■ Mixer Additives

Complete Technical Guide

Citric Acid | Stabilisers | Flavour Fixatives | Emulsifiers | Mixer Operation

2026

Acidulants Texture Stabilisers Flavour Fixatives Emulsifiers

Table of Contents

Sec Topic

1 The Mixer — Equipment & Components

2 Why Additives Are Added — Core Principles

3 Citric Acid — Full Technical Detail

4 Texture Stabilisers (Pectin, CMC, Xanthan Gum)

5 Flavour Fixatives & Emulsifiers (Gum Arabic, Lecithin, Modified Starch)

6 Orange Oil & Flavour Addition

7 Complete Additives Reference Table

8 Mixer Step-by-Step Operation Protocol

9 Dissolving Methods for Each Additive

10 Common Errors & Troubleshooting

11 Final QC Parameters Before Filling

Section 1: The Mixer — Equipment & Components
The mixer (blend tank) is a stainless steel vessel equipped with internal mixing systems. Its purpose is to
ensure that all additives are perfectly and uniformly distributed throughout the juice before filling. It is one
of the last processing stages before the product reaches the consumer.

1.1 Main Components

Component Function & Details

Stainless Steel Tank

Main vessel. 316L grade resists citric acid corrosion. Available in sizes: 500L to 20,000L. F
(Food Grade 316L)

Agitator (Mixer Shaft) Internal rotating paddle or propeller. Creates turbulent flow that blends all ingredients. Var

Dosing Pumps Precision metering pumps for adding small quantities of additives accurately. Typically per

pH Meter (in-line or portable) Measures juice acidity in real time. Critical for controlling citric acid addition. Must be calib

Brix Meter / Refractometer Measures sugar concentration. Inline models give continuous reading. Portable models us

Thermometer / Temperature probeMonitors juice temperature throughout mixing. Important — temperature affects pH readin

CIP (Clean-In-Place) System Automated cleaning system. Circulates: water rinse → NaOH caustic (1-2%) → water rins

Inlet & Outlet Valves Hygienic butterfly valves. Inlet: juice entry. Outlet: to filling line. All valves: food-grade gask

1.2 Mixer Capacities & Sizing

Production Scale Typical Mixer Size Agitator Speed Range

Small (< 5,000 L/day) 500 – 2,000 L 30 – 120 RPM

Medium (5,000 – 20,000 L/day) 2,000 – 10,000 L 20 – 80 RPM

Large (> 20,000 L/day) 10,000 – 50,000 L 10 – 40 RPM

Section 2: Why Additives Are Added — Core Principles
Natural orange juice, after processing, faces several quality challenges during storage and distribution.
Additives are used to solve these problems — not to replace the juice, but to preserve its quality and
ensure consistency.

Problem Without Additives Effect on Product Solution

Pulp and solids settle to bottom Unacceptable appearance — sediment

Texture
layer stabilisers (Pectin, CMC, Xanthan)

Oil and water separate Oil layer on top — unappetising Emulsifiers (Gum Arabic, Lecithin)

Natural flavour lost during pasteurisation

Flat, cooked taste — not fresh Flavour addition + flavour fixatives

pH varies between batches Inconsistent taste — quality problemsCitric acid for pH standardisation

Bacterial growth over time Product spoilage — safety risk Citric acid (pH control) + pasteurisation

Vitamin C oxidation Colour browning + nutritional loss Citric acid (antioxidant effect)

Natural colour fades in storage Pale, unappealing colour Stabilisers + oxygen exclusion
Section 3: Citric Acid — Full Technical Detail

3.1 What Is Citric Acid?

Property Detail

Chemical name 2-hydroxypropane-1,2,3-tricarboxylic acid

Chemical formula C6H8O7

Food additive code E330

Physical form White crystalline powder or fine granules

Solubility Highly soluble in water — 1 kg dissolves in approx 1.5 L water at 20°C

Origin Natural: found in citrus fruits. Industrial: produced by fermentation of glucose using Asperg

Taste Sharp, clean sourness — same as natural citrus acidity

3.2 Functions of Citric Acid in Juice

pH Adjustment & Orange juice pH varies naturally between 3.2 and 4.5 depending on
Standardisation variety, season, and ripeness. This variation causes inconsistent
taste between production batches. Citric acid is added to bring
every batch to the same target pH (typically 3.5 – 3.8), ensuring the
product always tastes the same. This is critical for branded
products where consumers expect identical taste every time.

