The juice of the matter: On-site assistance in Thailand

ZACMI’s support never stops, that’s true, but we had taken a small break from this column because there has been (and still is) quite a buzz in the company, with numerous projects ready to take off. Today, however, we’ve decided to return with episode 11 of the ZACMI Worldwide Tour, a bi-weekly appointment that is fundamental for us, as it highlights the on-site support provided by our specialised technicians to our clients all over the world.

Yes, because the often overused phrase “We never leave you alone” is something we at ZACMI take very seriously, offering technological and technical support wherever in the world it’s needed. On that note, today we are in Thailand assisting one of our long-standing clients who produces fruit juice with pulp.

Since the topic is so interesting (both from an organoleptic and strictly production standpoint), we also take the opportunity to offer a brief overview of the social and cultural aspects of the product, because the F&B sector is not just about technology, meticulous attention to hygiene, and innovation—it’s also about culture, traditions, and a whole lot of fascinating details that are unknown to most. So, let’s begin!

What is ZACMI doing in Thailand?

Two of our technicians travelled to Bangkok to install ZACMI’s new monoblock system within the company’s production line.

We’re talking about:

• A washer, which is used to clean PET bottles,
• A piston filler, designed to handle different viscosities,
• A capper.

The latter is not part of our supply (but, as you may know, ZACMI also works as a system integrator, selecting the best suppliers to optimise time, costs, and the functionality of the machines to be implemented in a production line, offering customers the advantage of having a single point of contact for the entire project).

Our two technicians are on-site not only for the installation but also for the initial startup and to carry out a test prior to actual production. This way, the company (which we will not name due to internal agreements) will be fully autonomous, as all the main issues, routine maintenance, potential production stoppages, and commissioning are addressed beforehand.

In short, thanks to ZACMI’s machinery, our clients will be able to continue producing fruit juice with pulp in complete peace of mind, benefiting from the best technology available on the market.

Fruit Juices: An Alcoholic (and Millenary) History

Fruit juice is a drink we’ve enjoyed since we were children, but how many of us know the origins of this type of beverage and the social importance it has had throughout human history?

The earliest traces of preparations similar to fruit juice date back to 8000 BC, when grapes were processed to produce wine. This process wasn’t quite the juice we know today, but rather a rudimentary transformation of the fruit into a fermented beverage. Grapes, easily available in regions like the Caucasus and the Levant, were harvested and pressed, and the resulting juice underwent natural spontaneous fermentation thanks to the yeasts present on the skin. This phenomenon led to the production of wine, which became one of the first transformed beverages in human history.

Archaeological findings, such as grape seeds and remnants of vessels containing wine residues (found in places like Jordan and Turkey), suggest that the first winemaking techniques were already being practiced at this time.

The Cultural and Social Importance of Fruit Juice

The processing of grapes to make wine wasn’t just a technical process; it also had cultural and symbolic significance. In many ancient civilisations, wine was considered sacred and was often used in religious rituals.

For example, the Egyptians and the Greeks associated it with deities of fertility and nature. In this context, grape juice can be seen as a precursor to other fruit-based beverages, as it demonstrates humanity’s ability to transform natural products into preserved foods with added value.

Technological Evolution

Over time, the processing techniques evolved. During the Roman era, grapes were used not only for wine but also for sweet preparations like jams or juices mixed with honey and spices. Pliny the Elder documents the importance of grapes in the Roman diet, both fresh and processed. However, the true distinction between fruit juice and wine only emerged much later, when methods to preserve juices without fermentation were developed.

Preservation Techniques: Fermentation (and Beyond)

Fermentation was another common technique used to preserve fruit juices. This natural process occurs through the action of yeasts and bacteria, which convert the sugars in the juice into alcohol and acids. For example, grape juice was fermented to produce wine, which could be preserved for long periods due to the alcohol produced.

Other juices, like apple or pear, could also be fermented to make alcoholic beverages.

However, the ancients employed various techniques to preserve fruit juices and prevent oxidation and spoilage, such as drying them in the sun and wind, preserving them with honey or sugar to make jams and preserves, and refrigerating them naturally in caves or with cold water. Less commonly, salt and vinegar were also used.

Let’s take a closer look at these techniques:

• Drying: One of the oldest methods, which involves removing moisture from fruits using the sun and wind to create long-lasting food stores. In ancient Egypt, solar dryers were used not just for food but also to make funeral masks.
• Preserving with honey and sugar: The ancient Greeks used honey as a natural preservative for fruit, thanks to its antibacterial properties. Sugar, being more expensive, was used for jams and preserves.
• Natural refrigeration: Food was stored in cooler underground caves or pits.
• Salt and vinegar: Although less common for fruit juices, in some cases, saline or acidic solutions were used to extend their shelf life, especially for fruits with low acidity.

Here’s another curious fact: in ancient Egypt, meat was preserved by soaking it in lemon juice or sprinkling it with salt, then storing it in jars along with flour and wine. The Greeks also used honey to preserve fruits like plums, apricots, figs, dates, and grapes, while vinegar was used for preserving fish.

