Fruit and Vegetable Processing short-term

Training program

picture

Based on February 2023, Curriculum Version 1

Module Title: - Performing Juice Extraction Process

TTLM Code: IND FVP2 M02 0223

Nominal duration: 45 hrs.

Prepared by: Oromia job opportunity creative and vocational bureau
February,2023
Adama, Ethiopia

Contents
Acknowledgment............................................................................................................................3
Acronym.........................................................................................................................................4

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 Introduction to the Module...........................................................................................................5
Unit one:Prepare the extraction equipment and process for operation...................................6
Self-check-1 ........................................................................................................................................23
Operation Sheet 1................................................................................................................................24
LAP Test...............................................................................................................................................25
Unit Two: Operate and monitor peeling, destoning and crushing process…………………26
Self- check-2 ......................................................................................................................................32
Operation Sheet 2................................................................................................................................33
LAP Test...............................................................................................................................................34
Unit Three:Operate and monitor the extraction process.........................................................35
Self -Check 3 .....................................................................................................................................45
Operation Sheet 3................................................................................................................................46
LAP Test ..............................................................................................................................................47
Unit Four:Perform pre-heating.................................................................................................48
4.2. Adjusting equipment and temperature.......................................................................................50
Self -Check 4 .....................................................................................................................................51
Unit Five: Shut down the extraction process............................................................................52
Self-check 5 .......................................................................................................................................59
REFERENCE BOOKS...............................................................................................................60

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 Acknowledgment
Oromia job opportunity creative and vocational bureau wish to extend thanks and appreciation to
the many representatives of TVET instructors and respective industry experts who donated their
time and expertise to the development of this Teaching, Training and Learning Materials
(TTLM).

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 Acronym
TTLM ……………………………………… Teaching Training Learning Methodology
LAP………………………………………… Learning Activity Performance

TVET…………………………………………...Technical and Vocational Education and

Training

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 Introduction to the Module
Juice and juice products represent a very important segment of the total processed fruit industry.
Juice products are being marketed as refrigerated, shelf-stable, and frozen, in a variety of packages
with increased emphasis on functionality, health attributes, new flavors or blends, and in some cases
fortified with vitamins and minerals. High-quality juice operations are dependent upon a source of
high-quality raw material.
The process starts with sound fruit, freshly harvested from the field or taken from refrigerated or
frozen storage. Thorough washing is usually necessary to remove dirt and foreign objects and may be
followed by a sanitation step to decrease the load of contaminants.
This module covers the units
 Extraction equipment and process for operation
 Peel, destone and crush process
 Extraction process.
 Pre-heating
 Shut down the extraction
Learning Objective of the Module
 Prepare extraction equipment and process for operation
 Operate and monitor peeling destoning and crushing process
 Operate and monitor the extraction process.
 Perform pre-heating
 Shut down the extraction
Module Instruction:
For effective use this module trainees are expected to follow the following module instruction:
1. Read the information written in each unit
2. Accomplish the Self-checks at the end of each unit
3. Perform Operation Sheets which were provided at the end of units
4. Read the identified reference book for Examples and exercise
5. Perform Operation Sheets which were provided at the end of units
6. Do the “LAP test” giver at the end of each unit

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 Unit one Prepare the extraction equipment and process for
operation

This unit is developed to provide you the necessary information regarding the following content
coverage and topics:
 Preparing, blending and confirming extraction materials
 Identifying and following workplace documentation
 Checking availability
 Carrying out the Line clearance procedures.
 Following Procedures to eliminate or the risk of cross-contamination.
 Loading Material into percolator and adding solvents
This unit will also assist you to attain the learning outcomes stated in the cover page. Specifically,
upon completion of this learning guide, you will be able to:
 Prepare, blend and confirm Extraction materials
 Identify and follow Workplace documentation
 Check availability
 Cary out the Line clearance procedures.
 Follow Procedures to eliminate or the risk of cross-contamination.
 Load Material into percolator and adding solvents

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 1.1. Introduction to extraction equipment and process for operation

Fruit juices are made from pure filtered fruit juice with nothing added. Sodium benzoate can be
added as a preservative to extend the shelf life, but this is not essential. Properly pasteurized
juice has a shelf life of several months. Most fruits can be used to make juice. The most popular
ones are pineapple, orange, mango, grapefruit and passion fruit
Extraction is the process of converting fruits and vegetables into a puree or concentrate that
is later on processed to obtain juices, creams, sauces, etc. Fresh fruits and vegetables are first
graded, of which the high-quality ones are used for fresh selling, canning or dehydrating.
Juice extraction the elimination of the juice from fibrous, solid particles—is a basic technological
step of fruit juice production. The fruit has to be prepared prior to juice extraction, which is then
followed by juice clarification. Subsequently, the finished drink is packed and preserved.
Objectives of fruit and vegetable processing:
 To reduce wastage and losses: Fruit and vegetable industry is the backbone of
horticulture industry as it takes care of all possible waste that occurs in spite of
improvement in the distribution and marketing of fresh produce.
 To handle glut: Produce during glut season utilized for making different processed
products, thus fruit processing helps in reducing wastage and handling excess produce
during glut season.
 To stabilize farm prices and income: It stabilizes farm price by utilizing the excess
produce in value addition to provide additional income to the farmers.
 To utilize marketable surplus: Processing utilizes marketable surplus as well as cull and
deformed produce, to ensure remunerative returns to the growers.
 To generate employment: Processing of fruits and vegetables being a labour intensive
helps to generate both direct and indirect employment for the masses.
 To add variety to the diet: Value addition/processing make the food more attractive and
palatable.
 To ensure nutritional security.
 To earn foreign exchange through export of processed fruit and vegetable products

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 1.2. Prepare, blend and confirm extraction materials
Best Fruits for Juicing Everyone knows that fruit makes great juice. With every bite you can
taste the sweet, natural juice that’s delicious and loaded with vitamins and minerals. While you
can conceivably juice nearly any fruit, there are a few that give you maximum amount of juice
and taste great. Juicing also leaves the extra stuff like seeds and skin behind, so you don’t have to
waste time peeling your fruit before getting the juice.

Apples Oranges
Papaya Pineapples
Pomegranate Grapefruit
Grapes Melon
Lemons Kiwi fruit
Limes

Best Fruits for Blending Not all fruits are as loaded with juice as apples or oranges, but that
doesn’t mean that they aren’t worth eating. These fruits still have plenty of beneficial vitamins
and minerals, not to mention other dietary aspects such as fiber. Your blender will let you drink
these fruits as a smoothie along with some extra liquid like water, milk, juice or yogurt.
Plus, your blender leaves in the fiber and other nutrients that a juicer leaves out. Here are a few
fruits that are better in your blender than the juicer:

Bananas Mango
Berries Avocado
Peaches.

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 Best Fruits vegetable for juicing: Just like fruit, you can juice vegetables too. This is the
perfect solution for anyone who struggles to get his or her daily dose of vegetables. Simply
throw your favorite vegetable in your juicer and drink it down. You can even mix you vegetable
juice with other veggies or fruits for a tasty juice cocktail. Try one of these vegetables in your
juicer for more vitamins and minerals:

 Beets  Wheat grass

 Broccoli  Celery
 Carrots  Cabbage
 Cucumber  Tomatoes
 Radish  Herb
 Leafy greens (kale, chard, spinach)

Best vegetable for blending: Many of the vegetables you use in your juicer can actually work
well in your blender as well. While the juicer gives you a more concentrated dose of vitamins
and nutrients, the blender lets you get the fiber or roughage found in veggies which can be
important for digestion. Here are a few of the best vegetables to mix in your blender for a
smoothie or puree:

 Squash
 Kale
 Spinach
 Herbs
1.3. Identify and follow workplace documentation
Market-oriented, successful food production must focus on the final consumer. The aim of fruit
and vegetable production is to deliver a safe and wholesome final product to the consumer.
Nevertheless, fresh fruits and vegetables have recently been identified and confirmed as a
significant source of pathogens and chemical contaminants that pose a potential threat to human
health worldwide. In order to develop proper practices and methods of production, hazards and
the risks that they may impose to consumer health have to be fully understood. An understanding
of the agents that affect fresh fruit and vegetable safety and quality makes it possible to develop

