Clarified Banana Juice

CONTENTS

INTRODUCTION
MANUFACTURING ASPECTS -FLOWCHART, OPERATION

EQUIPMENTS USED
HACCP- DEFINITION,PRINCIPLES, DECISION TREE, VARIOUS HAZARDS & THEIR CONTROL MEASURES. REFERENCES

BANANA
Botanical name: Musa paradisiaca Family: Musaceae

Introduction
largest produced and maximum consumed India ranks first with an annual production share of 25 % of the total. The fruit has a very short post-harvest shelf life because of its highly

perishable nature.
value addition of fruits is less than 2 % of the annual agricultural produce. Short shelf life and increased production make it necessary for the

development of nonconventional products from banana.

And that leads to the Banana Juice Manufacture. Other than Banana juice ,

Banana Powder, Banana Cake and Banana Biscuits.

Flow Chart
Ripe fruits with Sugar(22), (esp. Cavendish) acid(if needed) washing Pasteurization(85 degree Celsius) Peeling minutes Pulping addition of enzyme (Pectinase 0.5%) cool and dry place) for 15-20 Blending Of juice Preservative and

Bottling Storage(Store at

RAW MATERIAL

BANANA selection of ripe banana (Preferably Cavendish).

free from any disease

good quality product.

Manufacture
The whole process start with selection of ripe banana(Preferably

Cavendish).The fruit free from any disease are selected to get good quality product. After selection, Fruits are washed , peeled and pulping is done in pulper with the help of Stainless Steel Sieves. After that they are treated with pectic enzymes(@ 40 degree Celsius). Addition of enzymes to the mash speeds up juice extraction and increases yields. The reduction in viscosity achieved by the action of the enzymes together with the elevated temperature lead to higher outputs and better degrees of clarification in the production of juices. After that the mass is pressed through cheese cloth to separate juice from solid matter. Then it is filtered with the help of filter aids esp. perlite and diatomaceous earth is used. After that blending of filtered juice with sugar , preservative(SO2)and acid(if needed).

Equipments used in fruit processing

Fruit washer

It is made of different grade stainless steel. It saves the energy and minimizes the product cost since cleaning water is recycled after filtration. a combination of water stream with a paddle system makes the water suitable for floating as well as sinking of the products.

Operating principle
It is made For cleaning and sanitizing of fruits. Fruits are passed through the washer by steam of water in

combination with variable speed compartment paddle system . The space is adjusted between 1.5-5 mm ,there is a special agitation system will intensifies washing/cleaning . Water is collected in separating tank with pump and it can be recycled after filtration.

Fruit elevators
It is used for conveying of fruits, to be fed to the crushers or

extractors and it is available in various size as per the requirements of consumers.

Pulping machine

Fruit pulping machine

These equipment are used for skin removal, pulping and finishing

of pulps from produce like mangoes, litchi, pineapples. The equipment incorporate scraper rotors, spiral scraper and brushes rotating at high speed which separate the skin and pulp. The secondary stage refines the pulp received from the primary stage.

Plate Heat exchanger The advantages : thermal treatment of products containing cells and

fruit pulp efficient heat transfer, i.e. small heat exchange area and thus low investment costs high degree of heat recovery (up to 96 %), this means low energy costs low space requirements due to large heat transfer surface in a compact assembly easy adaptation to changed capacity parameters by expansion or reduction of plates, i.e. high flexibility short dwelling times in the heat treatment section, thus gentle product treatment

Shell And Tube Pasteurizer On a large scale, Shell and Tube Pasteurizer is used

for pasteurization of fruit juices. It is specifically designed for the thermal treatment of low- to high-viscosity products and for products containing particles, pulp and fibers. It utilizes the colder product on the outside to cool down the product inside the innermost tubes. This means the product is warmed or heated in a countercurrent configuration without putting any additional energy, and passed to the heater and then to the heat-holding section. Advantages of using the new product/product shelland-tube heat exchanger: 1) smaller heat transfer areas compared to a product/water module 2) very good energy recovery possible 3) significantly lower capital investment and operating costs

Banana Juice Extractor (In Africa)

In African Countries ,these type of juice extractor

is used. The Banana Pulp is added with spear grass. The role of the added spear grass is to modify the rheological properties of the pulp thus its use is a must if banana pulp mass is to release the juice. This is not used very much because the efficiency of the process is just 47% compare to others.

Banana Juice Extractor

 Extraction Chamber-This is an aluminum

container in which juice extraction occurs. Its walls are rough to increase frictional force resulting in increased shear force required for juice release from the juice cells of the bananas. Arm Mixer- This one squeezes and mingles the grass-banana mixture resulting in juice release. It rotates around the extraction chamber as well as about its axis. During the extraction process the grassbanana mixture driven by the mixer arm counteracts with the rough walls of the extraction chamber thus increasing the shear

HACCP HACCP is a systematic approach to identify,

assess and control the risk of biological, chemical, and physical hazards. The Seven Principles are-

1) Identifying the potential hazard. 2) Determining the CCP. 3) Establishing control measures. 4) Establish a monitoring system. 5) Establish a corrective action. 6) Establish a procedure for verification.