Preservation & Most bacteria, yeasts, and moulds cannot grow at pH below 4.0. By
Antimicrobial Effect keeping juice pH at 3.5 – 3.8, citric acid creates an environment
hostile to microbial growth. This extends shelf life and works
synergistically with pasteurisation — the lower the pH, the more
effective the heat treatment.

Antioxidant / Colour Citric acid chelates (binds) metal ions such as iron and copper that
Protection catalyse oxidation reactions. By neutralising these catalysts, it
slows the browning reaction and helps maintain the bright orange
colour throughout the product's shelf life.

Vitamin C Stabilisation Ascorbic acid (Vitamin C) is destroyed by oxidation. The acidic

environment created by citric acid slows this oxidation and helps
retain Vitamin C content — an important nutritional claim for the
product.

3.3 Addition Rate & Calculation

 Scenario Addition Rate Notes

Standard pH adjustment 0.1 – 0.3% of juice volume Most common — fine tuning only

Significant pH correction (very 0.3

sweet
– 0.5%
batch)
of juice volume Dissolve in 2 portions — check pH between additions

Concentrated juice (higher Brix)

Calculate on final volume afterConcentration
concentration increases acidity — may need less

Per 1,000 litre batch example 1.0 – 3.0 kg citric acid To drop pH by approx 0.1 – 0.3 units

■ CRITICAL: Never add citric acid dry directly to juice. Always dissolve in water first (minimum
1:3 ratio by weight). Undissolved crystals cause localised over-acidification.
■ Never add large quantities at once. Add in small increments, measure pH after each addition,
wait 3-5 minutes before measuring again.

3.4 Dissolution Method

Step Action Detail

1 Weigh citric acid Accurate to ±10 grams for large batches

2 Add to clean container Food-grade plastic or stainless steel — no aluminium

3 Add warm water (40-50°C)3 litres water per 1 kg citric acid minimum

4 Stir until fully dissolved 2-5 minutes manual stirring — solution becomes clear

5 Allow to cool to < 30°C Do not add hot solution to cold juice — causes localised heating

6 Add to mixer slowly Via dosing pump or slow pour while agitator running

7 Mix 3-5 minutes Then measure pH

8 Adjust if needed Add more in small increments to reach target

Section 4: Texture Stabilisers
Texture stabilisers prevent separation and sedimentation, give the juice a pleasant body and mouthfeel,
and maintain uniform appearance throughout shelf life.

4.1 Pectin (E440) — Primary Stabiliser

Property Detail

Origin Natural — extracted from citrus peel or apple pomace. Same material present in orange p

Form White to light yellow powder

Function Creates a network structure in the juice that suspends pulp particles and prevents settling.

Types used in juice Low-Methoxyl (LM) Pectin — works in low-sugar, acidic products like juice. High-Methoxyl

Addition rate — fresh juice 0.05 – 0.15% of juice volume

Addition rate — nectar / pulpy 0.15 – 0.5% of juice volume

Per 1,000 L batch example 0.5 – 1.5 kg pectin

Dissolution Method for Pectin:

• MUST be dissolved in HOT water (75 – 85°C). Cold water will not dissolve pectin properly.
• Add pectin powder SLOWLY to hot water while stirring — never dump all at once.
• Stir vigorously for 5-10 minutes until completely dissolved (no lumps).
• Cool solution to 40-50°C before adding to juice in mixer.
• Pectin requires ACIDIC conditions (pH < 4.5) to function — always add AFTER citric acid.
■ If pectin is added before citric acid, it may not form its stabilising network properly.