And since we’ve mentioned lemon…

The First True Fruit Juice? Lemonade!

In the 16th century, in Italy, what we can consider the first true fruit juice was developed: lemonade. This beverage, made from water, lemon juice, and sugar, represented a significant innovation compared to previous preparations, which were often based on this citrus fruit but were more rudimentary and less widespread.

The origins of lemonade can actually be traced back to older traditions. As early as the 13th and 14th centuries, in Egypt, there were drinks made from lemons, dates, and honey, but these were alcoholic and did not correspond exactly to modern lemonade. With the introduction of sugar into Europe, the recipe for lemonade became established as a refreshing and thirst-quenching drink, accessible to a wider audience.

In Italy, lemonade became particularly popular due to the availability of fresh lemons, especially those from the Amalfi Coast and Sicily. These regions were renowned for the quality of their citrus fruits, which contributed to a unique and distinctive flavour. The preparation of lemonade quickly spread among the nobility and wealthy families, becoming a symbol of sophistication.

In the 17th century, lemonade began to gain attention outside Italy. In Paris, in 1676, a company called Compagnie de Limonadiers began selling fresh lemonade to passers-by. This marked the beginning of the commercialisation of the beverage in Europe. The popularity of lemonade grew further with the introduction of carbonation methods in the 18th century, which led to the creation of carbonated versions.

The true industrialisation of fruit juice production in Italy began in the early 20th century with Adolfo Bonvicini, who founded Massalombarda S.A. in 1926. This company became a pioneer in fruit processing and the launch of the “Yoga” brand, which became synonymous with fruit juice in Italy.

A Fruit Juice… Mandated by Law!

In the 18th century, it was discovered that citrus juices (lemons, oranges, grapefruits) could prevent scurvy, a disease caused by a deficiency in vitamin C (ascorbic acid), which is essential for collagen synthesis and various bodily functions. This condition was common among sailors and travellers who, during long periods at sea, did not have access to fresh fruit and vegetables, leading to a diet lacking this crucial vitamin.

In the 18th century, the British doctor James Lind conducted experiments on sailors suffering from scurvy, showing that those who consumed lemon or lime juice showed significant improvement compared to those who did not. This led to the mandatory introduction of citrus in naval rations, drastically reducing scurvy cases among sailors.

We…Break it down

We have discussed the early production of fermented grape juice and the importance of citrus juices, but what exactly are fruit juices with pieces and how are they made and preserved?

Fruit juices with pieces, also known as pulp juices, are a variation of traditional fruit juices. These products not only contain the liquid extracted from the fruit but also pieces of fruit or pulp, offering a richer taste experience and a thicker consistency.

The production of beverages made from fruit juice with particulates (such as orange cells and fruit pieces) is of Japanese origin and was imported to the West in the 1990s.

These beverages are becoming increasingly popular, especially in North Africa and the Middle East, due to the growing consumer demand for natural and healthy products.

Fruit juices with pieces must contain a significant percentage of fruit, which may vary depending on local regulations. Typically, they can include up to 10% fruit pieces.

These juices can be made from a variety of fruits, such as oranges, peaches, and apples. The presence of fruit pieces gives the product a more natural and appealing look. Unlike fully filtered juices, juices with pieces tend to retain a greater amount of fibre and nutrients, making them a healthier option.

The production of fruit juices with pieces involves several steps:

• Fruit Selection: Fresh, ripe fruit is used, which may be refrigerated or frozen.
• Pressing: The fruit is pressed to extract the juice. During this process, the liquid is separated from the pulp.
• Pulp Incorporation: After pressing, the pulp or fruit pieces are added back into the juice to create the final product.
• Pasteurisation: The juice is pasteurised to ensure food safety and prolong its shelf-life.

Fruit juices with pieces differ from other categories like:

• Pure Fruit Juice: Made exclusively from the liquid extracted from the fruit without any pulp added.
• Nectars: Contain a mixture of juice and water, with added sugars up to 20%.
• Juices from Concentrate: Made by rehydrating concentrated juice, which has had most of the water removed.

But what are the advantages of fruit juices with pieces?

• Greater Satiety: The presence of fruit pieces can contribute to a greater feeling of fullness compared to filtered juices.
• Taste and Aroma: Juices with pieces often offer a more intense taste and richer aroma due to the pulp.
• Nutritional Benefits: They retain a greater amount of vitamins and minerals compared to fully filtered juices.

In short, fruit juices with pieces represent a tasty and nutritious alternative to traditional filtered juices. Thanks to their rich composition and available variety, they are gaining popularity among consumers looking for more natural and healthy products.

Liquid and Whole Pieces: How to Manage Different Viscosities?

Filling containers with fruit juices containing pieces presents various techniques and challenges that must be addressed to ensure an efficient and safe production process. Below are the main techniques used and the associated issues.

