04 the multipurpose fruit factory

THE MULTIPURPOSE FRUITS FACTORY MODELSpeaker Francesco Caponetti - Corporate Key Account

Mr. Mario Gozzi R&D manager CFT S.p.A.

The multipurpose fruits factory model.

Energy consumption for a traditional fruit juice line.

Energy savings and flexibility in CFT technologies:

- Extraction: Zenith fruit puree cold extraction technology.

- Evaporation: Apollo falling film and Poseidon TVR evaporators.

- Aseptic filling: Macropak AF/2.

INDEX

The multipurpose fruits factory model

Freshfruits

Purchaseraw fruits

Logisticinlet

ProcessWashing

andsorting

Extraction Evaporation Asepticconditioning

Logisticoutlet

Storage Selling

Conclusion:Fruit juice lineFruit puree lineFruit preparation line

3 different products 1 similar know-how

Energy consumption for a 6 t/h fruit juice line

Conveyingfrom storage

Washingand sorting

Millingheating

enzymation

Juiceextraction

Juiceclarification Evaporation Sterilization andaseptic filling

Electric consumption (Kw) Steam consumption (10x Kg/h)

140

120

100

80

60

40

20

0

Extraction

Overview of traditional technologies for fruit juices extraction

Hot extraction + decanter.

Mill + belt press.

Mill + hydraulic press.

Destemmer crusher + membrane press (for pomegranates and grapes).

Extraction: summary of characteristics in traditional technology

Inactivation delay.

Adding of high quantities of ascorbic

acid to preserve color (for cloudy juice).

Single product oriented lines.

Open air environment:

- Possibility of contamination

Necessity for manual CIP.

Batch pressing operations.

Extraction: target for new technology

Reduce the consumption of ascorbic acid.

Increase product consistency and reduce syneresis.

Preserve color.

Maintain aroma and other organoleptic properties.

Stabilize final product to achieve better shelf-life.

Stabilize semi-finished product to separate in season

from off season activities.

Multipurpose high flexibility lines.

Extraction: target for new technology, where to act

Extraction: apple puree ultra fast anaerobic extraction

Partially O2Elimination

Inactivationof Mash

Cold Extraction

Inactivation ofClean Puree

O2Elimination

Cold Extraction

Inactivation ofClean Puree

Hot Extraction (with cooker)

Time (sec.)

Cold Extraction

Zenith: Ultrafast Anaerobic Extraction

0,5 1,0 1,5 600 600,5

Inactivation Delay

Enzymatic Browning Reactions*

* Source: Processing Fruits Edited by Diane M. Barrett, Laszlo Somogyi, Hosahalli Ramaswamy

Extraction: why anaerobic?

Extraction: why cold extraction?

Fruit Enzyme On Pulp[U/g]

On Peel[U/g]

Peel/Pulp

Apple Golden Peroxidase 0.0042 0.0309 7.36

Apple Golden Pectinesterase 0.374 0.346 0.93

Pear Conference Peroxidase 0.013 0.062 4.68

Pear Conference Pectinesterase 1.028 3.21 3.12

Pear Williams Peroxidase 0.019 0.048 2.50

Pear Williams Pectinesterase 1.703 3.135 1.84

Normally the enzymes concentration in the peel is higher than in the pulp (expecially for the oxydative enzymes).

Extraction: why ultrafast?

Minutes

A

b

s

o

r

b

a

n

c

e

(

4

2

0

6

6

0

)

n

m

Natural apple color

Addition of 850 ppm VIT.C

Without VIT. C

* Values referred to Golden Delicious apple

absorbance vs inactivation delay*

0 ppm 200 ppm 400 ppm 600 ppm 800 ppm

Hot

Cold

New

* Values referred to apple puree Golden delicious

Determination of ascorbic acid for color stabilization*

PATENT PENDING

Zenith technology (embodyment for ultra fast and cold extraction principles)Cross-sectional view

Zenith embodyment : qualitative comparison between traditional extractions and Zenith technology

Hot Extraction Cold Extraction Zenith

Viscosity

Colour

Molds

Pesticides

Black/Brown specks

Taste

Ascorbic acid free

Industrial results from a CFT customer in South America

Product: Williams Pear aseptic pureeBrix: 30/32 Ascorbic Acid: 150 ppm

Color hunter: L (benchmark value 50)

Hunter L,a,b color scale Color hunter: b (benchmark value 10)

Product: Peach aseptic pulpBrix: 30/32 Ascorbic Acid: 150 ppm

Color hunter: L (benchmark value 47)

Color hunter: a (benchmark value 5) Color hunter: b (benchmark value 28)

Extraction: industrial results, working cost savings

Ascorbic acid cost savings in Zenith compared to traditional extraction technologies.

