Tabelle
For customers involved in the production of carbonated soft drinks, we have decided to publish on our website the document that is most in demand in this area – a technological guide to the production of soft drinks based on microemulsions of CO2 -Extracts developed by All-Russian Institute of Beverages (VNIIPBiVP) on behalf of Biozevtika.
The document is published in two parts. The first part (sections 1-5) contains basic information on the technology of making drinks, syrup mixtures and water treatment. The second part (sections 6-10) contains a description of the main methods of quality control, sanitary and hygienic requirements, a full list of relevant regulatory documents and GOSTs.
STATE HOUSEHOLD SCIENTIFIC INSTITUTION “ALL-RUSSIAN RESEARCH INSTITUTE OF BREWING, NON-ALCOHOLIC AND WINE-MAKING” (FGBNU VNIIPBiVP)
PERMIT
Director of FGBNU VNIIPBiVP (L.A. Oganesyants) May 16, 2016
TECHNOLOGICAL GUIDE
for the production of non-alcoholic carbonated beverages based on microemulsions of CO2 extracts
TI 9185-227-00334600-2016
Registered for the first time. Date of introduction: 06/01/2016
DEVELOPMENT FGBNU VNIIPBiVP for “Biozevtika” (2016)
This technological instruction applies to the production of non-alcoholic carbonated beverages based on water-soluble microemulsions of CO2 extracts, produced under the production conditions of Biozevtika, intended for use as bulk non-alcoholic beverages.
Soft drinks based on microemulsions of CO2 extracts are made in accordance with GOST 28188-2014 and recipes.
1. Properties of the end product
1.1. Characteristics of ready-made drinks according to GOST 28188-2014 and recipes.
1.2. The beverages must meet the requirements specified in the recipes in terms of organoleptic and physico-chemical characteristics.
1.3 Beverages must comply with the Technical Regulations of the Customs Union TR CU 021/2011 “On Food Safety” with regard to safety indicators.
Microbiological indicators are listed in Chart 1.
Chart 1
| Product volume (cm³) in which yeast and mold are not allowed | Yeasts and molds, CFU/100 cm³, not more | |
| BGKP (coliform) | Pathogen, including Salmonella | |
| 100 | 25 | 15 |
The content of toxic elements is given in Table 2.
Chart 2
| Indicators | Permissible values, mg/kg, no more |
| Toxic elements: | |
| lead | 0,3 |
| Arsenic | 0,1 |
| Cadmium | 0,03 |
| Mercury | 0,005 |
1.4 The nutritional value and shelf life of beverages must be specified in the recipes.
- Properties of raw materials and technological aids
2.1 For the production of beverages, raw materials and technological aids are used, which must meet the requirements of regulatory documents and, in terms of safety indicators, must comply with TR TS 021/2011, TR CU 029/2012.
2.2 Raw materials, technological aids and packaging are stored in accordance with the requirements of regulatory documentation for this type of product.
- Technological scheme and description of the technological process
The technological scheme for the production of non-alcoholic carbonated beverages based on microemulsions of CO2 extracts includes the following stages:
• Annahme von Rohstoffen
• Wasse
• Acceptance of raw materials
• Acceptance of raw materials
• Water treatment
• Preparation of sugar syrup
• Preparation of mixed syrup
• Preparing a drink
• Pasteurization
• Filling, sealing, sorting, labeling and transfer of the finished products to the warehouse
• Storage and transport of finished products3.1 Obtaining Raw Materials
Raw materials are accepted in accordance with the requirements of regulatory and technical documents for each type of raw material.
3.2 Water treatment
3.2.1 Water treatment is carried out according to the “Technical Instructions on Water Treatment for the Production of Beer and Soft Drinks” TI 10-5031536-73-90 through water treatment plants that allow obtaining water that meets the requirements indicated in TI 10-5031536- 73-90.
