Thermostable fruit fillings production equipment complex

Heat-stable fillings maintain their physical properties even when exposed to high temperatures; they do not spread, bubble, contract, or even burn. They preserve their color and volume, even during freezing and subsequent thawing.

The complex for the production of thermostable fruit fillings is suitable for processing products such as:

Advantages:

• The equipment complex can be customized based on the required level of processing and raw material input, including preparatory phases such as fruit handling, washing, grinding, and key technological processes like mixing, vacuum boiling, and swelling with cooling.
• We provide a diverse array of additional options and equipment for the production line, including fundamental technological elements like inline homogenizers and auxiliary components such as ice water stations, steam generators, and more.
• Various levels of automation for technological processes are available, catering to different recipes, from dosing by weight to automatic dosing through a flow meter system.

In the production of these fruit fillings, equipment such as digesters for syrup production, vacuum-evaporation installations for boiling the fruit/berry component, and a specialized mixer for dissolving and blending various additives are commonly used. To impart heat-resistant properties to the fruit filling, a range of additives is typically incorporated. Traditional techniques involve adding pectin and starch into the boiled fruit mass together with syrup.

The production process is usually divided into two parts, which are carried out in parallel:

- boiling the syrup/fruit and berry mass at a temperature of about 85-88 degrees

- mixing with water, dissolving dry components (additives): pectin, starch, etc.

After which the two masses are mixed into one to activate the swelling process while the mass is cooling.

To produce syrup, atmospheric syrup cookers equipped with a frame anchor mixer are employed to dissolve sugar, resulting in a 60° Brix solution.

For boiling fruits in a 60° Brix solution, vacuum evaporation units are utilized. The presence of a vacuum is essential to lower the boiling temperature of the mixture, ensuring it stays below 85–88 degrees Celsius. Temperatures exceeding 90 degrees can cause sugar to revert to a liquid form. Even with the addition of pectin, starch, or other fillings, this can compromise its thermostable properties, leading to spreading and leakage during baking.

Following the process of boiling the fruit mass, gradual additions of pectin solutions with starch, citric acid, and powdered sugar are mixed in. The mixture is allowed to swell and cool down to approximately 70 degrees before being pumped into a dosing or storage container. Further cooling down to around 45 degrees takes place over 50-60 minutes, aiding the formation of a gelatinous structure essential for preserving the vitamins and colors within the filling.

The fillings can either be smooth and homogeneous or alternatively, it can be interspersed with various fractions of fruits or berries. To achieve a uniform filling, an inline homogenizer can be utilized, typically installed in the circulation circuit of a vacuum evaporation unit (optional).

Basic Version

A 150-liter mixer designed for hard-to-wet and poorly soluble powders. It facilitates the preparation of a mixture containing pectin, starch, powdered sugar, and citric acid dissolved in water. The mixer is equipped with a specialized high-speed stirrer - propeller, ensuring effective mixing and dissolution of powders to achieve a uniform solution. This solution mixture is then added into the vacuum evaporation unit through a pump.

The vacuum evaporation unit, boasting a 600-liter capacity, is dedicated for boiling a fruit mixture with a 60° Brix solution. This process results in a mass with 48-53% dry substances. After cooling down to 70 degrees, the pectin-based solution is mixed in with the resulting fruit filling. The evaporator, designed as an inclined version of a 3-layer vacuum reactor with gravity stirring, features a frame stirring device with a reinforced electric drive and fluoroplastic scrapers suitable for thick and viscous products. The vacuum evaporation unit is additionally equipped with an external forced circulation circuit, including a remote heat exchanger and a vacuum system. For this complex modification, a coolant, specifically steam supplied from an external source, is provided. However, the steam connection, shut-off, and control valves for steam are not included in the delivery set and must be arranged by a certified company in accordance with local regulations.

The control of the complex is semi-automatic, with shut-off and control valves incorporating a mechanical function.

The basic version does not include a syrup cooker, as sugar can be directly dissolved in the vacuum evaporation unit.

Options:

• Syrup maker for efficient sugar dissolution and obtaining a saturated solution/syrup.
• Inline homogenizer for creating a homogeneous structure within the fruit fillings.
• Flow-through stainless steel filter positioned before entering the vacuum evaporation unit when adding the syrup from a syrup cooker or a pectin mixer.
• Jacket for the vacuum evaporation unit designed for a heat transfer medium.
• Container for the finished product with a jacket for the heat transfer medium (1000 l).
• Frequency converters for the mixing systems of the mixers and vacuum evaporators.
• System for collecting and discharging condensate to enhance evaporation (a complete cooking system) when using non-dehydrated fruits or berries.
• Adjustment for the vacuum depth.
• CIP heads for washing.

Technical requirements

To ensure the proper functioning of the system, the following conditions are necessary:

• A source of ice water with a temperature of 5-7 degrees for supply to the condenser of the vacuum evaporation unit (if this option is selected).
• A steam source at 0.7/3 bar as the supply for the jacket of the vacuum evaporation unit/heat exchanger.
• Connection to the water supply and sewerage system.