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 practices to minimize potential negative impacts. This chapter defines the most common
potential hazards associated with fresh fruit and vegetables and provides information about the
role of fresh produce in causing foodborne diseases and their influence on consumer health.
The Workplace Documents assessment measures skills that individuals use when they read
real workplace documents and use that information to make job-related decisions and solve
problems. The documents include messages, emails, letters, directions, signs, bulletins, policies,
websites, contracts, and regulations.
Documentation of Food processing: There are six simple steps to follow that will help you
organize your company’s documentation processes and thereby better prepare your facility to
pass an audit. Each step can be catered according to you company profile, but the basis of this
plan works across the industry. Furthermore, the following process has been recognized by The
Global Food Safety Initiative (GFSI): Food Safety Systems Manual: The food safety manual is a
collection of documents which contains all validated and authorized written policies; procedures;
programs; specifications; work instruction; register forms; and other documents that are
necessary to consistently achieve the production of safe food.
Policies: A policy is a statement of principles and commitments that establishes the course of
actions and acceptable methods. They are in place to guide senior management decision making
to achieve company goals, both in the present and the future. The food safety policy must come
from, and be signed, by senior management, who is also responsible for allocating appropriate
resources in order to enforce the company’s policies.
Specifications: Specifications are an exact statement of the particular characteristics or attributes
required to comply with applicable regulations, as well as the customers’ needs and the
company’s performance standards regarding a good; method; material; process; work; or,
system. Specifications must be written in a fashion that allows them to be measured and
evaluated to determine the degree of compliance by the manufacturer.
Procedure: Usually, this document describes routine activities that require different functions,
from the simple to the complex, and possibly involves several participating parties to meet its
accomplishment. A procedure consists of a series of steps that must be followed in a regular,
definite sequence in order to achieve consistent results every time. The following elements are
usually included in written procedures: title of the procedure; objective; scope of work;

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 definitions; references; responsible parties; materials and equipment; activities description; and,
register.
Work Instructions or Standard Operating Procedures (SOP): SOPs are fixed, step-by-step
actions, with definite start and end points. These instructions must be followed in the same order
to perform the specific tasks correctly, thereby assuring consistent results every time.
Product specification:
The product specification includes information about the ingredients/materials and their
characteristics contained in the delivered food products. This information are most of the time
based on the purchase conditions and includes data such as the product description, origin,
sensory properties, materials (including allergens) or certifications.
Forms and Registers: A form is a document designed to collect objective data generated from a
process or activity. Once a form has been filled out, it becomes a register. Documents aid in a
company’s ability to organize itself, its processes, and to pass audits. The larger the firm, the
greater becomes the need for documenting its systems. Note, there is no time like the present;
pressure is on the food industry to develop GSFI approved standards; customers are savvy; and
regulatory entities call for formalizing and documenting food safety management.
Standard forms
Ensure details are accurate.
Include relevant details, such as date, time and place of incident.
Fill in all required fields.
Follow the instructions on the form.
Store forms in the appropriate place.

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 1.4. Check availability
Extraction Equipment
In order to prepare fruits and vegetable juices at commercial level, several equipment’s are
needed. Some of the important equipment’s required for processing of specific fruit and
vegetables are discussed herein.

Kitchen Blenders: or bulk blending or thicker mixtures, a countertop kitchen blender will come
in handy. While these have more parts to clean, they’re also more versatile and have a larger
capacity. Most come with variable speeds from chopping action to liquid puree, meaning you can
add almost any ingredient and get a smooth blend from it.

Fig1.1 juice blender

https://freshjuiceblender.com/products/fresh-juicer-portable-blender

Functions to Consider when using juice blender:

Not all blenders are made the same, and you may be wondering which features you need. If you
want a quick individual serving, a single-serving blender is fine. However, if you prefer to blend
in batches, you may need a larger kitchen blender.

Percolator: Percolators emit a robust aroma and a distinct gurgling sound while brewing. It is
extremely convenient when making fruit you want to stay piping hot for large gatherings.

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 Primula’s percolator is made of durable aluminum and features a matching lid, lipped spout and
stay-cool black plastic handle

Fig1.2 Percolator

Fruit Pulpier: Designed for extracting the pulp of most fruits’ vegetables such as mangoes,
guavas, peaches, tomatoes, bananas, carrot, apples etc.
The Pulpier cum finisher is used for extraction of pulp by separating skin and fiber from fruits.

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 Fig1.3. Fruit juice Pulpier
Filter/ Sieve: Stainless steel big basin 28-40 cm filter water wash fruit vegetable wash basket
drain rice Mesh Sifter Colander Strainer Sieve

Fig 1.4 filter/ Sieve

Juice collection vessels or tanks tanks to the pump fresh juice can be transported for
example to a pasteurizer or buffer tank. The pump is switched on and off automatically
by means of a special fluid level sensor, after collecting the right amount of juice in the
basin. The pump can also always be started manually by pressing the appropriate button.

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 Fig1.5 tanks
Fruit and vegetable crusher: Suitable for crushing hard seedless fruits & vegetables such as
pineapple, apple, tomato, carrots etc. before pulping or juice extraction.

Fig1.6. Fruit and vegetable crusher

Twin pulper Suitable: To deseed or deskin and extract pulp from fruits & vegetables like
mango, litchi and tomato. It consists of two stages of pulping. First stage is for deseeding or
deskinning. The pulp extracted from first stage goes into the second stage for refining. All
contact parts are made of SS with optional covers in MS or SS.

Hammer crusher Suitable to crush seedless fruits & vegetables before pulping or juice
extraction. Fitted with swing type hammer which ensures even granulating of crushed
material.

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 Storage of Fruits and Vegetables
There are five methods of storing vegetables and fruit: drying, canning, curing and salting,
freezing and common storage. Which method is chosen depends upon the type of produce,
the quality desired and the facilities available for storage.
Regardless of the method chosen, some general rules should be followed:
 Use only fresh produce.
 Begin the preservation process immediately after harvest.
 Avoid damaged, cut, bruised and pest or disease infested produce.
 Use all preserved produce within one year of storage.
Freezing: A common and very desirable way to preserve certain types of garden produce is
through freezing. This method does not improve quality, but is fairly easy to do if one has access
to a freezer and takes the time to package properly so that moisture is retained. Like other
preservation methods, freezing prevents microorganisms from growing causing spoilage. One
large advantage of freezing is that the nutritional quality remains relatively good, plus food can
be kept for many months with little change in color. For certain soft produce, the texture may
change considerably, though the importance of this is largely depends upon how the food will be
subsequently used. Green peppers can be frozen but will become watery when brought back to
room temperature. The texture will be very different from fresh produce, but the color will
remain good.
Factors to Consider fruit storage time.
A Clean Storage Space: Always keep the storage area clean of debris and discard fruits and
vegetables as soon as they begin to show signs of decay. Containers should be removed during
the summer, washed and dried in the sun.

