Clean the pipette immediately after transferring the juice.

Carefully place pH meter probe into the solution and turn on

(remember to calibrate the pH meter first if required).

Squeeze the burette fill bottle, containing 0.1 Normal sodium

hydroxide (NaOH), to fill the burette

Open burette’s tap and allow a trickle of NaOH to run into an empty

beaker

This is to ensure no air is trapped in the burette prior to use.

Squeeze the burette fill bottle again until the NaOH level in the

burette reads zero at the top of the scale.

Hold the beaker containing the juice mixture under the burette and

while swirling the beaker, slowly add the NaOH to the juice

Keep swirling the beaker whilst slowly adding NaOH to the solution

until it reaches a pH of 8.2. Look at the scale on the burette and record

how much sodium hydroxide you have added to the flask.

Multiply the figure you have recorded by 0.064—this is the citric acid

level of your sample.