Fruit pulp (juice) beverage process operation documents

Purpose

To guide the production operation of ice flower fruit pulp (juice) beverage products, so as to make the production in an orderly manner, avoid the occurrence of errors, and ensure the quality of the products.

Scope

This document is applicable to the whole production process of Ice Flower’s fruit pulp (juice) drinks in glass bottles and plastic bottles.

Attention:

1 each raw and auxiliary materials should be quality control officer for quality assessment before feeding.

2, the raw material slurry by the operator and quality control personnel jointly acceptance assessment of qualified before entering the next process.

Blending

Fruit pulp and stabilizer as the first material added to the blending tank for the first time to set the volume, the quality control of the first set of material for testing, give the amount of sugar and acid injection to add sugar and acid, and then according to the arabic numerals on the auxiliary material containers identified in the order of sequence to join the other materials in turn.

The main additives used for blending are numbered in accordance with the principle of confidentiality, and the specific numbering sequence is shown in the appendix.

3.1 Quality acceptance of raw and auxiliary materials before putting into use

3.1.1 The raw and auxiliary materials are mainly used by the blending and weighing personnel for sensory evaluation before feeding, to prevent unqualified raw and auxiliary materials into the production process.

3.1.2 If the raw materials are judged to be qualified, they will be weighed and fed directly; if they are unqualified or suspected to be unqualified, they will notify the quality control officer to do the final processing. Those that can not be fed and used will be labeled as unqualified or suspected unqualified, isolated and returned to the warehouse by the day shift staff.

3.1.3 Quality judgment method of raw and auxiliary materials

A, the main use of look, smell, touch, product, if necessary, physical and chemical testing.

a, look: color, tissue state, impurities, packaging identification (based on GB7718).

Packaging identification of the main inspection items: company name, address, date of production, shelf life, production license, model, product name, packaging seal integrity, certificate of conformity.

b, smell: (liquid raw materials) smell, first smell the smell of large packages is normal, whether there is acidic corruption, oxidation and other odors, if necessary, works taste.

c, touch: powdered solids take a little in the palm of your hand grinding, feel the granularity, sand feeling.

d, taste: fruit pulp and sugar can be used to dilute the recovery method, by more than three people on its tasting to judge the quality of good and bad.

B, a variety of raw and auxiliary materials to judge the standard see raw and auxiliary materials acceptance criteria

C. Packaging marking and acceptance of raw and auxiliary materials

a, unopened packaging to see: product name, company name, company address, production date, shelf life, production license number (has been incorporated into the production license management), model, certificate of conformity, packaging integrity, no leakage and other phenomena.

b, open the main contents of the color, the presence of odor, impurities, lumps, whether deterioration and other items.

3.1.4 Production of raw and auxiliary materials, work equipment placement and use.

a, production of raw and auxiliary materials are placed on the tray, is strictly prohibited direct contact with the ground.

b, the raw and auxiliary materials have been opened in the workshop to be placed for use is strictly prohibited open mouth, temporarily unused must be tied or cover.

c, raw and auxiliary materials in use regardless of whether the opening or not, the implementation of the principle of the first to use.

d、Weighing and adding and dissolving all kinds of raw materials in strict accordance with the operating procedures.

e, all contain raw and auxiliary materials of the utensils and containers, dissolving tanks, etc. in the production and non-production season are covered, and is strictly prohibited to open placed.

f, all storage of raw and auxiliary materials in contact with the utensils must be kept clean, every day to ensure that the cleaning, disinfection 1 time, and make records.

3.1.5 Equipment requirements and health maintenance

a, blending tank utensils available food-grade stainless steel or plastic drums, once a day by the process operator to clean and disinfect.

b, blending tanks, auxiliary tanks and other production equipment, piping and ancillary facilities made of food-grade stainless steel or plastic, is strictly prohibited the use of easy embroidery or easy to fall off the material or non-food materials, appliances must be heat-resistant, acid, alkali corrosion resistance, a variety of gaskets with heat-resistant, acid-resistant, alkaline-resistant food-grade gaskets.

c. The equipment should be cleaned and sterilized in strict accordance with CIP requirements, and COP cleaning should be done for the ones that can’t be made for CIP. 3 steps of cleaning should be done before each start of blending, and 5 steps of cleaning should be done at the end of production.