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 Monitor the Temperature: Monitor temperatures to avoid produce being destroyed by any
exposure to low or high temperatures, which can happen in extreme cases. Thermometers should
be placed inside and outside the storage facility. Stored produce will give off heat during storage
making it necessary to regulate temperatures by use of the ventilation windows. If the outside
temperature is 25 degrees and the inside is 32 degrees with the ventilation windows closed, the
temperature will begin to rise and windows should be opened to lower the temperatures. Close
the ventilation windows when outside temperatures are above the desired storage temperatures.
Because certain crops are more sensitive to low temperature injury, learn their freezing point.
Most fall within a range of 29 to 31 degrees.
Regulate the Humidity: Over time, vegetables and fruit will give up moisture and shrivel.
Maintain proper moisture levels during storage by regulating humidity. This can be done by
increasing the water in the air through humidifying or by using plastic bags and box liners for
storage in individual crops. Humidification is simply taken care of by sprinkling water inside the
storage area, but not directly on the produce. For root crops which lose moisture regardless of
attempts to humidify with free water, placing them in plastic bags is perhaps the best way to keep
them fresh. Plastic liners and bags should be ventilated by creating holes. Produce should never
be sealed shut.
Handling Fruit and Vegetables: Handle all produce with care to avoid wounds which become
good sites for storage diseases. Pick all produce dry or let dry before storage. Pack produce in
plastic or wooden baskets or boxes. Move the produce to the storage area when the field heat has
been reduced. Harvesting in the early morning or cooling overnight outdoors will help.
Fruit juice storage

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 Fruits are perishable commodities and their quality is deteriorated during transportation due to
the action of environmental factor (temperature and sunlight) and enzymes. With the application
of innovative technologies deterioration can be minimized and juices can be stored for longer
period of time. In this research project fresh, properly ripe fruits were selected and their juice
was extracted. The extracted filtered juices were pasteurized at 72 o C for 15 minutes following
by condensation using evaporation. The product was stored at refrigeration temperature and
evaluated for chemical and organoleptic analyses like ascorbic acid, malic acid, tartaric acid,
acidity, pH, total soluble solids, reducing and non-reducing sugars at zero to thirty days after
every ten days interval. Results showed that the loss of ascorbic acid was minimum in peach
which was 11.42 %. The maximum loss of ascorbic acid was recorded in mango which was
16.05 % at the end of storage period of 30 days. In case of malic acid, it had been increased
slightly. The minimum increase of malic acid was found in AJC (Apple juice concentrate) which
is 2.78 % while the maximum increase of malic acid was recorded in PJC (Peach juice
concentrate) which is 5 % at the end of storage period. Tartaric acid was detected in least
quantity as compared to other organic acids because it was present in trace amounts. The
minimum decrease of tartaric acid was in peach juice concentrate which was 0.26% while the
maximum decrease of tartaric acid was recorded in mango juice concentrate which was 0.93%.

1.5. Carrying out line clearance procedures

Standard Operating Procedure:
Basic Principle of Production should be clearly understood before these activities are done. It
covers several aspects of production, ranging from starting materials, equipment, premises,
methods, procedure, documents etc. Each of this aspect can be described in more detailed
information, as the scope of this principle is quite large. This basic principle can be “translated
“into practical aspects by a various standard operating procedure.
Line Opening: A Line Opening is carried out after a Line Clearance has been completed and
signed to ensure that all related components, machine settings, BPN, Expiry Date, Date of
Manufacture (if required) and information boards are all correct and complete before Production
starts.
If a foreign product/material is found during a production run then these MUST be completed:
 Stop the line immediately.
 Record in the Non-Compliance Logbook.

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  Report to and give to the area Manager immediately.
 Communicate to the Team.
Line Cleaning: The Line Cleaning form must be signed by an Authorized Person. More than
one Team member may clean and clear the line, but it is the responsibility of the Operator trained
and assessed in Line Cleaning to ensure that the tasks have been performed and the Line
Basic production principles in line clearance:
Starting materials: should be approved according its specification, identification and approval
label should be appeared on each packing. not yet expired or has been retested.
Work area and equipment are clean and free from any starting materials or other materials not
required for the current operation.
Any necessary in-process controls and environmental controls should be carried out and
recorded.
Means should be instituted of indicating failures of equipment or of services (e.g., water, gas) to
equipment.
Defective equipment should be withdrawn from use until the defect has been rectified.
Production equipment should be cleaned according to detailed written procedures and stored
only under clean and dry conditions.
Containers for filling should be cleaned before filling. Any significant deviation from the
expected yield should be recorded and investigated.
Any deviation results should be recorded and reported to the supervisor(s)
Repair and maintenance operations should not present any hazard to the quality of the products.
Sanitization according to written procedure. Calibration or services of weighing, measuring or
control equipment should be done on pre specified interval base.
Record of calibration or services should be kept and maintained.

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 1.6. Following procedures to eliminate or control the risk of cross-contamination.
Food safety versus food quality Defects and improper food quality may result in consumer
rejection and lower sales, while food safety hazards may be hidden and go undetected until the
product has been consumed. If detected, serious food safety hazards may result in market access
exclusion and major economic loss and costs. Since food safety hazards directly affect public
health and economies, achieving proper food safety must always take precedence over achieving
high levels of other quality attributes.
Food safety and quality assurance in fresh produce should be ongoing processes that incorporate
activities from the selection and preparation of the soil in agricultural operations through the
final preparation and consumption of the food. Both food safety and quality assurance (QA)
should focus on the prevention of problems, since once safety or quality has been reduced it is
difficult or impossible to restore. Also, implementing QA programmers should help ensure that
problems experienced in the past do not affect the future product the same way.
Prevention of produce contamination during handling and application Contamination of fresh
produce by pathogenic micro-organisms derived from organic fertilizers can occur in numerous
ways and can affect the edible product either directly (e.g., by application of contaminated
fertilizer on the edible crop) or indirectly (e.g., by cross-contamination of produce by infected
soil that has been fertilized). Good agricultural practices should be followed in order to minimize
risks of such produce contamination.
Food Contamination: Cross-contamination is the physical movement or transfer of harmful
bacteria from one person, object or place to another. Food becomes contaminated through a
variety of mechanisms. Some things that can contribute to foodborne illness are: inadequate hand
washing, cross-contamination, storage and cooking temperatures, and contamination of food by
animal waste
Best Practices for Fruit Processing: To meet consumer demands for fresh and safe fruits and
vegetables, growers and processors must adhere to high safety standards to prevent product
contamination and ensure good quality. Foodborne illnesses have also been of particular concern
in recent years as outbreaks of Salmonella, Listeria and E. coli often make the news. Preventing
foodborne illnesses from entering the consumer market can protect people’s health and even
potentially save lives. Product contamination can tarnish brand reputation if recalls are issued,
and it can even result in driving a company out of business. Assuring food safety practices

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 during produce processing is essential to providing safe and healthy ready-to-eat fruits and
vegetables from companies that consumers trust. Produce processing involves numerous stages
from farm to store that differ based on the final product. After produce is harvested, it’s
transported to processing facilities where it’s then further prepared to make it safe for public
consumption. Removal of potentially harmful bacteria from the produce is an important part of
produce processing. Some of the activities that produce processing can include are:
 Sorting by color or size
 Washing and sanitizing
 Adding preservatives to increase shelf life
 Chopping or mixing
 Cooking or freezing
 Pasteurizing for juices
 Canning and packaging
Each of these common steps in produce processing involves their own best practices for food
safety, but food safety must begin at the growing facility or farm. Best practices should be
followed from farm to fork to reduce the majority of common food contamination occurrences.
Once produce leaves the farm, it’s transported to various processing facilities depending on the
intended final product. Whether it’s chopped, cooked, frozen, cleaned or processed into a new
product, there are general food safety guidelines for ready-to-eat foods such as fruit and
vegetables that are essential to protect against microbial contamination. These basic food safety
procedures can help prevent contaminations due to human mishandling, improper packing
processes, and contamination of containers or improper temperature management:
Clean and secure loading docks: Loading docks should be kept clean and free of grass, dirt or
outside debris. When not in use, loading docks should be closed and locked to ensure outside
pests or traffic cannot enter the processing facility.
Clean and sanitize all surfaces regularly: Any food contact surface should be cleaned and
sanitized regularly to prevent cross-contamination or spreading of microbial contamination. This
includes counters where food is prepared and tools such as knives and machines used for
processing produce. It’s essential to first clean, which removes any dirt or debris, then follow
with a sanitizing step to kill bacteria present. Materials used in any food processing facility

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 should be easy to clean and sanitize. It’s best practice to create a written cleaning and sanitation
schedule and ensure it is performed regularly.
Enforce good employee hygiene: Gloves should be worn when handling produce, and
employees should practice good personal hygiene. Restrooms and employee break rooms should
be in a separate area from anywhere produce is processed.
Test for harmful bacteria regularly: While it’s important to visually check the cleanliness of
food contact surfaces, harmful bacterial pathogens are microscopic and cannot be seen with the
naked eye. That’s why regular testing for microbes on food contact surfaces is essential to
identify and minimize any areas contamination.
Establish preventative plans and hazard controls: Good Manufacturing Practices
(GMP’s) and Hazard Analysis and Critical Control Points (HACCP) are essential and effective
measures for identifying and controlling risks during produce processing. Creating a written
preventative plan is an essential step for food manufacturing safety.
Report hazards immediately: Employees should be trained on the importance of food hygiene
so they can recognize potential hazards and report them to management at the earliest possible
sign. This allows necessary steps to be taken for minimizing the possibility of contaminated
product reaching consumers and potentially causing foodborne illness. Catching a potential
hazard or risk early may be the only chance for effective remediation prior to release of the
product into commerce.
Blanch produces before freezing: Blanching is the process of quickly and briefly boiling or
steaming vegetables or fruit. Blanching is an effective method to inactivate enzymes and damage
microbes before freezing which can limit deterioration of the produce.
Freeze produce quickly: After blanching produce, it should be frozen rapidly. Reducing the
temperature of the product quickly will prevent it from further cooking and help ensure the
continued freshness of the product while also slowing the activity of any microbes that might be
present.
Add ascorbic acid or other preservatives: Another effective technique for stopping enzyme
activity in frozen produce is by additional of ascorbic acid, commonly known as vitamin C, to
prevent any further chemical deterioration.

