某某公司饮料技术手册.PDF

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1、CRC PRESSBoca Raton London New York Washington,D.C.A Technical Handbookfor the Beverage IndustryThe Soft DrinksCompanionMaurice Shachman 2005 by CRC Press LLC This book contains information obtained from authentic and highly regarded sources.Reprinted material is quoted withpermission,and sources ar

2、e indicated.A wide variety of references are listed.Reasonable efforts have been made to publishreliable data and information,but the author and the publisher cannot assume responsibility for the validity of all materialsor for the consequences of their use.Neither this book nor any part may be repr

3、oduced or transmitted in any form or by any means,electronic or mechanical,including photocopying,microfilming,and recording,or by any information storage or retrieval system,without priorpermission in writing from the publisher.The consent of CRC Press LLC does not extend to copying for general dis

4、tribution,for promotion,for creating new works,or for resale.Specific permission must be obtained in writing from CRC Press LLC for such copying.Direct all inquiries to CRC Press LLC,2000 N.W.Corporate Blvd.,Boca Raton,Florida 33431.Trademark Notice:Product or corporate names may be trademarks or re

5、gistered trademarks,and are used only foridentification and explanation,without intent to infringe.Visit the CRC Press Web site at 2005 by CRC Press LLC No claim to original U.S.Government worksInternational Standard Book Number 0-8493-2726-1Library of Congress Card Number 2004045866Printed in the U

6、nited States of America 1 2 3 4 5 6 7 8 9 0Printed on acid-free paperLibrary of Congress Cataloging-in-Publication DataShachman,MauriceThe soft drinks companion:a technical handbook for the beverage industry/MauriceShachman.p.cm.Includes index.ISBN 0-8493-2726-11.Carbonated beverages.I.TitleTP630.S4

7、46 2004663.62dc222004045866PrefaceWith this handbook,I am not attempting to compete with the numerous textbooks available on thesubject of beverage manufacturing technology.These books,whether written in simple laymanslanguage or in elaborate technical jargon,generally cover adequately,in detail and

8、 in scope,thetechnical processes of beverage manufacture.All the relevant issues involved,from water treatmentthrough ingredients,syrup making,filling,and packaging,are usually aptly dealt with in a system-atic step-by-step manner.Ancillary matters such as quality,hygiene,inventory control,costing,a

9、ndgeneral troubleshooting are often added in appropriate dedicated chapters.Also,I do not aim to compete with the sophisticated in-house technical manuals compiled bylarge international beverage manufacturing conglomerates for benefit of their technical managementteams and operational staff.These ch

10、unky tomes aim to cover in minute detail and in sophisticatedorderly fashion every technical aspect of the beverage manufacturing process,and indeed,they donot miss much.So then,what is my companion handbook all about?Basically,it is an anthology of items relevant to technical and sometimes general

11、issues Iencountered in the 30-odd years of my association with the beverage industry.I think that theseissues have either not been specifically mentioned in the textbooks and manuals or that they havenot been sufficiently elaborated upon in them.This is not due to any fault of these books andmanuals

12、.By their nature and function,they must necessarily be prescriptive and authoritative and,as such,do not allow for theoretical discussion or academic debate.The chapters included in this anthology are presented in seemingly haphazard fashion,in nospecific sequential order.They are of subject matter

13、that most production and quality personnelencountered or could eventually encounter at one stage or another of their careers.This anthologyattempts to elaborate on some of the technical concepts that in the rush and turmoil of routineworking hours are accepted by technical and other staff at face va

14、lue,without probing into theirreal significances and meanings.Also,this handbook,in accordance with its description as a Soft Drinks Companion endeavorsto supplement the knowledge and expertise of technical staff members of not-so-big organizations,who have not been fortunate enough to receive the t

15、raining afforded to their equivalents in largeinternational conglomerates.They do not always enjoy the advantages of having a head officetechnical center at their beck and call.Furthermore,this Soft Drinks Companion handbook hopes to assist the individual,new,would-be beverage-manufacturing entrepre

16、neur who is usually clueless as to what is technicallyinvolved in such a venture.The anthology will,in one form or another,give such a person a basicidea of the technical issues involved,albeit these are not presented in as methodical and systematica format as found in general textbooks and manuals.