4.2 CMC — Carboxymethyl Cellulose (E466)

Property Detail

Origin Semi-synthetic — derived from natural cellulose (plant cell walls)

Form White to off-white powder, various grades by viscosity

Function Increases juice viscosity, prevents phase separation, improves suspension stability

Advantage over pectin Works in both acidic and neutral pH — more versatile. Also cheaper.

Disadvantage Can give slightly artificial mouthfeel at high doses

Addition rate 0.05 – 0.15% of juice volume

Per 1,000 L batch 0.5 – 1.5 kg CMC

Dissolution Method for CMC:

• Dissolve in COLD or LUKEWARM water (20 – 40°C). Hot water causes CMC to clump badly.
• Add powder slowly to water while stirring — not water to powder.
• Stir for 15-20 minutes. CMC dissolves slowly and forms a slightly viscous solution.
 • Add to mixer while agitator is running. Mix for minimum 10 minutes.

4.3 Xanthan Gum (E415) — High-Performance Stabiliser

Property Detail

Origin Fermentation product of Xanthomonas campestris bacteria on glucose

Form Cream-coloured to light brown powder

Function Extremely powerful stabiliser and thickener. Creates pseudoplastic behaviour — thick at re

Key advantage Effective at very low doses. Stable over wide temperature and pH range. Resists breakdow

Addition rate 0.02 – 0.05% ONLY — very small amounts. Over-addition makes juice gel-like.

Per 1,000 L batch 200 – 500 grams maximum

Dissolution Method for Xanthan Gum:

• Pre-mix xanthan powder with sugar or salt (1:5 ratio) before adding to water — this prevents
clumping.
• Add the pre-mix slowly to water at room temperature while stirring vigorously.
• Use high-speed stirring for 15-20 minutes until fully dissolved.
• Add to mixer very slowly — the solution is already quite viscous.
■ Xanthan Gum is VERY powerful. Measure accurately. Overdose creates unacceptable gel
texture that cannot be corrected.
Section 5: Flavour Fixatives & Emulsifiers
Flavour fixatives solve a fundamental problem: juice flavour (orange oil) is oil-based and does not mix with
water. Without fixatives, the oil floats to the surface and the flavour is lost. These additives encapsulate
and anchor the flavour in the juice.

5.1 Gum Arabic (E414) — Primary Flavour Fixative

Property Detail

Origin Natural exudate (sap) from Acacia senegal trees — mainly Sudan and Sahel region

Form Pale yellow to amber powder or lumps

Mechanism Gum Arabic has a unique molecular structure: protein-polysaccharide complex. The protei

Result Oil droplets are surrounded by Gum Arabic shells → they cannot coalesce or rise to the su

Additional function Also acts as a mild texture stabiliser and gives a smooth mouthfeel

Addition rate — flavour fixing 0.1 – 0.3% of juice volume

Addition rate — heavier stabilisation

0.3 – 1.0% of juice volume

Per 1,000 L batch 1.0 – 10.0 kg depending on application

Critical Method — Pre-mixing with Orange Oil:

Gum Arabic must be combined with the orange oil BEFORE adding to the juice. This is the key step that
creates the flavour emulsion:

1 Dissolve Gum Arabic in warm water (40-50°C): stir 10-15 minutes until completely clear.

2 In a separate small container: combine measured orange oil with the dissolved Gum Arabic
solution (approximately 1 part oil to 5 parts Gum Arabic solution by volume).

3 Mix vigorously with high-speed stirrer or homogeniser for 5-10 minutes. The mixture should
become opaque/milky — this indicates the oil has been broken into tiny droplets.

