The complete process of the mango juice production line

Mango juice is one of the most popular products in the global tropical fruit juice market. The industrial production of clarified Mango Juice or cloudy Mango Juice with pulp fiber retained follows a set of standardized process. Understanding the complete process of the mango juice processing line is the key to ensure product quality, extend shelf life and reduce operating costs. This article  mainly introduce the whole process from fresh fruit receiving to aseptic filling, helping you to better understand the technology and main equipment required for the production line of mango juice.

Mango juice production line flowchart

Raw Material Receiving and Conveying

Fresh mango, after unloading and preliminary inspection, enters the processing area through belt conveyor or elevator. Reasonable receiving and conveying system can reduce manual operation and the risk of fruit damage.

 Washing and Sorting

Washing is the first step in food safety control. Mango is sent to the bubble cleaner through the elevator, and the high pressure water flow cooperates with the bubble to roll, which can effectively remove the dust, insect eggs and some pesticide residues on the surface. Then the unqualified raw materials are removed by manual or optical sorting equipment.

Peeling and core removal

Mango kernel and peel remover is a key equipment to ensure pulp yield and product stability, which can effectively separate the pulp from the core and peel.

Pulping and refining

The peeled mango pulp is immediately sent to the pulping machine. A screw propeller and screens of different apertures are installed inside the equipment. The pulp is forced through the sieves (1.2-1.5mm coarse and 0.5-0.8mm fine), while the peel and coarse fibers are separated and discharged. Through this step, the delicate mango pulp is obtained, which is the basis of all the mango juice products.

Different Processing Techniques for clarified and Cloudy  mango Juices

Enzyme hydrolysis and clarification (only required for clarified  juice cleaning)

If the objective is to produce clear mango juice, an enzyme hydrolysis treatment is required. The pectinase was added to the mango pulp in an enzyme hydrolysis tank, controlled at a temperature of 50-55 ℃, and reacted for 30-60 minutes. The pectinase can decompose the cloudy pectin substances. Upon hydrolysis, the slurry is passed through ultrafiltration equipment or diatomaceous earth filter to remove suspended particles and obtain clear and transparent liquid.

When producing turbid juice, this step is completely skipped to retain the full taste and natural cloudy appearance of the pulp fibers.

Allocation and Standardization

Mango juice is standardized in blending cans to ensure consistent taste and concentration for each batch. Based on the requirements of the target market, the operator will add:

Purified water (concentration adjusted)

Gravel or Fructose Slurry (Adjust Sweet)

Citric acid (adjust acidity)

Vitamin C (antioxidant)

Final inspection was performed to confirm that Brix, pH and total acidity met product standards.

Homogeneous (only required for Cloudy juice)

Homogenization is an indispensable step for Cloudy mango juice. Mango juice is forced through a high pressure homogenizer to crush the pulp particles below 5 microns at a pressure of 150-200 bar. The homogeneous product is extremely smooth in taste and effectively prevents delamination and precipitation during storage.

Degassing

Either clear or turbid juice is sent to the vacuum degasser. Under vacuum, the oxygen dissolved in the fruit juice is forced out and pumped out. Degassing can:

Prevents enzyme browning (maintains color)

Reduce oxidation loss of vitamin C

Avoid oxidative deterioration of flavor substances

Degassing is a key guarantee to extend the shelf life of mango juice.

 Sterilization and Aseptic Filling

The degassed mango juice immediately enters the UHT  Instantaneous Sterilizer. Typical process parameters are 105-110 ℃ for 5-15 seconds. This strength is sufficient to kill all microbes, including heat resistant spores, and inactivate enzymes while preserving the original shade, aroma, and thermo-sensitive nutrients of mango juice to the maximum extent possible. UHT sterilization is the prerequisite for normal temperature distribution.

The sterilized mango juice was rapidly cooled to 25-30 ° C and then, in a aseptic environment maintained by a Laminar Flow Hood and HEPA filter, infused into a pre-sterilized packaging container. Common packing forms include:

Aseptic bag (5-220kg, for industrial raw materials)

Glass or PET bottles (for retail use)

Sterile docking techniques must be used during filling to prevent any secondary contamination. Upon completion of filling and sealing, the finished products can be labeled, packed and stored after passing the inspection. The shelf life of mango juice with the above process can reach 12-18 months under normal temperature.

summary

In summary, a complete mango juice processing line, from fresh fruit to a shelf-stable finished product, requires ten core steps: sorting, washing, peeling and pitting, pulping, enzymatic hydrolysis (clear juice), blending, homogenization (turbid juice), deaeration, UHT sterilization, and aseptic filling. Each step has its critical control points; negligence in any step can affect the final quality.

If you plan to build a new mango juice plant or upgrade your existing production line, please contact ksvonfo for customized solutions.