17、I also attempted,by means of this handbook,to cater to the general curious public and toconvey the message that making soft drinks is not,as often described,a simple matter of puttingsome sugar,bubbles,and flavor into a bottle of water.Okay,it is not as complicated as sending aspace mission to Mars,

18、but then read on.2005 by CRC Press LLC ContentsIntroduction to Soft DrinksSome StatisticsWhat is a Soft Drink?Why Soft Drinks?Benefits of Soft DrinksChapter 1Brix The BasicsThe Brix ConceptDensityDensity vs.Specific GravityBrix/Density TablesWhy is Brix Used in the Soft Drinks Industry?How is Brix M

19、easured?Chapter ReviewChapter 2Taste Testing Theory and PracticeThe Sense of TasteWhy Test for Taste?When Do We Do Taste Tests?Types of Taste TestsOnline Taste TestingThe Expert Taste PanelThe Two-Sample Preference Taste TestThe Triangular Taste TestThe Hedonic Ranking Taste TestTaste-Testing Techni

20、ques and RulesBallot SheetTastersChapter ReviewChapter 3Food Laws General IssuesGeneral OverviewWhat are Food Laws?South African Food LawsWhy Are Food Laws Included in This Technical Handbook?Acts and Regulations of Food LawsSoft Drink LegislationWhat Is the Purpose of Food Laws?How Are Food Laws Ma

21、de?Enforcement of Food LawsGeneral Food Laws Regulations Applicable to Soft DrinksChapter Review 2005 by CRC Press LLC Chapter 4Emulsions The Cloudy DrinksCloudy DrinksEmulsions as Clouding AgentsFlavor EmulsionsEmulsion TechnologyStokes LawOil DensityWeighting AgentsOil Droplet Size and Distributio

22、nStabilizersWater and Other Emulsion IngredientsHomogenizationTurbidity StrengthBeverage EmulsionsQuality Control of Beverage EmulsionsChapter ReviewChapter 5Water Treatment The Key ProcessWhy is Water Treatment Necessary?Raw Water Adverse Quality FactorsSuspended MatterChemical CompositionMicroorga

23、nismsSource Water Quality VariationA Short DigressionWater Treatment TechnologyThe Multiple Barrier ConceptMultiple Barrier Water TreatmentEnhanced FiltrationCoagulation/FlocculationBatch SystemIn-Line SystemMembrane FiltrationReverse OsmosisNanofiltrationUltrafiltrationConcentrateMembranesSystem De

24、signAlkalinity ReductionHydrated Lime TreatmentIon ExchangeDisinfectionChlorinationChemistry of ChlorinationFree and Combined ChlorineChlorine DemandChlorination in the Multiple Barrier SystemTrihalomethane(THM)2005 by CRC Press LLC OzonationWhat Is Ozone?Ozone GenerationDisinfection with OzoneOzone

25、 vs.ChlorineBottled WatersUltraviolet IrradiationUV Light DoseUV Light Disinfection EquipmentHow Effective Is UV Light Disinfection?Activated Carbon PurificationWhat Is Activated Carbon?The Carbon FilterTypes of Granular Activated CarbonBackwashingCarbon Regeneration and ReplacementPolishing Filtrat

26、ionThe Polishing FilterChapter ReviewChapter 6Brix Sugar InversionSugar Chemistry TerminologyWhat is Sugar Inversion?Why Is It Called“Sugar Inversion?”Sugar Inversion and Soft Drink TechnologyInversion in Final SyrupsFresh Brix and Inverted BrixWhat Is the Impact of Inversion in Soft Drink Technolog