4 The resulting pre-emulsion is now stable and ready to add to the mixer.

5 Add pre-emulsion to the juice in the mixer while agitator is running at HIGH speed.

6 Mix for minimum 15 minutes at high speed to ensure even distribution.

5.2 Modified Starch (E1450 / E1442)

Property Detail

Origin Natural starch (corn, waxy maize) chemically modified to improve emulsification

Function Similar to Gum Arabic — encapsulates oil droplets and prevents separation. Also adds bo

Advantage vs Gum Arabic Significantly cheaper — used in economy products

 Property Detail

Disadvantage Lower emulsification efficiency. May affect mouthfeel at higher doses.

Addition rate 0.5 – 2.0% of juice volume

Dissolution Cold water — disperse slowly while stirring. Then heat to 60-70°C to fully hydrate.

5.3 Lecithin (E322)

Property Detail

Origin Natural — from soya beans (most common) or sunflower seeds or egg yolk

Form Liquid (crude) or powder (de-oiled)

Function Powerful natural emulsifier. The lecithin molecule has one water-loving end and one oil-lov

Advantage Extremely effective at very low doses. Natural origin — clean label appeal.

Addition rate 0.02 – 0.1% of juice volume

Per 1,000 L batch 200 grams to 1 kg

Note Liquid lecithin can be added directly to mixer. Powder lecithin should be pre-dispersed in s
 Section 6: Orange Oil & Flavour Addition

6.1 Why Add Flavour to Orange Juice?

This is a common question: if it is already orange juice, why add flavour? The answer lies in what happens
during processing:

Process Effect on Flavour

Flash Pasteurisation (85-95°C) Heat volatilises aromatic compounds — up to 30-40% of fresh aroma is lost

Evaporation (concentration) 75-80% of water removed — most volatile flavour compounds leave with the water vapour

Long-term refrigerated storage Remaining aroma compounds slowly degrade over months

De-aeration Some volatile aromatics removed with the extracted oxygen

The result is juice that tastes flat or 'processed'. Adding back orange oil and essence restores the fresh,
vibrant flavour consumers expect.

6.2 Types of Flavour Used

Type Origin Quality Level Addition Rate Notes

Cold-pressed Orange Oil

Natural — direct from peel
Premium
pressing 0.01 – 0.05% Best quality. Must be pre-emulsified wit
(from your oil line)

Orange Essence Oil Natural — recovered byHigh

distillation during0.005
concentration
– 0.02% Collected in evaporator condenser. Ver

Natural Orange Flavour Natural identical — lab synthesised

Medium but chemically
0.02 – 0.1%
same as
More
natural
stable than natural oil. Consistent

Artificial Orange Flavour Synthetic compounds Economy 0.01 – 0.05% Used in low-cost drinks. Not suitable fo

6.3 Addition Rate Calculation Example

For a 1,000 litre batch of fresh pasteurised juice:

Rate Quantity for 1,000 L

nge oil 0.02% (midpoint) 0.02% x 1,000 L = 0.2 L = 200 ml

the oil) 5x the oil volume 5 x 200 ml = 1,000 ml solution (containing ~100g Gu

m added — 200 ml oil + 1,000 ml Gum Arabic solution

Section 7: Complete Additives Reference Table

Additive E Code Category Rate (% vol) Per 1,000 L Dissolve In Add Order

Citric Acid E330 Acidulant 0.1 – 0.3% 1 – 3 kg Warm water 40°C 1st

Pectin (LM) E440 Stabiliser 0.05 – 0.5% 0.5 – 5 kg Hot water 80°C 2nd

CMC E466 Stabiliser 0.05 – 0.15% 0.5 – 1.5 kg Cold water 20°C 2nd

Xanthan Gum E415 Stabiliser 0.02 – 0.05% 200 – 500 g Mix with sugar first2nd

Gum Arabic E414 Fixative / Emulsifier 0.1 – 1.0% 1 – 10 kg Warm water 40°C 3rd

Modified Starch E1450 Fixative / Thickener 0.5 – 2.0% 5 – 20 kg Cold water then heat
3rd

Lecithin E322 Emulsifier 0.02 – 0.1% 200 g – 1 kg Direct / oil disperse3rd

Orange Oil (natural) — Flavour 0.01 – 0.05% 100 – 500 ml Pre-mix with Gum Last
Arabic

Orange Essence — Flavour 0.005 – 0.02% 50 – 200 ml Pre-mix with Gum Last
Arabic
Section 8: Mixer Step-by-Step Operation Protocol
This protocol must be followed in the exact order shown. Deviation from the order can result in improper
additive function, inconsistent product, or batch rejection.