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 1.7. Loading material and adding solvents
Fruits and vegetables are rich in carotenoids, phenolic compounds, Vitamin C, among others.
Extraction processes for these compounds depend on several factors such as the technique that is
used, the raw material, and the organic solvent. Conventional techniques generally require large
amounts of organic solvents, high energy expenditure, and are time consuming, which has
generated interest in new technologies that are referred to as clean or green technologies. These
can reduce or eliminate the use of toxic solvents, and thus preserve the natural environment and
its resources. The aim of this review is to discuss recent techniques used to extract bioactive
compounds from natural sources, in order to reduce the economic and ecological impact of these
processes.
The efficiency of conventional extraction methods depends on the choice of solvent and the
polarity of the compound, since solvents of different polarities are needed for identification and
isolation. The polarities of compounds vary and it is difficult to develop a single method for the
efficient extraction of all compounds. A good solvent provides low toxicity, a low boiling point,
quick mass transfer, preservative action, and the inability to make the complex extract dissociate.
The yield and the amount of the extract obtained also depend on several other factors such as the
type of extract, the temperature, and the extraction time
Methods of Extraction
Method of production for all the fruit-based vegetable the first stage is the extraction of juice or
pulp from the fruit. The following are the key manufacturing stages:
 Selection and preparation of raw material
 Juice extraction
 Filtration (optional)
 Batch preparation
 Pasteurization
 Filling and bottling.
Any fruit can be used to make fruit juice, but the most common ones include pineapple,
orange, grapefruit, mango and passion fruit. Some juices, such as guava juice, are not filtered
after extraction and are sold as fruit nectars.

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 Self-check-1 Written Test

Name…………………………………………… ID………………………… Date…….

Directions: Answer all the questions listed below. Examples may be necessary to aid some
explanations/answers.
Test II: choose the best answers
1._____________is the process of converting fruits and vegetables into a puree or concentrate
that is later on processed to obtain juices, creams, sauces
A. Concentration B. Extraction C. filtration D. All
2. Objectives of fruit and vegetable processing
A. Reduce wastage and losses B. Stabilize farm prices and income
C. Utilize marketable surplus D. Generate employment E. All
3. Which of the following methods are storing vegetables and fruit?
A. Drying B. Canning C. Curing and salting D. Freezing E. All
4. Factors to Consider when fruit storage?
A. Temperature B. Humidity C. Handling D. All

Test II: Short Answer Questions

1. List out best fruit for juicing?
2. Writ best fruit and vegetable for blending?
3. List out all juice extraction equipment’s?
4. Food Contamination?
5. List out best practice for food processing?

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 Operation Sheet 1- Preparing the extraction equipment and process for operation

Procedure for Preparing the extraction equipment and process for operation
Step 1- wear personal protective equipment
Step 2-collect and order equipment
Step3- clean an equipment
Step 4- follow Work Instructions or Standard Operating Procedures (SOP).
Step 5- Load material into percolator

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 LAP Test Perform Test

Time started: ________________________ Time finished: ________________

Name………………………………. ID… Date………
Instructions: Given necessary templates, tools and materials you are required to perform the
following tasks within 1 hour. The project is expected from each student to do
it.

Task- Prepare extraction equipment and process for operation

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 Unit Two Operate and monitor peeling, destoning
and crushing process

This unit is developed to provide you the necessary information regarding the following content coverage
and topics:
 Starting and operating the peeling, crushing process
 Performing Destoning process
 Performing Crushing process
This guide will also assist you to attain the learning outcomes stated in the cover page. Specifically, upon
completion of this learning guide, you will be able to:
 Start and operate the peeling, crushing process
 Perform Destoning process
 Perform Crushing process

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 2.1. Introduction to peeling, destoning and crushing process
The juice extraction from fruits and vegetables can be done by size reduction methods as
crushing, chopping and comminuting. This is usually employed for fruits that are fully ripened
and too soft for whole or diced or sliced packs.
The following points must be remembered in such situations.
 Crushing of products by chopping them into small pieces (0.025-0.075 inch) prior to
heating speeds enzyme activity. Hence it is required to remove the air at the time of
crushing and immediately after comminuting.
 Therefore, direct super-heated steam introduction into the chopper or crusher is applied.
 Super-heated steam aids in creating a partial vacuum. So superheated steam preferably
under a vacuum will eliminate the air and aid immensely in creating a better consistency
in the final product. The equipment used for separation of the pulp is known as a pulper,
where mainly the compression force is used. Basket press is a common equipment for
taking out juice from soft fruits as oranges.
2.2. Starting and operating peeling and crushing process
2.2.1. Peeling
Peeling is an operation that allows for a better presentation of the product, and at the same time
fosters sensory quality, for the material with a firmer and rougher texture is eliminated.
Moreover, the skin often presents a color that has been affected by the thermal processes
normally used in processing methods.
Peeling facilitates the operation of cutting raw material into pieces or into slices before
processing. Peeling is an operation that allows for a better presentation of the product, and at the
same time fosters sensory quality, for the material with a firmer and rougher texture is
eliminated. Moreover, the skin often presents a color that has been affected by the thermal
processes normally used in processing methods.
Peeling facilitates the operation of cutting raw material into pieces or into slices before
processing
Trimming and peeling (skin removal): This processing step aims at removing the parts of the
fruit which are either not edible or difficult to digest especially the skin.
Up to now the industrial peeling of fruit and vegetables was performed by three procedures:
mechanically; by using water steam; chemically; this method consists in treating fruit and

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 vegetables by dipping them in a caustic soda solution at a temperature of 90 to 100° C; the
concentration of this solution as well as the dipping or immersion time varying according to each
specific case.

2.2.2. Crushing:

Powered machines that are used to crush pineapples or other hard fruits consist of a rotating
screw inside a casing. The casing has a screen in the base. Juice/pulp drains from an outlet in the
base of the casing and skin is ejected from the end of the casing down a chute. The casing should
be fitted with wing nuts to remove it easily.

Fig 2.1. fruit crusher

Crushers should be cleaned after use as follows:
1. Remove the hopper and wash with detergent. Rinse with clean water and allow to dry.
2. Remove the casing and wash as for the hopper
3. Wash the screw and screen thoroughly, using a brush and detergent. Rinse with clean
water.
4. Clean the chute and juice/pulp pipe with a water hosepipe and spray gun.
5. Ensure that no particles of fruit remain in the machine after cleaning

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 2.3. Performing destoning process
Destoning is the process of removing stone or contamination from fruit and vegetable
processing of different size and color. It is a Post harvesting process for Value addition of
harvested fruit. Be it fruit, Pulses & any cereals, at the time of harvesting Mud & stones come
along with harvested fruit. The fruit enters the cylindrical screen through a hopper, transported
by a worm screw.