3.2.2 Treated water should be clear, colorless, odorless and tasteless, and have the following key characteristics:
• Turbidity - no more than 1.0 mg/dm³ on the standard scale
• Chromaticity - no more than 10 degrees on a platinum cobalt or simulation
scale
• Total hardness - no more than 0.7 0J (mg-eq/dm³)
• Alkalinity - no more than 1.0 mg-eq/dm³
• pH - 3-6According to microbiological indicators, the treated water must meet the following requirements:
• Total number of bacteria in 1 cm³ of undiluted water - no more than 25
• Number of bacteria of Escherichia coli group in 1 dm³ - no more than 33.2.3 The technological scheme of water treatment includes filtration, softening, clarification, iron removal and water disinfection.
The choice of water treatment method depends on the quality of the source water.
Water filtration is carried out to remove coarse impurities, coloring and odors from it.
Washing and disinfecting sand and carbon filters is carried out at least once a month.
Water softening is carried out to reduce the total salt content (desalination) and especially to reduce the concentration of hardness salts.
Increased alkalinity is neutralized with citric acid.
Water with a turbidity of more than 1.0 mg/dm³ must be specially treated for clarification. The water is clarified by the method of settling and coagulation.
Deferrization of water is carried out by filtering through sand filters with the addition of reagents for modifying quartz sand.
The water is disinfected by bactericidal irradiation. Germicidal lamps are located along the water flow.
Water to be disinfected by bactericidal irradiation should be low in color and not contain colloidal and suspended substances that absorb and scatter ultraviolet rays.
It is possible to use other disinfection methods, e.g. B. Filtration through decontamination filters, ozonation, treatment with silver ions, chlorination. When water is disinfected by chlorination, the residual content of active chlorine in the water after dechlorination should not exceed 0.3 mg/dm
3.3 Production of sugar syrup
The calculated sugar mass is added to the mixed beverage syrup in the form of sugar syrup. Sugar syrup is prepared hot in a special tank with a mechanical stirrer (syrup maker).
Sugar is fed into the syrup maker, where it is dissolved in water at a temperature of 55°C-60°C with constant stirring. After the sugar has completely dissolved, the syrup is brought to a boil and boiled for 30-40 minutes to completely destroy the slime-forming bacteria. Syrup readiness is judged by reaching 63%-67% mass fraction solids in syrup. Then the cooking is stopped.
Then the hot syrup is filtered from coarse mechanical impurities through the simplest filters – traps, and for finer filtration through cartridge, membrane or plate filters, after which the syrup is cooled in a heat exchanger to a temperature of 10°C-20°C and poured into a Mixing tank is passed. The syrup maker is rinsed with a small amount of treated drinking water, with the wash water also being sent to the mixing tank.
In order to make sugar syrup with a certain mass fraction of solids, the required amount of sugar and water per brew is calculated.
Calculation example:
It is necessary to produce 166.67 dm³ of sugar syrup with a mass fraction of solids of 65%. We find the density of a 65% sugar solution equal to 1.3163 kg / dm³. The mass of 166.67 dm³ of syrup is:
166.67 x 1.3163 = 219.39 kg
The amount of sugar in this syrup:
(219.39 x 65) / 100 = 142.60 kg
The amount of water is then:
(219.39 x 35) / 100 = 76.79 kg
When boiling sugar syrup, water evaporates by 2% – 5%, depending on the cooking time.
Therefore, the water consumption required to dissolve sugar, taking into account its evaporation (we take 5% for calculation), is 76.79 x 1.05 = 80.63 kg.
Actual consumption of commercial sugar increases according to its moisture content. The mass fraction of moisture in commercial granulated sugar is 0.15%, therefore the required amount of commercial sugar is:
142.60 + (142.60 x 0.15) / 100 = 142.81 kg
3.4 Preparation of blended syrup
Mixed syrup is made by combining and thoroughly mixing the components in quantities that ensure the preservation of the organoleptic and physico-chemical properties of the drinks specified in the recipes.
3.4.1 Before preparing the mixed syrup, all equipment, including piping, shut-off and control valves, must be checked for leaks, washed thoroughly, disinfected and washed again with water.
