TECHNOLOGY

Vacuum boiling in food production leverages the principle that the boiling point of water decreases as pressure decreases. We use it for all our production.

• Cooking Under Vacuum
  Offer a option to easier preserve delicate flavors and nutrients that might degrade at higher temperatures.
• Evaporation
  Vacuum evaporation is a must for usage in the production of concentrated products like fruit juices and syrups. By reducing pressure, water boils off at a lower temperature, thus preserving more of the food’s natural flavor and nutrients.
• Drying and Dehydration
  We also use vacuum drying where needed. Lower boiling points mean less exposure to high heat, which helps retain color, flavor, and nutritional value.
• Cooling
  With this method we rapidly cools products when needed by utilizing the boiling of water at reduced pressure to remove heat. This not only speeds up the cooling process but also helps in achieving uniform cooling which is crucial for food safety and quality.

Benefits

• Preservation of Nutrients and Flavor
  Since the process occurs at lower temperatures, there’s less degradation of heat-sensitive vitamins and flavors.
• Reduced Energy Costs
  Lower boiling temperatures mean less energy is needed to heat the food products, making the process more energy-efficient.
• Improved Safety
  By rapidly cooling products or cooking at lower temperatures, bacterial growth is minimized, enhancing food safety.
• Enhanced Product Quality
  Products processed under vacuum have better texture, color and nutritional integrity compared to traditional methods.

Vacuum boiling gives us an option to produce the product at maximum temperature at 60°C. It benefits us in Gentle Processing for many heat-sensitive foods can be processed without significant loss of flavor, color  or nutrients. This is particularly useful for Fruit Juices concentrations without degrading vitamins or antioxidants.

Distilling and reintroducing aroma and flavors back into fruit juices during the boiling or concentration process is a sophisticated method used to enhance the sensory profile of the final product.

Boiling at lower temperatures under vacuum helps preserve the delicate compounds in fruit juices. However, this also means that volatile aromatic compounds can be lost as vapor.

For that we use Distillation and Aroma Capture from the vapor of the boiling juice, rich in aromatic compounds, which we led it through a condenser where it’s cooled and condensed back into a liquid. This liquid, known as the distillate or essence, contains concentrated flavors and aromas.

In some setups, we control to selectively capture different compounds based on their boiling points, allowing for even more precise flavor management.

After the product has been concentrated to the desired level, the captured essence is reintroduced into the juice. This step can be done at various stages, but often, it’s added back just before or after the final product packaging to maximize flavor impact.

• Flavor Concentration
  The process not only concentrates sugars and nutrients but also intensifies the natural flavors of the fruit, which might otherwise be diminished during traditional heating.
• Aroma Preservation
  By capturing and reintroducing the volatiles, we maintain or even enhance the aromatic profile of the juice, which is crucial for consumer appeal.
• Quality Control
  This method allows for precise control over the flavor profile, enabling us to adjust or standardize the taste across batches or products.
• Reduced Thermal Degradation
  Since volatile compounds are removed before they can degrade at higher temperatures, the essence can be added back in a way that avoids further heat exposure.
• Consumer Experience
  The result is a juice with a rich, true-to-fruit flavor profile, which stand out all our products from competitors.

Adding inverted sugar to fruit products significantly enhance their quality, flavor, and shelf life due to several unique properties of invert sugar. That is why we add only that sugar to all our products which has sugar in it.

• Enhanced Flavor
  Invert sugar is sweeter than regular sucrose because it consists of glucose and fructose. This enhance the natural sweetness of fruit without overpowering its flavor. The fructose component particularly complements the natural fruit flavors preserves taste richer.
• Moisture Retention
  Invert sugar acts as a humectant, meaning it helps retain moisture in food products. This property is crucial for extending the shelf life of fruit products, keeping them moist and preventing them from drying out.
• Prevention of Crystallization
  In fruit products where sugar might otherwise crystallize, such as in jams or marmalades, invert sugar helps prevent this by lowering the amount of sucrose that can form crystals. This gives a smoother texture and a more homogeneous product experience.
• Preservation
  By reducing water activity in the product, invert sugar also contribute to preservation extending the shelf life of fruit products by inhibiting microbial growth.
• Color Enhancement
  Invert sugar promotes the Maillard reaction which can lead to a richer color in products enhancing both appearance and flavor.
• No separation
  Invert sugar gives us the benefit that all our products mixed in beverages will not separate in a served glass even 2 hours in front of customer.

Some Application

• Jams and Jellies
  Invert sugar is naturally present in jams due to the combination of sugar with the fruit’s acid and heat during cooking. Adding more further improve texture and shelf-life.
• Fruit Syrups and Purees
  For making syrups or purees, invert sugar achieve a stable, sweet product that won’t crystallize and separate over time. If these products are used in cocktails it balance acidity and enhance the fruit’s natural flavors without diluting the drink.