Filling Techniques

• Level Filling with Vacuum and Recirculation: This technique uses a system with a slight vacuum to manage the variable viscosity of juices with pieces. Product recirculation helps maintain a constant temperature during filling, reducing foam formation and ensuring even distribution of the pulp.
• Volumetric Fillers: Modern volumetric fillers, based on magnetic flow meters, allow precise control of the juice volume filled into each container. These machines can be programmed to handle different formats and product types, including those with pulp.
• Hot Filling: For juices that require pasteurisation, hot filling is a common practice. This method involves heating the juice to high temperatures before filling, contributing to greater food safety and extending the product’s shelf life.
• Gentle Filling Systems: To minimise damage to fruit pieces, systems designed for gentle filling are used, such as those that create a vacuum inside the containers during the process.

Challenges in the Filling Process

• Viscosity Management: Fruit juices with pieces can have variable viscosities due to the presence of pulp and fibres. It is essential that filling machines are able to adapt to these variations to avoid clogs or malfunctions. ZACMI has focused much of its efforts on this aspect, creating machinery that is not only robust and long-lasting but also able to minimise production stops while maximising OEE (Overall Equipment Efficiency).
• Foam Formation: Foam can be a significant issue during filling, especially with thicker juices or those containing pulp. Foam formation can reduce filling efficiency and compromise the final product quality.
• Microbiological Contamination: Juices are susceptible to microbiological spoilage, so it is crucial to implement strict hygiene protocols during the filling process to ensure food safety. This includes sterilising containers and equipment used.
• Temperature Control: Maintaining the correct temperature during filling is critical, especially for hot filling. Incorrect temperatures can negatively affect the juice quality and increase the risk of spoilage.
• Raw Material Variability: The quality and characteristics of the fruit used can vary significantly, affecting the consistency and taste of the final juice. It is important to closely monitor raw materials to ensure a uniform product.

Filling containers with fruit juices containing pieces requires the use of advanced techniques to address challenges related to viscosity, foam formation, and food safety. Investing in modern equipment and adhering to rigorous hygiene practices are key elements to ensuring an efficient production process and the quality of the final product.

PET: an ideal container for juices (and more)

Up until now, we’ve shared a lot about fruit juices, but we haven’t touched on their containers. So, to wrap up this article, let’s provide some information on bottles and the choice of materials used to create them.
PET (polyethylene terephthalate) containers are widely used for packaging beverages, foods, and other products thanks to their numerous highly beneficial characteristics. Here’s an in-depth look at what they are and the benefits they bring.

What are PET Containers?

PET is a thermoplastic resin belonging to the polyester family, derived from crude oil. It is identified by the recycling symbol number 1 and is mainly used for the production of beverage bottles, food containers, packaging, and textile fibers. Its chemical structure gives PET unique properties that make it ideal for many applications. 

Characteristics of PET

• Lightweight: PET containers are significantly lighter than those made from glass or metal, making them easier to transport and reducing logistics costs.
• Durability: PET is resistant to impacts and weather conditions, making it suitable for use in different environments without compromising the quality of the contents.
• Barrier to External Agents: This material offers good protection against moisture, gases, and light, helping maintain the freshness and quality of packaged products.
• Chemically Inert: PET does not react with food or beverages, preventing contamination and ensuring food safety.
• Transparency: Its transparency allows the contents inside to be visible, making it particularly attractive to consumers. 

Benefits of PET Containers

• Recyclability: PET is fully recyclable and can be transformed into new products without losing its core properties. This helps reduce the environmental impact and promotes a circular economy.
• Sustainability: Using PET helps reduce the consumption of natural resources compared to other materials like glass or aluminum. The production of PET bottles requires less energy than making glass bottles.
• Versatility: PET containers can be used for a wide range of products, from food liquids to chemicals, thanks to their chemical and physical resistance.
• Competitive Costs: Producing PET containers is generally less expensive than other materials, making packaged products more accessible to consumers.
• Ease of Storage: Due to their light weight and durability, PET containers can be easily stacked, optimizing storage space during transport and distribution.

PET containers, in short, represent an effective and sustainable solution for packaging various products. Their distinctive characteristics, along with numerous environmental and economic benefits, make them a preferred choice in the packaging industry.

As environmental awareness grows, PET recycling continues to play a crucial role in reducing plastic waste and adopting more sustainable practices.

Personalized support, wherever you are

The fruit juice industry, as you’ve likely realized by now, has undergone millennia of evolution, from simple natural fermentation to sophisticated production processes. Today, thanks to cutting-edge technologies such as those provided by ZACMI, companies can guarantee high-quality, safe, and authentic-tasting products.

Our mission is to offer tailored solutions for every production need, combining reliability, efficiency, and innovation. We achieve this (also) by coming directly to your company whenever you need us. That’s why we’ve chosen the motto for this column: Tech Wizards On Your Turf.

As we continue our journey around the world with the ZACMI Worldwide Tour, we are ready to support our customers wherever excellent technology and top-notch after-sales service are needed to meet your highest expectations.

See you in a few weeks!