27、y?How Is Inverted Brix Converted into Fresh Brix?How Is the Fresh Brix of a Sucrose-Sweetened Beverage Determined?Chapter ReviewChapter 7Fruit Juices A Special TechnologyGeneral OverviewSingle-Strength JuiceBrix Acidity CorrectionThe Brix/Acid RatioCalculating the Percentage of Juice in a BeverageOt

28、her Juice-Related IssuesPulp ContentMicrobiologicalPreservationCloud StabilityChapter ReviewAuthors CommentChapter 8Food Laws Labeling the PackageOverview 2005 by CRC Press LLC General PresentationLegibilityLanguageLetter SizesIdentificationProhibited StatementsIngredients ListIngredient NamesOrder

29、of Ingredients in List“Carryover”IngredientsSpecial ListingsSoft Drinks in Vending MachinesThe Word“Natural”Claims on Soft Drink LabelsProhibited ClaimsNutritional ClaimsNutrition InformationLabeling of Products for ExportChapter ReviewChapter 9Syrup Making The Heart of the ProcessThe Syrup Proporti

30、oning SystemWhy is Syrup Proportioning Used?A Little Bit of HistoryAdvantages of the Syrup-Making SystemTank Size and Storage Space CostsVersatilityProduct IntegrityOther AdvantagesIn ConclusionSyrup-Making TechniqueGeneral Process OutlineWorking Model of Final Syrup PreparationSimple SyrupBulk Simp

31、le SyrupFiltering the Simple SyrupAdding the Beverage Base IngredientsThe Sight-Glass ProblemTopping Up to Final VolumeThe Topping-Up Water and Final Brix CalculationReleasing the Syrup to ProductionSight Glass vs.DipstickBulk RTD PreparationA Tale of Syrup TailsChapter ReviewChapter 10 Microbiology

32、 All about the“Bugs”General Chapter OverviewA Matter of Terminology 2005 by CRC Press LLC The Microbiologist in the Soft Drinks IndustryWhat is Micro about?Microorganism GrowthWhat Is the Damage?General Characteristics of MicroorganismsBacteriaYeastsMoldsMicrobiological TestingMembrane Filtration Me

33、thodPour Plate MethodFundamentals of Micro Testing PracticesThe Micro LaboratoryLab-Testing Glassware and MaterialsSampling from Sample Points in Processing EquipmentFlaming of Sample BottlesBlank Control SamplesDuplicate PlatesMiscellaneous Micro Testing PrinciplesThe Membrane Filtration MethodPrep

34、aratory StepsMembrane Filtering and PlatingIncubation of SamplesColony CountDisposal of Completed Test MaterialMicrobiological SpecificationsMicro Testing of Factory EquipmentMicro Swabs by Membrane FiltrationATP Bioluminescence AssayPreservativesChapter ReviewChapter 11 Syrup Shrinkage Splitting Ha

35、irs?What is Syrup Shrinkage?Syrup Shrinkage ExplanationShrinkage CalculationDiscussion of CalculationWhat Is the Impact of Syrup Shrinkage?Chapter ReviewChapter 12 Carbonation Putting in the FizzOverviewA Little Bit of HistoryCarbon Dioxide(CO2)Gas VolumesTesting for Gas VolumesCarbonating the Bever

36、ageCO2as an Ingredient Stock ItemOther Items Related to Carbonation 2005 by CRC Press LLC PET BottlesGas Volume SpecificationAltitude Correction in Gas Volume TestingChapter ReviewChapter 13 Unitization A Unique Ingredients SystemChapter OverviewNonunitized SystemsThe Beverage Base UnitUnit DesignCo

37、dingLabelingPreparation of UnitsThe Full Unit ConceptBenefits and Advantages of UnitizationProcurement of Ingredients,Inventory,Production Forecasts,Etc.Inconsistencies in Batch Sizes of SyrupsLabeling and Grouping of the Weighed Ingredients for the Syrup RoomOrderly and Well-Controlled Measuring of

38、 Part Unit Ingredient QuantitiesMass Production of a Single ItemBuffer Stocks between Ingredients and Syrup MakingSimplified Issuing of Ingredients to Syrup MakingEasy Stock and Inventory Control for Production PlanningStandardized and General Costing SimplifiedSimplified Final Production Yield Calc

