Orange Juice
Orange Juice
Background
Orange juice is defined in the United States Code of Federal Regulations
as the "unfermented juice obtained from mature oranges of the
Citrus sinensis
or of the citrus hybrid commonly called Ambersweet." True fresh
squeezed juice is difficult to market commercially because it requires
special processing to preserve it. Orange juice is commonly marketed in
three forms: as a frozen concentrate, which is diluted with water after
as a reconstituted liquid, which has been concentrated and then
d or as a single strength, unconcentrated beverage
called NFC or Not From Concentrate. The latter two types are also known as
Ready To Drink (RTD) juices.
Citrus fruits, like oranges, have been cultivated for the last 4,000 years
in southern China and Southeast Asia. One variety, the citron, was carried
to the Middle East some-time between 400 and 600
Arab traders transported oranges to eastern Africa and the Middle East
sometime between 100 and 700
, and during the Arab occupation of Spain, citrus fruits first arrived in
southern Europe. From there, they were carried to the New World by
explorers where they spread to Florida and Brazil by the sixteenth
century. By the 1800s, citrus fruits achieved worldwide distribution. In
the 1890s, the demand for them greatly increased because physicians
discovered that drinking the juice of oranges or other citrus fruits could
prevent scurvy, a vitamin deficiency disease.
The popularity of orange juice dramatically increased again with the
development of the commercial orange juice industry in the late 1920s. In
its early days, the juice industry primarily relied on salvaged fruit,
which was unsuitable for regular consumption because it was misshapen,
badly colored or blemished. In the 1930s, development of porcelain-lined
cans and advances in pasteurization techniques led to improved juice
quality and the industry expanded significantly. Then, in 1944, scientists
found a way to concentrate fruit juice in a vacuum and freeze it without
destroying the flavor or vitamin content. Frozen concentrated juices were
first sold in the United States during 1945-46, and they became widely
available and popular. After World War II, most Americans stopped
squeezing their own juice and concentrated juice became the predominant
form. With the increase in home refrigerators, frozen concentrate became
even more popular. The demand for frozen juices had a profound impact on
the citrus industry and spurred the growth of the Florida citrus groves.
Frozen concentrates remained the most popular form until 1985 when
reconstituted and NFC juices first out-sold the frozen type. In 1995, NFC
juices were responsible for 37% of the North American market. This is in
comparison to reconstituted juice, which held about 39% of the market.
Today, commercial aseptic packaging allows RTD juices to be marketed
without refrigerated storage. The current worldwide market for orange
juice is more than $2.3 billion with the biggest area being the United
States followed by Canada, Western Europe, and Japan.
Raw Materials
The primary ingredient in orange juice is, of course, oranges. Oranges are
members of
the rue family (Rutaceae), and citrus trees belong to the genus
Oranges, along with all citrus fruits, are a special type of berry
botanists refer to as a hesperidium. Popular types of oranges include
navel, Mandarin, and Valencia. A blend of different types of oranges is
generally used to provide a specific flavor and to ensure freedom from
bitterness. Selection of oranges for juice is made on the basis of a
number of factors such as variety and maturity of the fruit. The fruit
contains a number of natural materials that contribute to the overall
flavor and consistency of the juice including water, sugars (primarily
sucrose, fructose, and glucose), organic acids (primarily citric, malic,
and tartaric), and flavor compounds (including various esters, alcohols,
ketones, lactones, and hydrocarbons.)
Other additives
Preservatives such as sulfur dioxide or sodium benzoate are allowed by
federal regulation in orange juice although the amounts are strictly
controlled. Similarly, ascorbic acid, alpha tocopherol, EDTA, BHA, or BHT
are used as antioxidants. Sweeteners may be added in the form of corn
syrup, dextrose, honey, or even artificial sweeteners. More often, though,
citric acid is added to provide tartness.
Manufacturers may also fortify juices with extra vitamins or supplemental
nutrients such as vitamin C, and less commonly, vitamins A and E, and beta
carotene. (Beta carotene is naturally present in oranges, but only to a
small degree.) There is some concern about the stability of these added
vitamins because they do not survive the heating process very well.