Fig2.2 DE stoning machine

The de-stoning/mashing unit is an easy mechanical machine used for removing the stones/seeds
and/or mashing from fruits, such as cherries, plums, peaches, apricots, William’s pear, tomatoes,
carnell cherry, apricots, raspberries, strawberries, blackcurrants etc.
DE stoning machine benefits:
 To remove stones or seeds from fruits
 To break up the mash / flavor
 To achieve a homogenous mash/pulp
 For distillery, jam and juice production
2.4. Performing and crushing process
1.Crushing process
There are many fruit-specific ways to extract juice. Some are well-established, large-scale
procedures for commercial fruits and will be explained in detailed for those fruits. Operations

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 range from kitchen to industrial scale depending upon volume, end use and raw material.
Provides some general guidelines for various fruit types. The goal in juice manufacture is to
remove as much of the desirable components from the fruit as possible without also extracting
the undesirables.
Contour peelers, such as used with apples can be adapted to a range of fruits that are
sufficiently firm and uniform to facilitate the rotary peeling action. Peeling systems that are
effective with some vegetables such as lye, abrasion, enzymatic, explosive, are less satisfactory
with delicate fruit flesh. Nevertheless, cleverly designed machinery can greatly facilitate these
lab our-intensive operations. Under all circumstances, a final human inspection and piece
selection/rejection step is mandatory.
Generally, a whole fruit is more stable than the juice, unless rapidly preserved after extraction.
So, fruit should not be committed to juice until the material can rapidly be stabilized or the
processes go to completion. Attention to quality at the pre juicing step is extremely critical.
Otherwise, surface debris and portions of skin or seed can easily ruin the color or flavor of an
entire batch of juice. Of course, in a similar sense, microbial and chemical contaminants at
juicing can and have caused disastrous public health consequences.
Juice extraction equipment ranges from hand operated crushers to tons/hour mechanical
extractors (With soft or comminuted fruit a cone screw expresser or paddle pulper fitted with
appropriate screens serves to separate the juice from particulate matter. Where skin or seed
shattering is a problem, brush paddles can replace metal bars. Two pullers in series with screens
of ~1 to 0.2 mm can effectively clean up many juices and often yield a usable thick pulp by-
product.
The juice extraction from fruits and vegetables can be done by size reduction methods as
crushing, chopping and comminuting. This is usually employed for fruits that are fully ripened
and too soft for whole or diced or sliced packs. The following points must be remembered in
such situations.
 Crushing of products by chopping them into small pieces (0.025-0.075 inch) prior to
heating speeds enzyme activity. Hence it is required to remove the air at the time of
crushing and immediately after comminuting.
 Therefore, direct super-heated steam introduction into the chopper or crusher is applied.

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  Super-heated steam aids in creating a partial vacuum. So superheated steam preferably
under a vacuum will eliminate the air and aid immensely in creating a better consistency
in the final product.
In this step fruit juice is pressed from pulped raw material with help of decanters or pressor.
Decanter is a horizontal, cylindrical screen lined with press cloth material, with a large inflatable
tube in the center that inflates and presses pulp up against the loath-covered wall The whole
assemblage is rotated after it is filled and closed and as the tube is bedding inflated. Juice is
expressed into a catch trough below and collected from a drain. Pressure on the tube reaches a
maximum of 6 atmospheres or approximately 600 kPa. Usually, a press aid is needed to keep the
pulp from adhering to the press cloth and stopping the free flowing of the juice. Solid waste from
juice extraction process is discharged at the end part of decanter and can be reused for getting
some additional juice extraction with help of enzymes.
2. Juice clarification:
For more fluid juices where cloud or turbidity is not acceptable primary extracted juice must be
treated further. A settling step can help, if the juice can be held refrigerated for a few hours. At
ambient tropical temperatures holding is not recommended. Rapid methods such as
centrifugation and filtration can produce a clear juice. A continuous or a decanting centrifuge
with automatic desludging to produce a clear or nearly clear juice is quite effective. (Juices
where a cloud is desired generally do not require filtration; centrifugation is adequate.) The
stream should be settled or coarse strained prior to centrifugation in order to reduce the sludge
load in the feed going to the centrifuge. A fine mesh shaker screen can further remove
particulates). A centrifuge is a very costly item; however, it greatly simplifies subsequent
filtration steps and is an essential component in many juices processing operations
3.Filtration
To make a clear juice, the extracted juice or pulp is filtered through a muslin cloth or a stainless-
steel filter. Some of the larger filter presses have a filter included. Although juice is naturally
cloudy, some consumers prefer a clear product. It may be necessary to use pectic enzymes to
break down the pectin and to help clear the juice. Pectic enzymes may be difficult to find and
expensive and therefore should only be used if really necessary and readily available.

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 Self- check-2 Written test

Name…………………………………………… ID………………………… Date…….

Directions: Answer all the questions listed below. Examples may be necessary to aid some
explanations/answers.
Test I: choose the best answers

1.Which one is benefit destoning machine?

A. Remove stones or seeds from fruits B. Break up the mash / flavor
C. Achieve a homogenous mash/pulp D. For distillery, jam and juice production E.all
2.Peeling is an operation that allows for a better presentation of the product, and at the same time
fosters sensory quality, for the material with a firmer and rougher texture is eliminated
A. True B. False
3._________is operation that allows for a better presentation of the product, and at the same time
fosters sensory quality, for the material with a firmer and rougher texture is eliminated
A. Crushing B. Peeling C. Filtering D. All

Test II: Short Answer Questions

1. What is peeling?
2. Why we use crushing?
3. Write the benefits of destoning?
4. Why we filter the juice?

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 Operation Sheet 2- Operating peeling, destoning and crushing process
Procedure _for peeling, destoning and crushing process
Step 1- wear personal protective equipment
Step 2- prepare best Fruits and vegetable for blending
Step 3- follow Standard Operating Procedures (SOP
Step 4- prepare juice blender, Filter/ Sieve, percolator and water.
Step 5-carry out line clearance process.
Step 6- Load material into percolator and check destoning
Step 7-start peeling process.
Step 8- perform crushing process
Step 9- perform Juice clarification/or filtering.

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 LAP Test Performance test

Name………………………………................ ID…………………. Date………

Time started: _________________Time finished: ________________

Instructions: Given necessary templates, tools and materials you are required to perform the
following tasks within 1:30 hour. The project is expected from each student to
do it.

Task1- starts juice extraction process.

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 Unit Three Operate and monitor the extraction process

This unit is developed to provide you the necessary information regarding the following content coverage
and topics:
 Monitoring extraction process.
 Identifying and reporting Out-of-specification product/process
 Maintaining work area
 Conducting Work.
 Maintaining and reporting Workplace document

This unit will also assist you to attain the learning outcomes stated in the cover page. Specifically, upon
completion of this learning guide, you will be able to:
 Monitor extraction process.
 Identify and report Out-of-specification product/process
 Maintain work area
 Conduct Work.
 Maintain and report Workplace document

3.1 Monitor extraction process

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 Quality Control: The freshness and quality of the expressed fruit juice is central to the quality
of the final product. The quality of each day’s production should be monitored and controlled to
ensure that every bottle of juice has the correct keeping and drinking qualities.
What is a hazard analysis? The hazard analysis is an evaluation of potential microbiological,
chemical, and a physical hazard associated with a particular product and process and is used to
determine which hazards are reasonably likely to occur and, if they occur, how they can best be
controlled. The regulation requires that the hazard analysis be written.
Acceptance of raw material: The production process of fruit juice and concentrates begins
with raw material purchasing. Fruit is verified in terms of quality before unloading. It should
look healthy and be ripe.
Fruit pulp preparation and processing: Raw materials from pre-production warehouse are
transferred to the dosing units (known as sorting units). The task of the sorting unit is to dose
fruits evenly to the vertical screw feeder (known as elevator). Sorting units have designs
individually adjusted to the capacity of elevator and floatable chutes.
A cutting line is controlled by the system automated with visualization and operated from a
touch panel on the control cabinet.
Juice yielding: A correctly performed pressing stage guarantees maximum yield of juice from
raw material. An extrusion process starts with pre-filling. Pulp is pumped to a closed cylinder,
filling up the pressure chamber space. It is a fully automated process owing to the self-
optimizing press control system, which determines the level of product extrusion at each process
stage. After completing the press filling-up cycle, pressing takes place. Piston presses the pulp
and juice flows out through filtering elements to both juice chambers encased in the resistance
board and press-down board. Then, the piston retracts, while the cylinder is rotating, thus, the
entire pulp is carefully loosened. This phase is repeated in cycles and each piston feed is a few
millimeters longer than the previous one.