3.2 Fructose syrup is directly pumped into the blending tank.

3.3 Stabilizer dissolution:

3.3.1 Use 75℃-85℃ hot water, dissolve 10-15min.

3.3.2 Operation procedure: firstly, pump 15-20 times of the total weight of stabilizer pure water (75℃-85℃) into the emulsifying tank, turn on the stirring, then slowly add the formulated quantity of stabilizer, keep warm and stir for 10-15min, and then pump it into the blending tank after it meets the requirement visually inspected by the quality control officer. Then flush the pipeline with 100-200kg of pure water and pump it into the blending tank.

3.3.3 Dissolve completely standard: take about 100-200ml samples with a glass cup, observe under natural light, no obvious colloidal particles, evenly dispersed, experiment with a centrifuge 3000-4000r/h, 10min. evaluation standard: no precipitation.

3.4 Dissolution of citric acid, potassium sorbate, sweetener and other excipients:

Citric acid, potassium sorbate, sweetener and other auxiliary materials are all added into the emulsifying tank, stirred with stabilizer and then pumped into the blending tank.

3.5 Dissolving of flavor

Flavors are not mixed, each added through the observation port of the blending tank.

3.6 Fixed capacity:

When all kinds of materials are added completely into the blending tank, the volume is fixed with pure water to the amount of blending. Determination of indicators, including soluble solids, pH, centrifugal precipitation, viscosity, sensory. The whole process of volume setting is completed within 30min, and each test by the quality controller is completed within 10nin.

Note: Each blending volume of up to 3 tons, other materials to join, stirring 5-10min after the determination of indicators, fine-tuning, fixed capacity, fixed capacity error shall not exceed 50kg per batch.

Sterilization, disinfection and filling

4.1 Homogenization and sterilization

4.1.1 Requirements of process parameters:

Pressure:18-20Mpa

Temperature:65-75℃

4.1.2 Operation process: open the blending tank discharge pump when it is to be homogenized, and send the material to the homogenizer.

Turn on the homogenizer, start homogenizing, start the circulation valve of homogenizer (before starting the homogenizer) and start pressurizing, add the first pressure and the second pressure according to the operating procedure of homogenizer, open the feeding valve when it reaches the required pressure, and close the circulation valve after 5-10s.

Note: open the cooling water valve before opening the homogenizer.

4.1.3 Sterilization temperature 105 ℃, time: 10-15s

4.2 Cleaning and disinfection, filling:

4.2.1 Washing and sterilizing:

Open the bottle washing machine water valve, transmission part, start on the bottle rinse

Second bottle washing: rinse with pure water, pay attention to the cleaning effect.

4.2.1.1 Bottle rinsing requirements

a. Bottle set up personnel in accordance with the provisions of the correct bottle on the obvious easy to see such as: cracks, deformation, perforation, dyeing of different colors, bottles and bottles in the presence of foreign bodies and other quality defects should be picked out.

b. The sterilized water used for cleaning bottles and bottle tops should be maintained at a sufficient and stable pressure so that the bottles and bottle tops can be rinsed clean.

c. The rinsing water shall be kept clean and free of foreign matter, color and odor.

d. Bottles that fall to the ground shall not be used directly and shall be rewashed before being put into use.

4.2.1.2 Bottle caps

a. Bottle caps for production shall be kept clean before production.

b, filling personnel in the bottle cap hopper to add the cap, it is strictly prohibited to hand direct contact with the bottle cap.

c. Bottle caps that fall to the ground or out of the hopper shall be rinsed with water and then re-sterilized for re-use.

4.2.1.3 Filling machine cleaning

a. Filling machine and its related pipeline should be cleaned before and after filling according to the specified CIP requirements, and record.

b, before each production should be cleaned according to the three-step cleaning method, the end of production should be cleaned according to the five-step cleaning method.

c, the end of pre-production CIP cleaning should be applied to empty bottles on the machine to run 3 laps, to ensure that each filling head run 3 times, remove the filling water to view the clear effect, you should view the following items:

-Bottle in the pipeline rinse water outlet and inlet PH value is consistent;

-The rinse water in the bottle is free of foreign matter, odor, color, clear and transparent.