Calcium in the form of tricalcium phosphate, is also frequently added to
orange juice.
The Manufacturing
Harvesting/collection
1 Oranges are harvested from large groves. Some citrus growers are
members of cooperative packing and marketing associations, while others
are independent growers. When the mature fruit is ready to pick, a crew
of pickers is sent in to pull the fruit off the trees. The collected
fruit is sent to packing centers where it is boxed for sale as whole
fruit, or sent to plants for juice processing. The oranges are generally
shipped via truck to juice extraction facilities, where they are
unloaded by a gravity feed onto a conveyor belt that transports the
fruit to a storage bin.
Cleaning/Grading
2 The fruit must be inspected and graded before it can be used. An
inspector takes a 39.7 lb (18 kg) sample to analyze in order to make
sure the fruit meets maturity requirements for processing. The certified
fruit is then transported along a conveyor belt where it is washed with
a detergent as it passes over roller brushes. This process removes
debris and dirt and reduces the number of microbes. The fruit is rinsed
and dried. Graders remove bad fruit as it passes over the rollers and
the remaining quality pieces are automatically segregated by size prior
to extraction. Proper size is critical for the extraction process.
Extraction
3 Proper juice extraction is important to optimize the efficiency of the
juice production process as well as the quality of the finished drink.
The latter is true because oranges have thick peels, which contain
bitter resins that must be carefully separated to avoid tainting the
sweeter juice. There are two automated extraction methods commonly used
by the industry. The first places the fruit between two metal cups with
sharpened metal tubes at their base. The upper cup descends and the
fingers on each cup mesh to express the juice as the tubes cut holes in
the top and bottom of the fruit. The fruit solids are compressed into
the bottom tube between the two plugs of peel while the juice is forced
out through perforations in the tube wall. At the same time, a water
spray washes away the oil from the peel. This oil is reclaimed for later
The second type of extraction has the oranges cut in half before the
juice is removed. The fruits are sliced as they pass by a stationary
knife and the halves are then picked up by rubber suction cups and
moved against plastic serrated reamers. The rotating reamers express
the juice as the orange halves travel around the conveyor line.
When the mature fruit is ready to pick, a crew of pickers pull
the fruit off the trees. Once collected, the fruit is sent to
plants for juice processing. Before extraction, the fruit is
cleaned and graded.
Some of the peel oil may be removed prior to extraction by needles
which prick the skin, thereby releasing the oil which is washed away.
Modern extraction equipment of this type can slice, ream, and eject a
peel in about 3 seconds.
4 The extracted juice is filtered through a stainless steel screen
before it is ready for the next stage. At this point, the juice can be
chilled or concentrated if it is intended for a reconstituted beverage.
If a NFC type, it may be pasteurized.
Concentration
5 Concentrated juice extract is approximately five times more
concentrated than squeezed juice. Diluted with water, it is used to make
frozen juice and many RTD beverages. Concentration is useful because it
extends the shelf life of the juice and makes storage and shipping more
economical. Juice is commonly concentrated with a piece of equipment
known as a Thermally Accelerated Short-Time Evaporator, or TASTE for
short. TASTE uses steam to heat the juice under vacuum and force water
to be evaporated. Concentrated juice is discharged to a vacuum flash
cooler, which reduces the product temperature to about 55.4° F
(13° C). A newer concentration process requires minimal heat
treatment and is used commercially in Japan. The pulp is separated from
the juice by ultra-filtration and pasteurized. The clarified juice
containing the volatile flavorings is concentrated at 50° F
(10° C) by reverse osmosis and the concentrate and the pulp are
recombined to produce the appropriate juice concentration. The flavor of
this concentrate has been judged to be superior to what is commercially
available in the United States and is close to fresh juice. Juice
concentrate is then stored in refrigerated stainless steel bulk tanks
until is ready to be packaged or reconstituted.
