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Orange Fruit Processing
Luis Cisneros-Zevallos, Ph.D.
Department of Horticultural SciencesTexas A&M University
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Commercially Important Orange Varieties
• Valencia - most widely grown, late maturing, good for FCOJ
• Pineapple - mid season maturing, good fresh &processing qualities
• Hamlin - early maturing, beats the freeze• Pera - late maturing, most popular in
Brazil
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Fruit Quality Factors
• Soluble solids
• Acidity
• Brix/acid ratio
• Juice color
• Low level of bitter compounds
• Good flavor
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Juice Categories
• Fresh unpasteurized
• FCOJ
• Chilled orange juice
• Canned orange juice
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Fresh Unpasteurized Juice
• Minimal treatment after extraction before packaging and distribution
• Excellent flavor, but shelf life < 3 days
• Must be stored at < 10C, preferably cooler
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Preparation for Processing
Washing
Sorting
Fresh Processed
Fungicide/wax Extractor
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Frozen Concentrated Orange Juice (FCOJ)
• Developed 1940’s• Initial product had poor flavor & color• Development of high vacuum, low
temperature evaporator improved quality• Concentrate was added to a small
quantity of fresh “cut back” juice to restore flavor & aroma lost during concentration
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Frozen Concentrated Orange Juice (FCOJ)
• Original low temperature evaporators have been replaced by: A) multi-effect, multi-stage, high temperature, short time evaporators B) thermally accelerated short time evaporators (TASTE)
• Volatile aroma & flavors compounds are collected (aqueous essence or essence oil)
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Concentrating Juices
Single strength juice
Pulp discharge ascake or slurry for laterreconstitution
Clarified serum
Concentrated serum for subsequentreconstitution
Centrifuge
3-effect thermal evaporator
2-effect thermal evaporator
Hyperfiltration
Hyperfiltration
1
2
3
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Multiple- (two-) effect evaporator
S1
F1
V1
P1
C1
F2
V2
C2
P2
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Frozen Concentrated Orange Juice (FCOJ)
• Juices of various origin are concentrated & stored in refrigerated tanks
• Frozen concentrates are blended to achieve desired final product
• Flavor is restored by addition of peel oil & essence
• Blend is packaged & distributed in frozen form
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Chilled Orange Juice
• Fresh juice - pasteurized, either hot filled or aseptically filled after cooling into sterile containers
• Blending to achieve uniform quality
• FCOJ - juice is reconstituted, pasteurized & peel oil added for flavor, then filled into sterile packages
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Package Considerations
• Glass - deterioration of color, flavor and loss of ascorbic acid
• Plastic containers or plastic lined cartons - orange flavor compounds migrate into the plastic container or container liner
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Canned Orange Juice
• Produced by reconstituting FCOJ or blending juices from several varieties
• Steps involved: A. Deaeration B. Deoiling C. Pasteurization D. Canning
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Juice Deaeration
• Reduces levels of dissolved oxygen
• Reduces flavor deterioration
• Prevents degradation of ascorbic acid
• Reduces frothing during the filling step
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Juice Deoiling
• Controls the peel oil level of freshly extracted juices prior to packaging
• Performed under vacuum with the application of mild heat to produce vapors which remove about 90% of the volatile peel oil
• U.S. standards specify an upper limit for peel oil content (limonene)
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Juice Pasteurization
• Required to inactivate enzymes and destroy microbial contaminants
• Inactivate PME to stabililize cloud• Juice is rapidly heated to 92C in tubular
or plate heat exchangers and held for 30 sec
• Juice is then pumped into filler tanks and rapidly filled into cans
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Juice Canning• After filling, live steam is injected into the
headspace followed by closing of the can
• Cans are inverted to sterilize the inside of the lid and cooled as they are conveyed
• Cans emerge with some residual heat to facilitate drying, thereby preventing rusting
• Plain tinned or enameled cans are typically used to prevent discoloration and loss of ascorbic acid
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Processing By-Products
• Orange flavor volatiles - aqueous essence, used for flavoring purposes
• Orange peel oils - cold pressed oil, used for flavoring purposes
• Water extracted soluble solids (WESOS) or pulp wash - used for beverages
• Waste products - animal feed, flavonoids, pectin
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Air in
Feed in
Product out
Spray Drier
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Fruit Sections
• Manual sections - Cold peel method where the peel & outer membrane is sliced off manually with a knife, or hot peel method where the peel is subjected to steam scalding or hot water immersion
• Sections are separated with knife from the peeled fruit, followed by packing into containers in juice or light syrup
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Syrup for Refrigerated Grapefruit Sections
• 12 - 15 Brix
• Citric acid (0.5 - 1%)
• Potassium sorbate and sodium benzoate (0.1% each)
• 30 day shelf life when stored at < 40F
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Fruit Sections
• New system - Vacuum infusion of hot water or pectic enzyme solutions into scored grapefruit peel
• Peel is easily removed and yield of sections is greatly improved
• Sections may be treated with calcium salts & edible coatings to improve quality
• Packaged in modified atmosphere films
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Strawberry
Cherry
Mango, papaya, pineapple
Grapefruit
BananaOrangeGrape
0 21105 150
21
10
5
15
O2 %
CO
2%
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CO2eCO2i
O2i O2e
Plastic filmAreaVolumePermeability O2
Permeability CO2
Thickness
ProduceWeightOxygen uptakeCO2 production
The MAP System
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Film
Gas and water vapor permeability
DiffusionAdsorption
Desorption
gas flux
High concentration
Lowconcentration
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O2e
CO2e
Oxygen and carbon dioxide transfer from a fruit
O2c
O2i
CO2i
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Post-harvest Handling
• The objective: To extend the shelf life of fresh horticultural commodities.
• We must understand the biological and environmental factors involved in deterioration.
• Use Post-harvest technology procedures which will delay senescence and maintain the best possible quality
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Post-harvest Handling(Some benefits)
• Standardize/Increase benefits: By sorting, sizing, washing.
• Extend shelf-life: Temperature, relative humidity, gas composition, light, physical damage.
• Provide added value: Fresh-cut, packaging
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Flow chart for Post-harvest handling operations
Harvesting
Washing
Sorting
Packing
Cooling
Storage
Transportation to Retail Stores
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Flow chart for Fresh-cut process
Harvesting
Washing/cooling
Sorting
Cooling
Cutting
Washing
Spinning
Packing
Storage
Transportation to Retail Stores