Hypothesis:- 40 t/h production. - 24 h/day. - 180 days/season. - 10 Euro/kg ascorbic acid price*.

40*103*24*180*10*(800-150)/106 = 1.123.200 Euro/year

* Buying price in February 2010 for an important european fruit processor

Specific application of Zenith on juices: New technology scheme

Decanter(First juice

extraction stage)

JUICEOUT

WasteOut

Collection Tank

FRUIT IN

Extractor

Lobe pump

SteamIN

CondensateWater

Concentric tubes heater

Star valve

Star valve

Inert gasinlet

CAKE TOSECOND EXTRACTION

References: 8 Zenith lines sold from January 2008

Country Application Working capacity

Italy Mediterranean fruits up to 20 t/h



Chile Apple, Pear, Peach, Apricot up to 25 t/h

Belgium Apple, Pear up to 5 t/h

Turkey Apple, Pear, Peach, Apricot up to 20 t/h

Argentina Apple, Pear, Peach, Apricot up to 20 t/h

Russia Apple, Pear up to 15 t/h

France Apple, Pear up to 15 t/h

Evaporation

Apollo falling film and Poseidon TVR evaporators

Evaporation: Apollo falling film for clear juice production

Vapor compressor

APOLLOTECHNOLOGICAL SCHEME

Product heating pipes

Product steams insideseparation chamber

Product recovery tankSeparation chamber

Vapor suction duct

Vapor outlet

Tube bundle heat exchanger

Apollo: technological highlights

GENTLE TREATMENT Temperature difference between steam and

product lower than 6C. Evaporation temperatures lower than 77C. Overall residence time shorter than 300

seconds. Steam economy 1:16 (value referred to

apple)OPERATIONAL FREXIBILITY Short, fully automated cleaning time (3

hours). Quick product change over cloudy/clear no

fiber contamination from cloudy to clear Simple and quick adjustment of evaporation

capacity by setting compressors rpm. Water removal capacity from 10 t/h to 60 t/h

Hypothesis:- 24 h/day. - 180 days/season. - 40 t/h water removal.- 0,09* Euro/kWh electricity cost.- 25* Euro/t steam cost.

Traditional 5 effects falling film evaporator:- Steam working cost 1.053.659 Euro- Electricity working cost 75.816 Euro

Total 1.129.475 Euro

Apollo falling film evaporator:- Steam working cost 270.000 Euro- Electricity working cost 231.974 Euro

Total 501.974 Euro Saving: 627.501 Euro* Buying price in April 2010 for an important turkey fruit processor

Apollo: saving compared to traditional falling film technologies

Poseidon T300 TE TVR

Juice process flowchart

Puree process flowchart

AlexandraHighlight

Evaporator for the concentration of both purees and juices. Triple effect falling film juice concentration. Double effect puree concentration. No fiber contamination. High flexibility. No quality compromises: full forced circulation in purees / full falling film in juices.

Poseidon T300 TE TVR

Aseptic filling - Macropak AF/2

Macropak AF/2: advantages

Multipurpose format:

- 10 / 20 kg bags

- 220 kg drums

- 1000 / 1500 kg bins

Multipurpose spout: 1 or 2 easily changeable kit.

Multipurpose products: high acid & low acid (with no use

of chemicals agents during aseptic filling).

1 day assembly time.

Macropak AF/2: 3D head details

Macropak AF/2: working capacity

High Acid product (bags/h) 100 64 21

Low Acid product (bags/h) 75 50 20

THANKS FOR YOUR ATTENTION !

The multipurpose fruits factory model

Foliennummer 1Foliennummer 2Foliennummer 3Foliennummer 4Foliennummer 5Foliennummer 6Foliennummer 7Foliennummer 8Foliennummer 9Foliennummer 10Enzymatic Browning Reactions*Extraction: why cold extraction? Foliennummer 13Foliennummer 14Foliennummer 15Foliennummer 16Foliennummer 17Foliennummer 18Foliennummer 19Foliennummer 20Foliennummer 21Foliennummer 22Foliennummer 23Foliennummer 24Foliennummer 25Foliennummer 26Foliennummer 27Foliennummer 28Foliennummer 29Foliennummer 30Foliennummer 31Foliennummer 32Foliennummer 33Foliennummer 34Foliennummer 35

04 the multipurpose fruit factory

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