39、ulationsGeneral AspectsOutsourcing the Unitization OperationGeneral Considerations for Converting to a Unitization SystemChapter ReviewChapter 14 Flavors The Magical IngredientsWhat are Flavors?Flavors and Soft DrinksHow Are Flavors Made?Flavor HousesFlavor CostsHow Is a Soft Drink Flavor Sourced?Ne

40、w Product Development BriefDevelopment Brief for Flavor HouseThe New Product Development ProcessThe Magic and Mystery in FlavorsChapter 15 Formulation A Spreadsheet TemplateChapter PreviewExercise Scenario DetailsThe Exercise,Step by StepThe Blank Spreadsheet TemplateStep 1 Entering Specifications a

41、nd Ingredients List 2005 by CRC Press LLC Step 2 Calculating the“Totals”ValuesStep 3 Entering Ingredients QuantitiesStep 4 Calculating Citric Acid AnhydrousStep 5 Calculating the Sugar QuantityStep 6 Calculating the Water QuantityChapter ReviewChapter 16 Microbiology The Biofilm ConceptWhat is a Bio

42、film?How are Biofilms Formed?Special Characteristics of BiofilmsBiofilm Bacteria vs.Planktonic FormBiofilm on Heat Exchanger PlatesBiofilms in the Soft Drinks IndustryPreventing Biofilms in the Soft Drink OperationChapter 17 Quality The Key to PerformanceWhat is Quality?Quality ManagementQuality Ass

43、urance and Quality ControlBuilding Quality into the Soft DrinkThe Quality Control DepartmentSome of the Quality-Building BlocksTasteAppearanceHealth HazardsQuality Building SupportQuality Rating SystemsBasic System Operation PrinciplesWorking Example of a Quality Index ReportHow Meaningful Is the Da

44、ta?Quality Rating as an IncentiveOutsourcing the Quality Rating SystemChapter ReviewAppendix 1 Brix/Density Conversion TablesAppendix 2 Temperature Correction Tables for Refractometric Brix ReadingsAppendix 3 Significance Tables for Two-Sample Preference Taste TestAppendix 4 Significance Tables for

45、Triangular Taste TestAppendix 5 Acidity Correction Tables for Refractometric Brix ReadingsAppendix 6 Microsoft Excel Template for Final Beverage Brix Calculation 2005 by CRC Press LLC Appendix 7 Glossary of Technical and General Terms Used in this Handbook 2005 by CRC Press LLC Introduction to Soft

46、DrinksSOME STATISTICSSoft drink is the name commonly given to a nonalcoholic bev-erage that is consumed cooled or chilled,as opposed to a hotbeverage,like tea or coffee.Soft drinks fall into several cate-gories distinguished by the industry as carbonates,still drinks,juices,dilutables,and bottled wa

47、ters.A carbonate,also calleda carbonated soft drink(CSD),is a fizzy drink containing gas-eous carbon dioxide,commonly called soda pop in the U.S.Stilldrinks are noncarbonated soft drinks,and they consist of aplethora of varieties,such as fruit drinks,energy and sports drinks,and health beverages,jus

48、t toname a few.In the last decade or two,bottled waters have become very popular,whether still orcarbonated,flavored or nonflavored,with or without natural sugars.Usually,these are preparedfrom natural spring waters or from other subterranean water sources and have high mineral contents,either natur

49、ally or added during manufacture.Dilutables is the name given to concentrated syrups,squashes,and cordials that are reconstituted with water by consumers to prepare beverages in ready-to-drink(RTD)forms.Juices and nectars are beverages made mainly from naturalfruit juices,the content of which is pre

50、scribed by local food lawregulations.Roughly speaking,juices contain pure,100%juice,whereas nectars have around 50%natural juice content.Juicesmay or may not be sweetened,but nectars are always sweetened,in one manner or another,to make up for the nonjuice portion of the beverage.Figure IN.1 givesan