PREPARATION — Before Juice Entry

• Verify mixer CIP was completed and sanitiser Check CIP log — do not proceed without
flushed confirmed CIP

• Calibrate pH meter with buffer solutions (pH 4.0 and Record calibration values. Replace
7.0) electrode if reading drifts > 0.05 pH

• Calibrate Brix meter / refractometer with distilled Clean prism with tissue before calibrating
water (should read 0.0°Bx)

• Prepare all additive solutions in advance Citric acid solution, pectin solution, gum
arabic solution, flavour pre-emulsion — all
ready before juice enters

• Record batch number, product code, planned Batch record must be completed in real
volumes, target pH and Brix time

STEP 1 — Fill Mixer with Juice

• Open juice inlet valve Juice flows from Finisher or balance tank

• Start agitator at LOW speed (20-30% of maximum) Low speed prevents foaming during filling

• Fill to 80-85% of mixer capacity Leave headspace for additives and foam

• Close inlet valve

• Measure and record: Brix, pH, temperature These are the 'baseline' values for this
batch

STEP 2 — Add Citric Acid

• Calculate required citric acid quantity based on Target pH: 3.5 – 3.8 for pasteurised juice
current pH vs. target pH

• Add prepared citric acid solution slowly via dosing Do not pour directly — use dosing pump for
pump control

• Run agitator at medium speed (40-50%)

• Mix for 3-5 minutes

• Measure pH — record result If pH not at target: add more in small

increments

• Confirm pH is within target range before proceeding DO NOT proceed to next step until pH is
confirmed

STEP 3 — Add Texture Stabiliser

• Add prepared pectin or CMC solution slowly while Never add dry powder directly
agitator running

• For Xanthan: add pre-dispersed solution very slowly Xanthan can cause localised gelation if
added too fast

• Increase agitator to medium-high speed (60-70%)

• Mix for 10 minutes

• Check juice consistency: should feel slightly more Take sample in clear glass — should be
viscous — no lumps uniform

STEP 4 — Add Gum Arabic & Flavour Pre-Emulsion

• Add prepared Gum Arabic solution This prepares the juice to receive the
oil-based flavour

• Mix 3 minutes at medium-high speed

• Add flavour pre-emulsion (orange oil + Gum Arabic) Pour in a thin stream near the agitator
slowly vortex

• Increase agitator to HIGH speed (80-100%) High speed is critical to break oil into tiny
droplets

• Mix at high speed for 15 minutes Do not reduce time — incomplete

emulsification cannot be corrected later

• Check: juice should be uniform orange colour, no

visible oil droplets on surface

STEP 5 — Final QC Check

• Stop agitator — take representative sample from Surface sample is not representative
outlet valve (not top of tank)

• Measure: pH, Brix, temperature Record all values

• Visual check: colour uniformity, no separation, no

foam layer

• Aroma check: fresh orange, no off-notes

• Send sample to laboratory for microbiological and

chemical analysis

• Only proceed to filling AFTER laboratory approval is If any parameter is out of spec: hold batch
received — do not fill

STEP 6 — Filling & Post-Filling

• Keep agitator running at LOW speed during filling Prevents settling during the filling operation

• Monitor temperature throughout filling Pasteurised juice must stay below 4°C
during cold fill

• Record start and end fill times, drum/bottle numbers

• After filling: close outlet valve, flush lines with water

• Initiate CIP cycle immediately after production is Never leave product in mixer lines or tank
complete overnight
Section 9: Dissolution Methods Summary
Additive Water Temp Method Time Critical Warning

Citric Acid 40 – 50°C warm Stir until clear 2 – 5 min Never add dry. Never add hot solution.

