Date: 6/2/2015

Second Semester

2015/2016

Al-Azhar University-Gaza

Faculty of Engineering & Information Technology

ASSIGNMENT

ORANGE JUICE MANUFACTURING

Prepared by:

Ahmed Ali AbuNasser 20113684

Submitted To:

DOC. Ahmed Issa

CONTENTS

ORANGE JUICE MANUFACTURING ..................................................... 1

BLOCKDIAGRAM .................................................................................................................... 1

THE MANUFACTURING PROCESS .................................................................................. 2

Harvesting/collection.................................................................................................................... 2

Cleaning/Grading ......................................................................................................................... 2

Extraction ..................................................................................................................................... 2

Filling/Packging ........................................................................................................................... 3

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BLOCKDIAGRAM

Figure 1: Block diagram of the juice factory.

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THE MANUFACTURING PROCESS

HARVESTING/COLLECTION

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

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

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

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in the tube wall. At the same time, a water spray washes away the oil from the

peel. This oil is reclaimed for later use.

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; 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.

FILLING/PACKGING

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

cannot 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.

LAYOUT OF FILLING/PACKGING

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A) Containers are loaded into a bulk hopper supply bin and fed via elevator to a

bottle orientator.

B) The bottle orientator sorts, and delivers orientated containers to the packaging

line.

Figure 2: A bulk hopper supply bin.

Figure 3: The bottle orientator.

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C) The Rotary Filler fills each container with a free flowing liquid product.

1. The conveyor system feeds empty bottles into the filler.

2. A star wheel system or timing screw (both not pictured in diagram) and container guide

position a bottle onto the rotating turret under each nozzle.

3. Product is pumped from the bulk supply tank to the manifold. Overall fill speed is

determined by how fast the product is pumped.

4. As the turret rotates the nozzle ports align with the stationary manifold ports creating

open flow paths.

5. Containers are filled as they rotate around the turret.

6. Full containers are returned to the conveyor line via a second star wheel system (not

pictured).

Figure 4: The rotary filler mechanism.

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D) Filled bottles continue on to the Rotary Capper. Here caps are placed and torqued

to each of the containers as they pass through the machine.

1. Filled containers enter the capper via timing screw and in-feed star wheel.

2. Caps are delivered simultaneously down the cap cute from the cap sorting system.

3. The Pick and Place tooling moves caps into position for the capping heads to grab.

4. The chuck capping head with cap rotates around to meet with a container

5. The cap has been placed onto the container. As container and closure continue to rotate

around the turret the chuck capping head will torque the cap in place.

6. Capped containers exit the system through the discharge bypass tooling and onward to a

labeler or other packaging system.

Figure 5: The rotary capper mechanism.

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E) A label sleeving system places a full body sleeve film label around each bottle.

F) The heat tunnel shrinks the newly placed full body sleeve label tightly to each

container.

Figure 6: The labeling sleeve machine.

Figure 7: The heat tunnel.

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G) The filled, capped, and labeled containers are filed into a Tray Forming and

Packing system. Here cardboard trays are formed, filled with containers,

wrapped in plastic film, and finally travel through a second heat tunnel system

in order to form a tight bundle pack.

H) Finished bundles are removed and palletized for final shipping.

Figure 8: Tray Forming and Packing system.

Figure 9: palletized bundles ready for final shipping.