Production process

Naberini news images

3 March 2014

Juice production involves a high quality flow production process that cuts on processing time; limits exposure to oxygen; limits the chances for juice contamination due to people interaction or unwanted contact with premises; preserves the natural flavor and taste, and, to the greatest extent possible, preserves the vitamin and nutritional value.

Packaging

Immediately after pasteurization juices are hot filled at temperatures about 80-84оC in the following packaging:
3 liter metallized bag of the type “bag-in-box”, which later is placed into a carton box;
0.750 liter brown glass bottle with a twist-off cap;
0.200 liter green glass bottle with a twist-off cap.

The colored glass bottles and the metallized bag have certain advantages to other packaging as: they do not affect or alter the taste and the color of the product; they prevent the adverse influence of the sunlight; they prevent oxygen, water and micro-organic penetration, and preserve the thermal stability of the product.

Shelf life

The strict raw material control, the high quality flow production process and high quality packaging allow for the shelf life to exceed one year. Nevertheless, company shows period of one year as recommended length of time before the product becomes unfit for consumption. The product should be refrigerated after opening: product in 3 l. bags should be consumed within 14 days, while product in the glass bottles should be consumed within 3 days. The lack of preservatives in the product makes it susceptible to fermentation and determines the time before the product becomes unfit for consumption. When pouring juice out of the 3 l. bag, the bag’s volume decreases thus preventing air from entering into the bag and negatively affecting the quality of the product.
Equipment and production process

Juice production complies with all relevant requirements for quality, hygiene, safety and durability of manufactured foods.

Production on the belt press line

Belt press line is composed by machines produced by the Austrian Kreuzmayr Maschinenbau GmbH.
Fruits are brought into the warehouse and are weighed. Production takes place at a specialized production line where the following steps are implemented: washing the fruits in an air-circulation washing machine; follow-up washing and fruit grinding; belt pressing of the ground fruit; collection of extracted juice, coarse filtration and transportation to a buffer tank; and pasteurization in a gas pasteurizer with automatic double pipe heat exchanger; hot filling in bags or bottles through automatic dosing station; placing the bags in cardboard boxes; labelling and date stamping.
Glass bottles are rinsed on the filling line prior to their filling. After hot filling glass bottles are closed on an automatic capping machine and laid sideways until complete cooling.

Production on the pulping line

Machines on the pulping line are also produced by the Austrian Kreuzmayr Maschinenbau GmbH.
Fruits are brought into the warehouse and are weighed. Production takes place at a specialized production line where the following steps are implemented: washing the fruits in an air-circulation washing machine; follow-up washing and feeding into a destoner using an elevator; removing fruit stones using a destoner machine; heating of fruit mash using a gas mash heater with double pipe heat exchanger to achieve a fine puree; pulping the fruit mash to a very fine puree; juice blending to achieve desired flavor, sweetness and texture; coarse filtration; transportation using impeller juice pumps;  pasteurization of blended juice by a gas pasteurizer with automatic double pipe heat exchanger; hot filling in bags or bottles through automatic dosing station; placing the bags in cardboard boxes; labelling and date stamping.
Glass bottles are rinsed on the filling line prior to their filling. After hot filling glass bottles are closed on an automatic capping machine and laid sideways until complete cooling.


List of equipment:
Air-circulation washing machine;
Washing machine with elevator and mill;
Belt press;
Impeller juice pumps;
Destoner;
Eccentric screw pumps;
Mash-heater with double pipe heat exchanger: gas-water-product;
Pulper/refiner;
Gas pasteurizer with automatic double pipe heat exchanger: gas-water-product;
Bag-in-box filler;
Automatic line for dosing, filling and capping of bottles;
Automatic line for labelling and stamping of packaging.

List of raw materials and packaging materials:

Firm; ripe; fresh, chilled or frozen fruits: apples , pears, aronia, grapes, plums, strawberries, wild raspberries, wild blackberries, wild cranberries, wild bilberries, blackcurrant, sour cherries , cherries, wild plums, cornelian cherry, peaches, apricots, elderberries.
3 liter bags with outer cardboard boxes;
750 ml brown glass bottles;
200 ml green glass bottles;
220 liter aseptic bags with oxygen barrier (bag-in-drum) for temporary storage of pasteurized fruit juice;
220 metal drums for storage of 220 liter aseptic bag with pasteurized juice in it;
Trays, trolleys, crates, scales, laboratory equipment.