We use innovative applications with reverse osmosis (RO) in the production of jams and slushi by focusing on maintaining the integrity of the fruit’s cellular structure while exchanging sugars for a new sensory experience in jams and jellies. It is a novel application where we leveraging the principles of osmosis for a molecular-level infusion rather than traditional maceration or cooking methods that might break down the fruit’s structure.

• Principle
  Osmosis in food involves the movement of water across the semi-permeable cell walls of fruit due to differences in solute concentration. We immerse fruit in a hypertonic sugar solution, which leads to water exiting the fruit cells and sugar entering, enhancing flavor and preservation.
• Preserving Cell Integrity
  By using a controlled osmotic process, we aim to allow sugar to permeate the fruit’s cellular structure without rupturing the cells. This requires careful management of osmotic pressure, concentration gradients and exposure time to ensure that the fruit pieces maintain their shape and texture.
• Specific Application in Jams
  By carefully balancing the sugar concentration outside the fruit with the natural sugars inside we promote sugar diffusion into the cells without causing them to burst. This technique would result in cherries that are whole yet infused with sugar, offering a unique texture and flavor profile.
• Balance
  Experiment to make a perfect balance between Concentration of Osmotic Solution – Temperature – Time
• Pretreatment
  Vacuum impregnation which we uses also enhance sugar uptake without cell disruption by reducing the pressure which helps in drawing sugar into the fruit more gently.

Type of heat exchange we uses to rapidly transfer heat between two fluids. Customized by our self to serve us also for homogenization.

One fluid flows through alternate channels between the plates, while the other fluid flows in the opposite direction in the adjacent channels. This counter-flow arrangement enhances the heating and cooling efficiency by maintaining a high temperature gradient between the fluids.

• Thermal Shock
  The sauce is heated to 92°C for 15 seconds, then rapidly cooled to 40°C. The PHE facilitates this quick change in temperature, ensuring that the process is uniform across the product to kill off harmful microbes while preserving quality.
• Homogenization
  As the sauce passes through the exchanger, the rapid temperature change can cause cellular disruption in ingredients like tomatoes, leading to the release of pigments and compounds like lycopene, which not only changes the color and flavor but also increases nutritional value.
• Efficiency and Precision
  The design allows for precise control over the heating and cooling process, critical for calculating the F0 factor commonly uses for NASA food control which measures the lethality of the heat treatment to bacteria without overly degrading the sauce’s quality.

All those technologies we combine to achieve a high level of concentration of real fruits while preserving their natural flavors, aromas and nutrients and in the same time get long shelf life, beautiful experience and no separation or color fading.

Hot-filling in combination with In-Mold Labeling (IML) using oxygen barrier labels and a modified atmosphere of CO2 and nitrogen is a sophisticated approach aimed at extending shelf life, preserving product quality and even enhancing consumer appeal. It also helps maintain color, flavor and nutritional content of the food.

Hot-Filling

• Process: Hot-filling involves filling containers with product that has been heated to a high temperature to kill microorganisms, thereby ensuring product sterility. Once filled, the containers are sealed while the product is still hot, creating a vacuum as the product cools which further helps in preservation.
• Advantages: Extends shelf life without the need for preservatives, reduces microbial growth and maintains product quality at room temperature.

In-Mold Labeling (IML)

• Method: IML involves placing a pre-printed label into the mold before the plastic is injected. The label becomes fused with the container during the molding process.
• Benefits:
  • Aesthetics: Offers high-quality, durable graphics that are part of the packaging.
  • Durability: Labels are resistant to moisture, chemicals and mechanical stress since they are integrated into the package material.
  • Recyclability: Both the label and the container can be made from the same material (often polypropylene) facilitating recycling.

Oxygen Barrier Labels

• Materials: Include an Ethylene Vinyl Alcohol (EVOH) layer which has excellent oxygen barrier properties. The barrier reduces oxygen transmission rates significantly protecting the product from oxidation over time.
• Application: In IML, the oxygen barrier is part of the label, providing a protective shield against oxygen ingress directly where it’s needed most – at the surface of the package.

Modified Atmosphere Packaging (MAP) with CO2 and Nitrogen

• Gases Used
  Nitrogen (N2): An inert gas that prevents oxidation by displacing oxygen in the package. It’s used to maintain product freshness, especially in foods susceptible to rancidity.
  Carbon Dioxide (CO2): Has antimicrobial properties, inhibiting the growth of aerobic bacteria, mold and yeast, which extends shelf life.
• Implementation
  After hot-filling, the package is typically flushed with a mix of CO2 and N2 to create a protective atmosphere. This mixture is tailored according to the product’s needs.

This method we particularly use for marmalade, sauces and jams in bigger packages.