Failure to meet the above requirements shall be re-cleaning.

d, when the cleaning requirements are met, the filling machine is ready to feed filling.

4.2.2 Filling:

4.2.2.1 Filling room purification requirements

a, filling room should reach 100,000 purification requirements, to ensure that the internal formation of positive pressure during normal production.

b. Filling room should be free of stagnant water, ambient temperature less than 30 ℃, walls and floors, equipment and facilities to maintain clean and sanitary.

c, the filling room is strictly prohibited to store items unrelated to production, fixed-point storage of work equipment, and labeling.

d. Filling personnel should often wash their hands and disinfect after work or during production.

e. Before each filling, 0.5% chlorine dioxide should be used to spray disinfection of the environment and equipment and facilities in the filling room.

f, personal hygiene All personnel entering the filling room shall wear work clothes and hats, filling personnel have the right to stop not wearing work clothes and hats to enter the filling room and filling unrelated personnel are prohibited from entering the filling room.

4.2.2.2 Filling temperature: glass bottles: 80-85 ℃, plastic bottles: 70-80 ℃.

4.2.2.3 sealing: filling machine operators must pay attention to the filling temperature at any time, filling volume, sealing effect, not up to the requirements of the filling machine should be adjusted at any time, the quality control officer at any time to spot check.

4.3 Pouring bottle sterilization, cooling

After coming out from the filling machine, directly enter into the pouring bottle sterilization process, pouring bottle sterilization 30-50s.

Temperature: glass bottle: 80-85℃, plastic bottle: 70-80℃.

Heating and cooling tunnel: turn on the water and steam, before starting the machine, the spray water reaches 60-70 ℃ before being allowed to feed the product, observe the temperature at any time, the cooling area of the exported products, the temperature of the center of the exported products is below 40 ℃.

4.4 Spray code:

4.4.1 dry bottle facilities before spray code work properly to ensure that the spray code is clear.

4.4.2 According to the specified requirements to adjust the production date, shift, batch number, location of the production process is not a certain situation shall not be arbitrarily adjusted.

4.4.3 The size of the spray code is set according to at least 10 words, and it is required to spray the font neatly and clearly without skewing or blurring, and there shall be no leakage of spraying, and once it is found to be not in line with the requirements, it shall be picked out in time and find out the reasons for the timely adjustments.

4.4.4 Do the daily maintenance of the printer to maintain health.

4.4.5 Spray code style:

Such as: 2011010111A

Year Month Day Batch Pot Shift Code

15:30

Time

4.5 Light Inspection, Sleeving and Labeling

The light check requires employees to change personnel every 1 hour.

Whenever any of the following exists during the light check selection process, it is judged to be unqualified and should be picked out and stored in separate isolation.

a: Bottle mouth not sealed tightly;

b: leakage;

c: bottle deformation;

d: the existence of cracks on the bottle;

e: Insufficient filling quantity (liquid level is obviously lower than the standard requirement);

f: bottles with crooked caps;

g: the presence of bottles with a strange odor;

h: the presence of foreign color in the bottle;

i: the presence of foreign substances in the bottle is found;

a-f Do backfill on shift.

g-i: the bottle is scrapped on the same shift.

4.5.1 Operate according to the requirements of labeling machine and labeling machine, and glass bottles are labeled manually.

The picker before labeling shall pick out the finished products with one of the defects and place them in the swing frame at the fixed point.