3.4.2 Before the components are placed in the mixing tank, they must be prepared.
Natural infusions, extracts, fruit drinks, juices (except concentrated ones) are filtered.
Due to the high content of terpenes, citrus infusions are diluted in a 1:5 ratio with purified drinking water and left to sit for at least 12 hours. Then decanted and filtered.
Dry powder or granular components should be added to the mix syrup in the form of aqueous solutions.
Dyes are added to the mixture in the form of aqueous solutions.
Citric acid is added to the mix syrup in the form of a 50% aqueous solution.
3.4.3 To extend the shelf life of drinks, preservatives can be used in the amount specified in the recipe. Preservatives are pre-dissolved in treated drinking water in a ratio of 1:10.
The total amount of potassium sorbate (sodium or calcium), including the sorbate contained in the raw material, based on sorbic acid, should not exceed 300 mg per 1.0 dm³ of the finished product.
The total amount of sodium benzoate (potassium or calcium), including benzoate, contained in the raw materials as benzoic acid should not exceed 150 mg per 1.0 kg of the finished product.
If a combination of preservatives is used, their total amount should not exceed 400 mg per 1.0 kg of finished product (including sorbates in terms of sorbic acid no more than 250 mg/kg and benzoates in terms of benzoic acid no more than 150 mg/kg).
3.4.4 The blended syrup is prepared cold by adding the components to the blender jar in the order listed, stirring constantly:
• Sugar syrup
• Citric acid solution
• Concentrated juices, concentrates
• Infusions, extracts, aroma bases
• Flavors, emulsions, clouding agents
• Color solutions
• Preservative solutionsAfter the addition of sugar syrup and other concentrates, the measuring cups are rinsed with a small amount of treated drinking water, with the wash water also being fed into the mixing tank.
The volume of the mixed syrup is adjusted to the volume calculated in the recipe using treated drinking water.
3.4.5 Blended syrup is mixed thoroughly for 15-20 minutes and filtered. It is allowed not to filter the mixed syrup if each component has been filtered separately before being placed in the mixing tank (emulsions with natural flavors are not subjected to natural filtration). Mixed syrup for the preparation of cloudy drinks is not filtered.
3.4.6 Before preparing a drink from a mixed syrup, check the controlled parameters. For this purpose, a “control drink” is produced in which the blended syrup intended for bottling the drink is mixed with treated water in a specified ratio at 20 °C in the laboratory. The “control drink” is mixed, tempered to 20 °C and the physico-chemical parameters are determined.
Checking the indicators for the “control drink” serves as a reference point when approaching the line at the start of the shift and when changing the mixture.
3.4.7 The prepared blended syrup is kept for 2 hours in order to suppress microflora and achieve stability in terms of organoleptic and physico-chemical parameters. It is not recommended to bottle the drink later than 24 hours after preparing the mixed syrup.
3.4.8 Mixed syrup drained from measuring glasses of technological equipment may not be used in production and processing.
3.5 Preparation of carbonated beverages
3.5.1 Before a beverage is prepared, all equipment, including piping, shut-off and control valves, must be checked for leaks, thoroughly disinfected and rinsed with treated water.
3.5.2 The blended syrup is slowly blended for 10 minutes before the beverage is bottled and transported to the bottling plant.
The mixed syrup is mixed with prepared water in the proportion specified in the recipe for a specific drink. A different dilution may be used with appropriate conversion.
3.5.3 In a synchronous mixing plant, mixed syrup pre-cooled to a temperature of (6.0 ÷ 8.0) °С and prepared water with a temperature of (2.0 ÷ 4.0) °С are mixed in a certain volume ratio and saturated with carbon dioxide charcoal.
3.5.4 It is permitted to use systems with pre-dosing of mixed syrup into a bottle. At the same time, the calculated volumes of mixed syrup and saturated water, pre-cooled to a temperature of (6.0 ÷ 8.0) °С and (2.0 ÷ 4.0) °С, respectively, are introduced one after the other.