Washing equipment and piping in production line

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 CIP (clean in place) station is used for washing installations, devices and pipelines in the
production line in CIP system.

A washing procedure consists of the following phases:

 Recovery of the products remains from the technological system,

 Pre-rinsing of superficial staining,
 Washing with the use of cleaning agents (acid washing and alkali washing),
 Rinsing with clean water,
 Optional disinfection
Closed circuit washing allows for cleaning agent economy and reduction of sewage discharged.
Working solutions are prepared in the CIP station in the concentrations recommended by the
manufacturer and in adequate temperatures. Solutions are retained in three tanks insulated with
a double coat and fed by a pump as needed.

FRUIT JUICE

Fruit juices are made from pure filtered fruit juice with nothing added. Sodium benzoate can be
added as a preservative to extend the shelf life, but this is not essential. Properly pasteurized
juice has a shelf life of several months. Most fruits can be used to make juice. The most popular
ones are pineapple, orange, mango, grapefruit and passion fruit. –

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 In particular extraction juice the following points should be observed:
 Only fresh, fully ripe fruit should be used; moldy or insect damaged fruit should be thrown away.
All unwanted parts (dirt, skins, stones etc.) should be removed.

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  All equipment, surfaces and floors should be thoroughly cleaned after each day’s production.
 Water quality is critical. If in doubt use boiled water or add one tablespoon of bleach to 5 liters
of water to sterilize it. If water is cloudy, a water filter should be used.
 Pay particular attention to the quality of re-usable bottles, check for cracks, chips etc. and wash
thoroughly before using. Always use new caps or lids.
 The concentration of preservatives should be carefully controlled for correct preservation of
squashes and cordials and may be subject to local laws. Check first and use accurate scales to
measure the preservative.
 The temperature and time of heating are critical for achieving both the correct shelf life of the
drink and retaining a good color and flavor.
 The correct weight should be filled into the bottles each time.
Monitoring by workers: Inspect juice, check for color and any pieces of fruit on sieve/cloth.
Color compared to standard color chart for the product
Control point: All juice passes through filter cloth. Juice having poor color or insufficient
sweetness either rejected or blended with other juices

3.2. Identifying and reporting out-of-specification product/process

Fruit juice is the unfermented but fermentable liquid obtained from the edible part of sound,
appropriately mature, ripe and fresh fruit or of fruit maintained in sound condition by suitable
means. Some juices may be processed with pips, seeds and peel, which are not usually
incorporated in the juice, but some parts or components of pips, seeds and peel, which cannot be
removed by Good Manufacturing Practices (GMP), will be acceptable. The juice is prepared by
suitable processes, which maintain the essential physical, chemical, organoleptic and nutritional
characteristics of the juices of the fruit from which it is derived. The juice may be cloudy or clear
and may have restored aromatic substances and volatile flavor components, all of which shall be
obtained by suitable physical means, and all of which shall be recovered from the same kind of
fruit. Pulp and cells obtained by suitable physical means from the same kind of fruit may be
added.

Quality criteria
 Shall contain no additives

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  The fruit juices and fruit nectars shall have the characteristic color, aroma and flavor of
juice from the same kind of fruit from which it is made.
 The product shall be free from seeds, bits of seed or bits of peel
 4 Shall be free from deterioration or spoilage
 The product shall be clean and free from foreign matter
 The fruit juices and fruit nectars shall conform to the requirements in pH value max
3.3. Maintaining work area.

Maintaining work area according to housekeeping standards

Good housekeeping is the foundation of a safe, healthy and pleasant workplace. It is essential
that all areas be kept clean, orderly, and with all necessary things in the proper places.
Employees should be aware of hazards arising from poor housekeeping. Good housekeeping
improves safety, efficiency and quality at the same time.

Work environment. Many production jobs in food manufacturing involve repetitive, physically
demanding work. Food manufacturing workers are highly susceptible to repetitive-strain injuries
to their hands, wrists, and elbows. This type of injury is especially common in meat- and poultry-
processing plants. Production workers often stand for long periods and may be required to lift
heavy objects or use cutting, slicing, grinding, and other dangerous tools and machines. To deal
with difficult working conditions and comply with safety regulations, companies have initiated
ergonomic programs to cut down on work-related accidents and injuries.

There are 11 tips for effective workplace housekeeping

 Prevent slips, trips and falls: Slips, trips and falls were the second leading cause of
nonfatal occupational injuries or illnesses
 Eliminate fire hazards: Employees are responsible for keeping unnecessary combustible
materials from accumulating in the work area. Combustible waste should be “stored in
covered metal receptacles and disposed of daily,” according to OSHA’s Hazardous
Materials Standard
 Control dust: Dust accumulation of more than 1/32 of an inch or 0.8 millimeters
covering at least 5 percent of a room’s surface poses a significant explosion hazard,

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  Avoid tracking materials: Work-area mats – which can be cloth or sticky-topped –
should be kept clean and maintained.
 Prevent falling objects: protections such as a toe board, toe rail or net can help prevent
objects from falling and hitting workers or equipment.
 Clear clutter: A cluttered workplace can lead to ergonomics issues and possible injuries
because workers have less space to move
 Store materials properly: According to OSHA’s Materials Handling, Storage, Use and
Disposal Standard
 Use and inspect personal protective equipment and tools: Wear basic PPE such as
closed-toe shoes and safety glasses while performing housekeeping,
 Determine frequency All workers should participate in housekeeping, especially in
terms of keeping their own work areas tidy, reporting safety hazards and cleaning up
spills, if possible.:
 Create written rules: Experts agree that housekeeping policies should be put in writing.
Written protocols could specify which cleaners, tools and methods should be used.
 Think long-term: Housekeeping should be more than a one-time initiative it should
continue through monitoring and auditing. Keep records, maintain a regular walkthrough
inspection schedule, report hazards and train employees to help sustain housekeeping. Set
goals and expectations, and base auditing on those goals,
3.4. Conducting work
3.4.1. Environmental Regulations and the Food Industry

Environmental standards are administrative regulations or civil law rules implemented for the
treatment and maintenance of the environment. Environmental standards are set by a government
and can include prohibition of specific activities, mandating the frequency and methods of
monitoring, and requiring permits for the use of resources or food process. Standards differ
depending on the type of environmental activity.
3.4.2. Food control

Food control is the regulation of the food supply industry and enforcement of food laws by
national or local authorities. Its purpose is to provide consumer protection and ensure that all
foods during production, handling, storage, processing and distribution are safe, wholesome and

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 fit for human consumption. A food control system ensures that foods conform to safety and
quality requirements and are honestly and accurately labeled, as required by law. The scope of
food control includes:
 Food safety, which refers to all those hazards that may make food unhealthy for the
consumer.
 Food quality standards, which includes all other attributes that influence a product’s
value to the consumer, e.g. composition, labeling, etc.
Food control covers all stages of production, processing and distribution of food. It covers
controls on food that is produced or imported for consumption within the region and food that is
exported outside the country.
The principal objective of the national food control system is the protection of public health by
protecting consumers from unsafe, unwholesome, mislabeled or adulterated food. It also
contributes to economic development by maintaining consumer confidence and providing sound
regulatory controls for domestic and international trade in food.
Components of a food control system
The main components of a national food control system are:
 food law and regulations
 food control management
 inspection services
 laboratory services for food monitoring and epidemiological data
 Information, education, communication and training.
To be effective, food law and regulations should be relevant, enforceable and ‘proactive’ (that is,
have a preventive component) so that they can provide a high level of health protection. They
must also include clear definitions to increase consistency and legal security.
There needs to be monitoring of compliance with food laws. Quantitative monitoring includes
counting the number of food premises inspected, the number of food samples taken, the number
of food complaints dealt with and the number of food poisoning cases dealt with.
Government regulators are responsible for auditing the performance of the food system through
monitoring, surveillance and enforcing legal and regulatory requirements. The more economic
and effective strategy is to entrust food producers and operators with primary responsibility for
food safety and quality. An important aspect of education is to promote voluntary compliance