Pectin (LM) 75 – 85°C HOT Add slowly while stirring 5 – 10 min Hot water only. Add AFTER citric acid.

CMC 20 – 40°C cold/luke Add

warmpowder to water slowly15 – 20 min Hot water causes severe clumping.

Xanthan Gum Room temp Pre-mix with sugar 1:5 then15

add
– 20
to water
min Overdose = irreversible gelation.

Gum Arabic 40 – 50°C warm Stir until fully clear 10 – 15 min Must be pre-mixed with oil before adding to

Modified Starch Cold then heat to 65°C

Disperse cold then cook 15 – 20 min Must be cooked/hydrated fully.

Lecithin (liquid) Not required Add directly or pre-disperse—in oil Avoid contact with hot water.

Orange Oil Not dissolved Pre-emulsify with Gum Arabic

5 – 10 min Never add directly to juice without emulsifie
Section 10: Common Errors & Troubleshooting
Problem Observed Most Likely Cause Corrective Action Prevention

pH too low (too acidic) afterToo

addition
much citric acid addedBlend
at once
with fresh juice to raise
AddpH.
in small
Cannotincrements.
remove citric
Measure
acid. after ea

Pectin lumps in juice Added dry or dissolved in cold

Filter
water
out lumps. Cannot fix Always
in mixer.
dissolve in hot water 80°C before a

Oil layer floating on surfaceOrange oil added without emulsifier,

Add moreor Gum
insufficient
Arabic solution
mixing
Always
time
andpre-emulsify
run high-speed
oil. Always
agitatormix
for additio
at high

Gel-like texture — too thickXanthan Gum overdose Dilute batch with fresh juice.
Weigh
May not
Xanthan
fully recover.
Gum accurately. Use in gr

Juice separates in drum / bottle

Insufficient stabiliser or Agitator
Cannotranfix
too
after
slowfilling.
during
Product
mixing
Verify
maystabiliser
be rejected.
addition. Check agitator sp

Flat flavour — no orange aroma

Flavour not added, or oil was
Addadded
freshwithout
flavour Gum
pre-emulsion
Arabic
Verify
(oil
andall
floated
remix.
additions
out) from batch record. Neve

pH reading unstable / drifting

pH electrode not calibrated,Recalibrate
or damaged with buffer solutions.
Calibrate
Replace
pH meter
electrode
everyifshift,
needed.
minimum tw

Product rejected by QC labAny parameter out of specification

Identify which parameter failed.
FollowAdjust
protocol
if possible.
strictly. IfNever
microbiological
skip QC step
fa
Section 11: Final QC Parameters Before Filling
Parameter Test Method Fresh Juice TargetConcentrate Target
Action if Out of Spec

pH Calibrated pH meter 3.5 – 3.8 3.2 – 3.7 Adjust with citric acid (if too high) or ble

Brix Refractometer 10.0 – 12.0°Bx 60 – 65°Bx Dilute if too high. Concentrate further if

Temperature Calibrated thermometer< 4°C at filling < -5°C at filling Cool further before proceeding

Colour Visual + Colorimeter Bright uniform orange

Deep amber-orangeInvestigate cause — possible oxidation

Aroma Trained sensory panel Fresh citrus, no off-notes

Concentrated orange,
Check
cleanflavour addition records

Viscosity Viscometer or pour test Slight body — flows Thick

freely — slow pour Adjust stabiliser addition in next batch

Sugar/Acid ratio Calculate from Brix + Acidity

10 – 14 8 – 14 Adjust citric acid or check incoming frui

Total Plate Count (TPC)

Microbiological culture < 100 CFU/ml < 100 CFU/ml HOLD batch — investigate pasteuriser

Yeast & Mould Microbiological culture < 10 CFU/ml < 10 CFU/ml HOLD batch — check sanitation

This document is intended for internal production and technical training use only. All parameters should be validated
against applicable food safety regulations, customer specifications, and local food law requirements.