Defects:

a: bottle deformation

b: the bottle cap is tightened, moving or bottle cap skewed

c: Leakage

d: There is sediment in the bottle

e: There are black spots in the bottle (no matter how many)

f: the presence of foreign objects in the bottle, foreign colors

g: the presence of foreign substances in the bottle, foreign color, odor

h: Other should be picked out

i: Insufficient filling quantity

Be sure to strictly control the quality when receiving labels

Set of labels when acceptance of the quality of the label, does not meet the standard shall not be put into use quality standards:

a: color pattern text and standard samples consistent with the previous qualified samples can be taken to compare.

b: size, specifications, product variety and production varieties corresponding to the packaging team

4.5.2 set of labels: must be set to the end, to do quasi, fast, does not affect the speed of production, so that the label is correct, not crooked, not anti-labeling, not reverse labeling, not good labeling phenomenon.

4.5.3 Shrinking label: the operator needs to operate correctly, there shall be no high label, inverted label, wrong label, crooked label, slanting label, wrinkles and other unqualified phenomena, found that it should be instantly singled out, if due to the reasons for the set of labels to inform the labeling staff in a timely manner, due to the reasons for shrinking the labeling machine timely adjustments to the difficult to deal with inform the head of the band shift.

Packaging

5.1 Packaging according to the specifications of the packaging labeling requirements, packaging found in one of the following cases should be singled out for separate storage: a: the bottle cap is not tightly closed, the bottle cap is not tightly closed.

a: Bottle cap is not tight

b: Bottle cap is skewed or the color of the cap is not right.

c: leakage

d: bottle deformation

e: bottles with foreign objects, different colors, product identification and content inconsistency

f: There are foreign substances, odors and colors on the bottle

g: labeling skewed, inverted and high labeling to not meet the labeling requirements

h: spray code date does not meet the requirements

i: Suspected of quality problems

5.2 The certificate of conformity with production date shall be pasted on the bottom of the carton in the process of sealing the bottom of the carton.

5.3 In the process of capping the box, attention shall be paid to the variety, specification and quantity of the contents whether it is in accordance with the volume requirements of the carton, and the certificate of conformity with the date of production of the product shall be affixed at the end of the carton in the center of the carton with the anti-counterfeiting mark before capping the carton.

5.4 In principle, the maximum number of layers per pallet is 7.

Each pallet should be labeled, the content of the label should be at least, but not limited to the following content:

a: Product name

b: Specification

c: Quantity

d: Batch production date (including hours and minutes)

e: Sorter

f:Quality controller

g:Warehouse

h:Warehouse time

Inspection: factory inspection

6.1 Sample extraction

6.1.1 Inspection samples are taken by the quality controller of each shift and placed separately, and the samples taken should be printed with date.

6.1.2 Sampling method: 6 cans of the first pot of each batch (2 cans each from the top, middle and bottom), and a total of 3 cans of the remaining pots in different locations, the QC shall ensure that the authenticity of the samples and the number of samples meet the requirements. If there is a failure, each time the failure to draw 2 cans of specific by the quality control officer to do the test (according to the test provisions of the operation). Quality controller in the production process according to the equipment and the actual situation in the production process can also be sampled at any time to send the laboratory for testing.

6.2 Sample testing arrangements

The lab technician collects samples every day, of which 2 bottles are taken from each batch for microbiology, one bottle for net content and physical and chemical items, and the remaining bottle for observation samples.

6.3 Testing items:

a. Sensory: color, lustre, smell, tissue state, foreign matter.

b. Physical and chemical items: net content soluble solids acidity (percentage)

c. Microorganisms: total bacteria, coliform bacteria, molds/yeasts.

6.4 Testing and judgment basis: enterprise standard

Normal finished products in the 2nd day after production to make a finished product factory inspection report, 4 copies of the report, the quality control section of a self-storage, sales, warehousing, production section, each one.

Qualified products can only be shipped out of the warehouse, unqualified or inspection report is not out of the warehouse is strictly prohibited to release.

Storage

7.1 The products are stored according to the pallet, according to the pieces of points into the warehouse. The treasurer must pay attention to the integrity of the signage and content of each pallet and each pallet of products must be signed by the quality control officer to confirm the permission to enter the warehouse, not up to the requirements shall not enter the warehouse.

7.2 Storage of products to be inspected separately, the existence of quality defects in the finished product stored in separate isolation, to be tested after the report, qualified in the original signage for the qualified logo, unqualified for the unqualified logo.