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 with food regulations. Voluntary compliance means that food producers and providers adhere to
the food laws voluntarily, because they understand the benefits of good practice, rather than be
prosecuted or penalized for breaching the regulations.
3.5. Maintaining workplace documentation
Workplace documentation
Maintaining a system of organized, accurate and consistent documentation in the workplace is both
necessary and beneficial. Making documentation a priority, especially when it comes to the company’s
HR department, can help mitigate disputes, offer resources when they are needed and answer important
questions about the company. In this article, we will discuss why documentation is important and ways
you might consider improving your documentation process.
What is a Material Safety Data Sheet (MSDS)?
A material safety data sheet is a technical document which provides detailed and comprehensive
information on a controlled product related to:
 health effects of exposure to the product
 hazard evaluation related to the product’s handling, storage or use
 measure to protect workers at risk of exposure
 Emergency procedures.
The Purpose of the Data Sheet
The data sheet is the second element of the WHMIS information delivery system and is intended
to supplement the alert information provided on labels. The third element of the system is the
education of employees in hazard information on controlled products, including instruction in the
content and significance of information on the MSDS.
Specifications: Food quality specifications are guidelines that are used to help develop food and
drink products. Written by manufacturers and retailers from the industry, these
cover product color, flavor, and texture, as well as tolerances for specific defects.
Manufacturing formulae: A formula is how a professional specialty food manufacturer will
document your information and is based on pounds, kilograms, grams and other weight
measurements. These weights are then converted to percentages so any amount or batch size can
be made on those confirmed percentages.
Standard Operating Procedures (SOPs: A standard operating procedure is a set of step-by-
step instructions compiled by an organization to help workers carry out complex routine

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 operations. SOPs aim to achieve efficiency, quality output and uniformity of performance, while
reducing miscommunication and failure to comply with industry regulations.
Batch production records: A batch manufacturing record is a document designed to provide a
complete record of the manufacturing history of a batch of product. The terminology is widely
applied within the Pharmaceutical & Chemical industries and is referenced in many of the
pharmaceutical and food regulatory agency requirements.

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 Self -Check 3 Written test
Name…………………………………………… ID………………………… Date…….
Directions: Answer all the questions listed below. Examples may be necessary to aid some
explanations/answers.
Test I: choose the best answers
1_______is an evaluation of potential microbiological, chemical, and a physical hazard
associated with a particular product and process.
A. Hazard analysis B. Quality control C. Safety D. All
2. The production process of fruit juice and concentrates begins with raw material purchasing
A. True B. False
3. washing procedure consists of?
A. Recovery of the products remains from the technological system
B. Pre-rinsing of superficial staining C. Washing with the use of cleaning agents
D. Rinsing with clean water E. All
4.The main components of a national food control system are:
A. Food law and regulations B. Food control management C. Inspection services D. all

Test II: Short Answer Questions

1. Write the Purpose of the material Data Sheet?
2. What is Food control?
3. Write Components of a food control system?
4. List out quality criteria?

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 Operation Sheet 3- pasteurization of juice
Procedure _ pasteurization of juice
Step 1- wear personal protective equipment
Step 2- select normal ripe fruit
Step 3- washing
Step 4- peeling if necessary
Step 5-crushing
Step 6- juice extraction
Step 7-filteration
Step 8- pasteurization
Step 9-cooling
Step 10. packing

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 LAP Test Performance Test

Name………………………………................ ID…………………. Date………

Time started: _________________Time finished: ________________

Instructions: Given necessary templates, tools and materials you are required to perform the
following tasks within 2hrs hour. The project is expected from each student
to do it.

Task1- Perform pasteurization process.

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 Unit Four Perform pre-heating

This unit is developed to provide you the necessary information regarding the following content coverage
and topics:

 Operating pre- heater.

 Adjusting the equipment and temperature
This unit will also assist you to attain the learning outcomes stated in the cover page. Specifically, upon
completion of this learning guide, you will be able to:

 Operating pre- heater.

 Adjusting the equipment and temperature

4.1. Operating pre-heater

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 4.1.1. Thermal Treatment
The optimal thermal treatment for processing the product is described below. In this example, we
use the HRS MI and MR series heat exchangers which are suitable for this application. Where
applicable and required, a temperature sensor and a visual thermometer is fitted to control the
process at various stages.
Pre-heater: The product is preheated in the MR type corrugated multi tube heat exchangers.
This is a direct recovery of energy using the product itself to provide the heat needed for the
preheating phase. After preheating, the product passes through the DE aerator.
Preheating: After DE aeration, the product is subjected to a second regenerative heat treatment
similar to the first. By using MR type corrugated multi tube heat exchangers, we can achieve
recuperation values between 70 and 80% heat recovery from the product.
The primary pasteurization is done as soon as possible after juice extraction, or as a first step in
the evaporator. This pasteurization is commonly done at 95–98°C for 10 to 30 seconds. The main
objective is to inactivate enzymes from the fruit, but microorganisms also are inactivated during
the pasteurization. Inactivation of enzymes generally requires more intensive pasteurization
conditions than what is required to destroy microorganisms
The first pasteurization, in order to deactivate enzymes, kills most microorganisms, leaving the
juice or concentrate commercially sterile. For NFC juice (Not from Concentrate) there is a risk
that microorganisms enter the juice during transport or bulk storage and recontamination the
juice. If the juice or nectar is made from concentrate the recontamination may occur during
storage and transport of the concentrate or during reconstitution with water. The water used for
reconstitution should always be of high quality.

4.2. Adjusting equipment and temperature

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 4.2.1. Pasteurization process
The heating medium is hot water, usually under the boiling temperature. The pasteurizer heat up
the raw materials to 68-70℃, keep this temperature for 30min and cool down suddenly to 4-
5℃. As the death point of most bacteria is 68℃ and under 30 min, so this process can eliminate
most bacteria. Then, the sudden temperature drop will cause the bacteria to die.
Pasteurization of juice can be done for temporary preservation (pre-pasteurization) and in this
case this operation is carried out with continuous equipment (heat exchangers, etc.); warm juice
is stored in drums or large size receptacles (20-30 kg). Pasteurization conditions are at 75°C in
continuous stream.
4.2.2. Fruit juice heating equipment’s
Nowadays, large fruit and vegetable juice manufactures usually adopt UHT technology to heat
up the liquid to high temperature and keep for very short time. Generally, there are plate
pasteurizer, tubular pasteurizer and steam pasteurizer 3 types, and plate pasteurizer is the most
prevalent. Plate pasteurizer integrates the function of preheating, sterilization, heat preservation
and cooling.

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 Self -Check 4 Written test

Name…………………………………………… ID………………………… Date…….

Directions: Answer all the questions listed below. Examples may be necessary to aid some
explanations/answers.
Test I: choose the best answers
1.Which of the following is low temperature?
A, blanching B. Pasteurization C. Freezing D, all
2.Microorganism growth quickly?
A. high temperature B. Low temperature C. Room temperature D. All
3.Pasteurization is
A. Kill all micro-organism B. Kill micro-organism below the boiling point of water
C. It is a process of food preservation D. B$C

Test I: Short Answer Questions

1. What temperatures are best for pre heating juice?
2. Write the equipment used to heating juice?
3.Write the uses operating pre heating?

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 Unit FIVE Shut down the extraction process

This unit is developed to provide you the necessary information regarding the following content coverage and
topics:
 Shutting down process.
 Identifying and reporting requirements.

This unit will also assist you to attain the learning outcomes stated in the cover page. Specifically, upon
completion of this learning guide, you will be able to:
 Shut down process.
 Identify and report requirements.