Reconstitution
6 When the juice processor is ready to prepare a commercial package for
retail sale, concentrate is pulled from several storage batches and
blended with water to achieve the desired sugar to acid ratio, color,
and flavor. This step must be carefully controlled because during the
concentration process much of the juice's flavor may be lost.
Proper blending of juice concentrate and other flavor fractions is
necessary to ensure the final juice product achieves a high quality
Pasteurization
7 Thanks to its low pH (about 4), orange juice has some natural
protection from
In an automated process, the juice is extracted from the orange
while the peel is removed in one step.
bacteria, yeast, and mold growth. However, pasteurization is still
required to further retard spoilage. Pasteurization also inactivates
certain enzymes which cause the pulp to separate from the juice,
resulting in an aesthetically undesirably beverage. This enzyme related
clarification is one of the reasons why fresh squeezed juice has a shelf
life of only a few hours. Flash pasteurization minimizes flavor changes
from heat treatment and is recommended for premium quality products.
Several pasteurization methods are commercially used. One common method
passes juice through a tube next to a plate heat exchanger, so the juice
is heated without direct contact with the heating surface. Another
method uses hot, pasteurized juice to preheat incoming unpasteurized
juice. The preheated juice is further heated with steam or hot water to
the pasteurization temperature. Typically, reaching a temperature of
185-201.2° F (85-94° C) for about 30 seconds is adequate to
reduce the microbe count and prepare the juice for filling.
Packaging/filling
8 To ensure sterility, the pasteurized juice should be filled while
still hot. Where possible, metal or glass bottles and cans can be
preheated. Packaging which can not withstand high temperatures (e.g.,
aseptic, multilayer plastic juice boxes which don't require
refrigeration) must be filled in a sterile environment. Instead of heat,
hydrogen peroxide or another approved sterilizing agent may be used
prior to filling. In any case, the empty packages are fed down a
conveyor belt to liquid filling machinery, which is fed juice from bulk
storage tanks. The filling head meters the precise amount of product
into the container, and depending on the design of the package, it may
immediately invert to sterilize the lid. After filling, the containers
are cooled as fast as possible. Orange juice packaged in this manner has
a shelf life of 6-8 months at room temperature.
Byproducts/Waste
Byproducts from orange juice production come from the rind and pulp that
is created as waste. Products made with these materials include dehydrated
feed for livestock, pectin for use in making jellies, citric acid,
essential oils, molasses, and candied peel. Certain fractions of orange
oil (known as d-limonene), have excellent solvent properties and are sold
for use in industrial cleaners.
Quality Control
Quality is checked throughout the production process. Inspectors grade the
fruit before
the juice is extracted. After extraction and concentration, the product
is checked to ensure it meets a number of USDA quality control standards.
The most important measurement in orange juice production is the sugar
level, which is measured in degrees Brix (percentages by weight of sugar
in a solution). The types of oranges used and the climate in which they
were grown effect the sugar level. Manufacturers blend juices with
different sugar levels together to achieve a desired sugar balance. The
final juice product is evaluated for a number of key parameters include
acidity, citrus oil level, pulp level, pulp cell integrity, color,
viscosity, microbiological contamination, mouth feel, and taste. A sensory
panel is used to evaluate subjective qualities like flavor and texture.
Lastly during the filling process, units are inspected to make sure they
are filled and sealed appropriately.
The Future
Future processing improvements are likely to come from the use of computer
controlled sizing and grading of fruit. Orange juice formulations will see
changes as the trend toward adding more nutrition-oriented ingredients,
such as antioxidants, continues. In addition, future formulas are likely
to be blends of orange juice with other, more exotic, fruit flavors, like
kiwi, or even vegetable juices, like carrot.
Where to Learn More
Nelson, P.E. and D.K. Tressler, ed.
Fruit and Vegetable Juice Processing Technology.
Westport, Connecticut: AVI Publishing Co., 1980.
Periodicals
"Juice Up."
Food Product Design
(July 1997).
"Unconcentrated Effort."
Food Processing
(November 1996).
Randy Schueller
Also read article about
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