3.6 Pasteurization
3.6.1 The blended syrup is pasteurized immediately prior to bottling, if provided for in the recipe, using the operating mode specified in the operating instructions for the pasteurizer used, for example:
– heating to 90°С–95°С and holding for 20–30 seconds (plate pasteurizer)
or other types of pasteurization used in the company that allow the production of beverages with fixed expiry dates.
3.6.2 When filling a beverage into glass bottles or metal cans, it is recommended to pasteurize the beverage already filled into the packaging using a device that provides the pasteurization mode provided for in the manufacturer’s technological instructions, e.g. bring heat to 65°C –68°С and hold for 20 minutes (tunnel pasteurizer).
3.7 Filling, sealing, sorting, labeling and transferring the finished products to the warehouse
The bottling takes place after checking the controlled physical and chemical parameters.
3.7.1 Beverages are filled in glass bottles, PET bottles, metal cans that comply with TR CU 005/2011.3.7.2 Glass bottles are washed in a bottle washing machine. The washing mode and the concentration of the washing solution are set by the manufacturer of the machine and are specified in the user manual.
3.7.3 PET bottles that enter the beverage bottling plant immediately after their production on the bottle blowing machine are not washed.
PET bottles delivered from other factories or warehouses are rinsed with treated drinking water.
3.7.4 Bottles are hermetically sealed with corks that comply with TR CU 005/2011.
3.7.5 If the already filled and closed beverage does not undergo pasteurization (e.g. in a tunnel pasteurizer), the packaging and closures are subjected to disinfection immediately before bottling. Various methods of disinfection can be used, for example, bactericidal irradiation, steaming or spraying with a cleaning solution approved by the Rospotrebnadzor authorities, followed by rinsing.
3.7.6 Permissible negative deviations of the net content from the nominal amount of each unit of consumer packaging with a drink – in accordance with the requirements of GOST 8.579-2002. Permissible positive deviations are determined by the company.
3.7.7 Ready-to-use beverages in consumer packaging are checked for organoleptic and physico-chemical parameters at the start of bottling and at intervals depending on the duration of bottling.
3.7.8 When using transparent packaging, the beverages are sorted after sealing and mixing. The main work is to look closely at the bottles on the fluorescent screen. At the same time, the absence of foreign inclusions, the cleanliness of the inner and outer surfaces of the bottles and the completeness of the filling are checked. Bottles found to be faulty are sorted out, booked and sent back as internal rejects for proper processing.
3.7.9 Each bottle is labeled with an adhesive (synthetic or dextrin-based). The glue used should stick the label firmly on the bottle, not damage the paper and label pattern, be easy to wash off when washing the bottles, and have no unpleasant odor.
3.7.10 From the bottling plant, the products are transported to the finished product warehouse where the finished product is stored and delivered to the consumer.
3.7.11 Accounting of finished products is carried out in accordance with the requirements of regulatory documents using universal counters for unit accounting of products.
3.8 Storage and Transportation of Finished Products
3.8.1 Storage and transportation of finished products is carried out in accordance with GOST 28188-2014.
3.8.2 Finished products are transported by all modes of transport in accordance with the regulations for the carriage of goods applicable to specific modes of transport.
- Mark
4.1 Labeling of packaging with beverages is carried out in accordance with the Technical Regulations of the Customs Union TR CU 022/2011 “Food in terms of its labeling” and GOST R 51074-2003.
- Requirements for the technological equipment
5.1 Standard alcohol-free industry technological equipment is used for the production of beverages, including an integrated water treatment plant, a mixing department and a bottling line.
5.2 The main requirements for technological equipment are excellent design, reliability, maintainability and ease of use. All machines and devices must be able to be maintained safely during operation. Devices and parts that come into contact with food raw materials, semi-finished and finished products must be made of highly resistant materials approved by the Rospotrebnadzor authorities for contact with these food products.
The second part of the technology guide (sections 6-10) can be found at this link.