THE MULTIPURPOSE FRUITS FACTORY MODEL

Speaker Francesco Caponetti - Corporate Key Account

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

Page 1

INDEX
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.

Page 2

The multipurpose fruits factory model

Fresh
fruits

Process

Logistic
outlet
Conclusion:
Fruit juice line
Fruit puree line
Fruit preparation line

Purchase
raw fruits

Logistic
inlet

Washing
and
sorting

Extraction Evaporation Aseptic

conditioning

Storage

Selling

3 different products

1 similar know-how

Page 3

Energy consumption for a 6 t/h fruit juice line

Electric consumption (Kw)

Steam consumption (10x Kg/h)

140
120
100
80
60
40
20
0

Conveying
from storage

Washing
and sorting

Milling
Juice
Juice
heating extraction clarification
enzymation

Evaporation

Sterilization and
filling

Page 4 aseptic

Extraction

Page 5

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).

Page 6

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.
Page 7

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.
Page 8

Extraction: target for new technology, where to act

Page 9

Extraction: apple puree ultra fast anaerobic extraction

Hot Extraction
(with cooker)

Partially O2
Elimination

Inactivation
of Mash

Inactivation Delay
Cold Extraction

Zenith: Ultrafast
Anaerobic
Extraction

Cold
Extraction

O2
Elimination

0,5

Inactivation of
Clean Puree

Cold
Extraction

Inactivation of
Clean Puree

1,0

1,5

600

600,5
Time (sec.)

Page 10

Extraction: why anaerobic?

Enzymatic Browning Reactions*

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

Page 11

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).

Page 12

Extraction: why ultrafast?

absorbance vs inactivation delay*
Without VIT. C

Absorbance (420 660) nm

Addition of 850 ppm VIT.C

Natural apple color

Minutes
* Values referred to Golden Delicious apple

Page 13

Determination of ascorbic acid for color stabilization*

0 ppm

200 ppm

400 ppm

600 ppm

800 ppm

Hot

Cold

New

* Values referred to apple puree Golden delicious

Page 14

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

PATENT PENDING

Page 15

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

Page 16

Industrial results from a CFT customer in South America

Page 17

Product: Williams Pear aseptic puree

Brix: 30/32 Ascorbic Acid: 150 ppm

Color hunter: L (benchmark value 50)

Hunter L,a,b color scale

Color hunter: b (benchmark value 10)

Page 18

Product: Peach aseptic pulp

Brix: 30/32 Ascorbic Acid: 150 ppm

Color hunter: L (benchmark value 47)

Color hunter: a (benchmark value 5)

Color hunter: b (benchmark value 28)

Page 19

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

Page 20

Specific application of Zenith on juices:

New technology scheme
JUICE
OUT
FRUIT IN

Inert gas
inlet

Star valve

Extractor
Decanter
(First juice
CAKE TO
extraction stage) SECOND
EXTRACTION

Star valve
Waste
Out

Steam
IN

Collection Tank

Concentric
tubes heater
Lobe
pump

Condensate
Water

Page 21

References: 8 Zenith lines sold from January 2008

Country

Application

Working capacity

Italy

Mediterranean fruits

up to 20 t/h

Italy

Mediterranean fruits

up to 20 t/h

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

Page 22

Evaporation
Apollo falling film and Poseidon TVR evaporators

Page 23

Evaporation: Apollo falling film for clear juice production

Page 24

APOLLO

Tube bundle heat exchanger

TECHNOLOGICAL SCHEME
Vapor outlet

Product heating pipes

Vapor compressor

Vapor suction duct

Product steams inside
separation chamber
Product recovery tank

Separation chamber
Page 25

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

Page 26

Apollo: saving compared to traditional falling film technologies

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

Page 27

Poseidon T300 TE TVR

Page 28

Juice process flowchart

Puree process flowchart

Page 29

Poseidon T300 TE TVR

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.

Page 30

Aseptic filling - Macropak AF/2

Page 31

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.
Page 32

Macropak AF/2: 3D head details

Page 33

Macropak AF/2: working capacity

High Acid product

(bags/h)

100

64

21

Low Acid product

(bags/h)

75

50

20

Page 34

The multipurpose fruits factory model

THANKS FOR YOUR

ATTENTION !

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