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 5.1. Shutting down process
Shutting down: Normal shutdown includes steps to render the systems safe, such as removal of
hazardous process materials and inert (asphyxiating) gases. The systems might be cleaned as part
of the shutdown; cleaning is often a process unto itself requiring its own set of startup, operation,
and shutdown procedures.
Shut down must be conducted using the standard procedures established for the machine or
equipment (not emergency procedures or other shortened/simplified method).
Equipment shut down pre conditions:
 A disconnect switch;
 A manually-operated switch by which the conductors of a circuit can be disconnected
from all ungrounded supply conductors, and, in addition, no pole can be operated
independently;
 A line valve, bolted blank flange, and bolted slip blinds;
 The machinery/equipment has no potential for stored or residual hazardous energy or re-
accumulation of stored energy after shutdown;
 The machinery/equipment has a single energy source which can be readily identified and
isolated;
 The isolation and locking out of that energy source will completely deenergize and
deactivate the machinery/equipment;
 The machinery/equipment is isolated from the one identified energy source and locked-
out during servicing or maintenance;
 The lockout device is under the exclusive control of the “Authorized Employee”
performing the service or maintenance;
 The servicing or maintenance does not create hazards for other employees;
 There have been NO accidents involving the unexpected activation or re-energization of
the machine or equipment during prior servicing or maintenance.

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 Fig5.1 juice extractor.

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 Juice extractor shut down process.
 Ensure the Juice Extractor is turned off by pressing the ‘On/Off’ switch on the control
panel to ‘Off’. Then switch the appliance off at the power outlet and unplug the cord.
 Remove the pulp container by tilting the base away from the motor base, and then unlatch
it from under the juicer cover and the container support extending from under the motor
base.
 Use the grip handle located on the safety locking arm to lift the locking arm from the
juicer cover and lower down out of position.
 Lift the juicer covers off the Juice Extractor.
 Step 5 Remove the filter bowl surround with the stainless-steel filter basket still in place.
 To remove the stainless-steel filter basket from the fi liter bowl surround, insert fingers
under the grooves marked ‘LIFT BASKET’ and lift the fi liter basket up. For easy
cleaning, it is recommended to remove the fi liter basket over the sink.
5.2. Identifying and reporting maintenance requirements
5.2.1. Maintenance

Maintenance is the function whose objective is to ensure the fullest availability of production
equipment, utilities and related facilities at optimal cost and under satisfactory conditions of
quality, safety and protection of the environment. The purpose of maintenance is to ensure the
maximum efficiency and availability of production equipment, utilities and related facilities at
optimal cost and under satisfactory conditions of quality, safety and protection for the
environment.

5. 2.2. Objectives of maintenance.

The more specific objectives of maintenance management are as follows:

 To optimize the reliability of equipment and infrastructure;
 To ensure that equipment and infrastructure are always in good condition;
 To carry out prompt emergency repair of equipment and infrastructure so as to secure the
best possible availability for production;
 To enhance, through modifications, extensions, or new low-cost items, the productivity
of existing equipment or production capacity;

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  To ensure the operation of equipment for production and for the distribution of energy
and fluids;
 To improve operational safety;
 To train personnel in specific maintenance skills;
 To advise on the acquisition, installation and operation of machinery;
 To contribute to finished product quality;
 To ensure environmental protection.
Scheduled maintenance
This includes the repair or replacement of worn components identified from a routine inspection
or condition monitoring. More detailed inspections require the recovery of components and
perhaps complete mooring lines (requiring vessels with lifting or winch equipment) Commercial
Off-The-Shelf (COTS) equipment manufacturers can usually recommend (or specify as part of
an equipment warranty) the required maintenance intervals and actions required for their
equipment.

Preventive The principle of preventive maintenance is anticipation. It is put into practice

maintenance in two forms: systematic (periodic) maintenance and condition-based
maintenance.
Corrective Also called breakdown maintenance, palliative or curative maintenance. This
maintenance form of maintenance consists of:
- troubleshooting on machines whose poor condition results in stoppage, or
in operation under intolerable conditions;
Systematic This consists of servicing equipment at regular intervals, either according to
maintenance a time schedule or on the basis of predetermined units of use (hours of
operation or distance travelled). The aim is to detect failure or premature
wear and to correct this before a breakdown occurs. The servicing schedule
is usually based on manufacturers’ forecasts, revised and adjusted according
to experience of previous servicing; this information is recorded in the
machine file. This type of maintenance is also called periodic maintenance.
Condition-based This type of maintenance, also called predictive or auscultative maintenance,
maintenance is a breakdown-prevention technique which requires no dismantling, as it is

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 based on inspection by auscultation of the equipment involved. It requires
continuous observation of an item of equipment in order to detect possible
faults or to monitor its condition.

Design-out This is also known as plant improvement maintenance, and its object is to
maintenance improve the operation, reliability or capacity of the equipment in place. This
sort of work usually involves studies, construction, installation, start-up and
tuning.
Preventive The principle of preventive maintenance is anticipation. It is put into practice
maintenance in two forms: systematic (periodic) maintenance and condition-based
maintenance.
Corrective Also called breakdown maintenance, palliative or curative maintenance. This
maintenance form of maintenance consists of:
- troubleshooting on machines whose poor condition results in stoppage, or
in operation under intolerable conditions;

- repairs.
Systematic This consists of servicing equipment at regular intervals, either according to
maintenance a time schedule or on the basis of predetermined units of use (hours of
operation or distance travelled). The aim is to detect failure or premature
wear and to correct this before a breakdown occurs. The servicing schedule
is usually based on manufacturers’ forecasts, revised and adjusted according
to experience of previous servicing; this information is recorded in the
machine file. This type of maintenance is also called periodic maintenance.
Condition-based This type of maintenance, also called predictive or auscultative maintenance,
maintenance is a breakdown-prevention technique which requires no dismantling, as it is
based on inspection by auscultation of the equipment involved. It requires
continuous observation of an item of equipment in order to detect possible
faults or to monitor its condition.

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 Planned Maintenance which is known to be necessary sufficiently in advance for
maintenance normal planning and preparation procedures to be followed.
Unplanned This is maintenance which is not carried out regularly as the need for it is not
maintenance predictable; it is sometimes called unscheduled maintenance.

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 Self-check 5 Written test

Name…………………………………………… ID………………………… Date…….

Directions: Answer all the questions listed below. Examples may be necessary to aid some
explanations/answers.

Test I: Short Answer Questions

1.Write shut down procedures for juice extractor.?
2.Write three shut down pre conditions?
3. Write maintenance requirements?
4.What are the uses of maintenance?
5.Writ the difference between planned and unplanned maintenance?

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 REFERENCE BOOKS.
[1] A Brief Report on Food Processing Sector in India, October 2013.

[2] Annual Report of Ministry Of Food Processing Industries, Government of India, 2011-12

[3] Bachmann Janet and Earles Richard (2000), Postharvest handling of fruits and vegetables,
Appropriate Technology Transfer for Rural Areas, pp 1-8.

[4] Bledsoe Gleyn, (2009), Cold chain and storage action plan, Chemonics International, US aid
from the American people, Private sector competitiveness enhancement program pp 1-50

[5] Cold Storage and Cold Chain – ‘the growth catalysts’, ET Roundtable on Cold Storages and
Cold Chains, 2013. [6] Human Resource and Skill Requirements in the Food Processing Sector
(2022) – A Report, 2011.
[6] Human Resource and Skill Requirements in the Food Processing Sector (2022) – A Report,
2011.
[7]IBIS World Industry Report: Global Fruit & Vegetables Processing, August 2013,
IBISWorld Inc. (“IBISWorld”)
[8] J,Jenny. January (2002), Postharvest Management of Fruit and Vegetables, Sydney
Postharvest Laboratory Information Sheet.
[9]Kachru R.P., 2012, Agro- Processing Industries in India- Growth, Status and Prospects,
Innovations Alimentarias INNOVAL C.A.
[10] Marketing and Food Safety: Challenges in Postharvest Management of Agricultural/
Horticultural Products in Islamic Republic of Iran, APO and FAO, 2006.
[11] Matapurkar Aneesh and Sinha Arnav, (2011) “Cold chain: Finally warming up to India?”,
Infrastructure Today, pp 22-25.

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 The trainers who developed the short-term training
N Name Qualification Field of Organi Mobile E-mail
o (Level) Study zation/ number
Institut
ion
1 Gadisa Berhanu BSc Food Negele 9234506 gadisabe08@gmai
science and Arsi 58 l.com
technology Tvet
College
2 Kitessa Benti BSC Food Batu 0919209 Jiregnabenti11@g
technology poly 764 mail.com
and process technic
engineering

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