Assembling HACCP team

Sl.Non Name Designati Educatio on n Productio n manager Quality controller M.Tech in food technolog y MSc (microbiol ogy) Work Skill experienc requirem e ent 2 years GMP, QMS GLP,GHP. Roles&re sponsibili ty Productio n line

Mr. . John

2 Mr. Orton

5 years

TQM,GMP Quality , GLP, QA managem microbiolo ent gist TQM,HAC Packaging CP section

Mrs. Wilson

Packaging M.Tech in specialist food technolog y MBA in marketing

4 years

Mr. Parker Marketing manager

8 years

Business studies & economic s

Marketing managem ent

Product Description Product Name Nature Fresh (Clarified banana

Juice) Imp. Characteristics Crystal Clear with good consistency Packaging Glass Bottles Shelf Life 6 Months Sold in Supermarkets, Hypermarkets Intended Use Of Product - The juice can be used for direct consumption purpose consumed by all age groups and also as an additive in other confectioneries and milkshakes etc.

Flow Chart with CCP and OPRP Ripe fruits with Sugar, (esp. Cavendish) acid(if needed) washing
OPRP 5

Blending Of juice Preservative and

OPRP1

CCP
OPRP2

Pasteurization(85 for 15-20

degree Celsius) OPRP3 Peeling minutes Pulping addition of enzyme (Pectinase 0.5%) degree Celsius)

Bottling Storage(5-15 Verified ByDr. Khan

DECISION TREE

PROCESS STEP

HAZA Q1 RD (A) Y Y Y

Q1(B) -

Q2 N N N

Q3 N N Y

Q4 Y

CCP/ OPRP -

CONTROL MEASURE GAP,COA,GMP, APPROVED SUPPLIERS

RECEPTION P N OF RAW C B Banana

Washing Peeling

C B P C B

Y Y Y Y Y

Y N Y N N

Y N Y

Y Y

OPRP1 OPRP2

Residual Chlorine should be less than 2 ppm. Pre and Post inspection Of peeler(PRP). Proper Cleaning operation (CIP). Pre and Post inspection Of pulper(PRP). Proper Cleaning operation (CIP).

Pulping

P C B

Y Y Y

Y N N

N Y

OPRP3

Addition Of B Enzymes

GMP,Procuring from certified dealers.

PROCESS STEP
Pressing Through Cheese Cloth Filtration With Filter Aids Blending ( Juice +Sugar & Acid) PASTEURI ZATION (HTST) (85C FOR 15 min.) Bottling

HAZA Q1 RD (A)
C B Y Y

Q1(B)

Q2

Q3

Q4

CCP/ OPRP

CONTROL MEASURE

N N

N Y

PRP,GMP

P C B P C B B

Y N Y Y Y Y Y

N -

Y N Y N N Y

Y N Y Y

Y Y N

OPRP4

PRE & POST INSPECTION OF PORE SIZE Pre and Post inspection Of Blender(PRP). Proper Cleaning operation (CIP). TIME- TEMPERATURE PROBES,EQPT.CALIBER ATION,TIME-TEMP GRAPH

OPRP5

CCP

C B

Y Y

N N

N Y

MAINTENANCE OF TEMPERATURE, Proper Washing,Presterilized Bottles

Hazard analysis or CCP documentation

Processing step Type of hazard Aspects considered Justification for CCP

Pasteurization Biological (85 degree Celsius for 15 min.)

85oC for 15 sec

There is no further step to eliminate pathogenic microorganisms(E.coli , lactic acid bacteria)

Determine Critical limits and Corrective Action

Step No. Proce ss Step Hazar d Contr ol CCP Critica Mo nito l Limit Test Frequ ency Temp. & Time Checki Every ng Shift Time and temper ature Checki ng filters weekly once ring

Respo nsibilit y
Produc tion Manag er

Correc tive Action

Heatin g at 85 Celsiu s for 15 -20 min. Filtrati on

Biologi cal

Temp. & Time

CCP

Mainte nance of correct time And temp.

Physic al

Use of Not a approp CCP, riate OPRP filters

Filters Size (.1-10 Micro meter)

Quality Pore Manag size of er filters shd. Be proper.

FOOD SAFETY POLICY

Fun Co.is committed to supply superior quality clarified

Banana Juice under safe hygienic conditions with adequate controls at all stages from raw materials inward to dispatch of finished products. This is achieved through; 1. Identifying & meeting customer needs, expectations & statutory requirements. 2. Continuously monitoring and improving food safety requirements through objectives & GMP Programs.

Verification or CCP validation

Banana juice / CCP validation report CCP Number-CCP Process stage-Pasteurization Of Juice Product- Banana juice Date of validation-10/7/12

Validation team members

Mr. John Mrs. Wilson

1. Collect the sample of juice after heat treatment 85C FOR

15 MIN 2. Analyze for E coli & salmonella sps. 3. None of the plates were positive for the presence of the microorganisms. 4. Review of the CCP record results to verify whether it is under control. 5. Co-relate the CCP values with the record. Validation results : E.coli found absent for sample on verifying CCP records for same period, no deviations were noticed, during last maintenance of machine on DT. The thermocouple temp found working fine & times also caliberated. Conclusion: CCP controls are satisfactory & effective. Validation byApproved by:

Documentation & record keeping

Training schedule record Records : Monitoring corrective action and CCP

verification records ,Minutes of food safety review , corrective action report , pest control report, review of consumer complaints etc. Electronic record data generated for time and temperature.

References
www.alibaba.com

Y.H.Hui, 2008. Handbook Of fruits and Fruit

Processing From Blackwell Publication. W.V.Cruess,2011. Commercial Fruit and Vegetable Products From AGROBIOS(India).

It Takes Time
The best time to

implement a food safety program is 20 years ago! The next best time is NOW!!

Thank You