HANOI UNIVERSITY OF SCIENCE AND TECHNOLOGY

PROJECT FOOD ENGINEERING

Design of nectar mango processing line

Nguyen Xuan Bao

Bao.NX211207@[Link]

FOOD ENGINEERING

Mentor: [Link] Vu Thu Trang

Sign of Mentor

Department: Food Engineering

School: School of Chemistry and Life Science
Hà Nội, 11/2023
 Opening

Vietnam is a tropical country with favorable climate and soil conditions for cultivating
various vegetables and fruits to meet domestic consumption and export demands. Among these,
mango is a tropical fruit tree that has been widely grown for a long time and holds significant
socio-economic importance for many regions across the country.
Although Vietnam has great potential for production and export to the global market, the
overall fruit and vegetable sector is still lagging behind other countries. Despite being one of the
largest producers in the world, mangoes are primarily used for fresh consumption, with only a
small portion exported, often leading to oversupply during peak harvest periods. Mangoes have
a short shelf life, and their juice is rich in nutritional value, providing health benefits. Therefore,
allowing them to spoil would be wasteful. As a result, many mango-based products have been
developed, such as mango jam, dried mango, mango candy, and popular mango beverages like
mango nectar, which offer both delicious flavor and a rich source of vitamins, meeting consumer
demands.
Currently, consumer preferences still lean toward self-prepared beverages that are
affordable and convenient. However, as living standards improve and people have less time, the
use of industrial beverages, especially those made from natural, health-beneficial ingredients, is
increasing.
For all these reasons, I have decided to choose my project which is designing the mango
nectar processing, under the mentoring of [Link] Vu Thu Trang, who I am deeply grateful
for all the support and guidance !

Sincerely!

INDEX
CHAPTER 1. ECONOMICAL ANALYSIS AND PLACEMENTError: Reference source not
found
1.1 Overview of fruit juice market............................Error: Reference source not found
1.2 Current fruit juice market....................................Error: Reference source not found
1.2.1 Classification........................................Error: Reference source not found
1.2.2 Nectar product overview......................Error: Reference source not found
1.2.3 Overview of Mango nectar..................Error: Reference source not found
1.3 Mango production state: worldwide and VietnamError: Reference source not found
1.3.1 Production state: worldwide................Error: Reference source not found
1.3.2 Production state: Vietnam....................Error: Reference source not found
1.4 Charateristic and variety of some Vietnamese mangoError: Reference source not found
1.5 Economical meaning of mango nectar................Error: Reference source not found
1.6 Technical analysis...............................................Error: Reference source not found
1.6.1 Location...............................................Error: Reference source not found
1.6.2 Climate.................................................Error: Reference source not found
1.6.3 Raw material area................................Error: Reference source not found
1.6.4 Electrical system and water system...............................................
1.6.5 Waste management system............................................................
1.6.6 Traffic system................................................................................
1.6.7 Human resource......................................................................Error: Reference
source not found
1.6.8 Market...........................................................................................
 CHAPTER 1: ECONOMICAL ANALYSIS AND PLACEMENT

1.1 Overview of the fruit juice market:

According to information from the Ministry of Industry and Trade, global industry analysts
(CAGR) forecast that the fruit and vegetable juice market will reach USD 186 billion by 2022,
with an average growth rate of 5-6% per year. This growth in the sector mainly depends on
consumers' increasing interest in health-beneficial beverages.
In 2022, the fruit juice market in Europe generated approximately EUR 38.5 billion in revenue,
corresponding to an average per capital revenue of around EUR 32.8. According to Statista
Market Insights, the juice segment of the beverage market is expected to grow to nearly EUR 38
billion by 2026. A closer look at these segments reveals that orange juice is the best-selling juice
in Europe, generating the highest revenue with nearly EUR 9 billion.
Currently, the total value of Vietnam's fruit juice market ranks fourth in Southeast Asia,
amounting to USD 450 million. The market is projected to grow at an annual rate of 8% (CAGR
2020-2025). The main segment of the market includes fruit juices and smoothies, with a market
size of USD 286 million in 2020. Research data shows that per capita fruit juice consumption in
Vietnam was 3.6 liters per person in 2020.
In recent years, a trend has emerged towards using fruit juices and milk-based fruit juices to
supplement body nutrients. According to a survey by market research company W&S on
demand and habits regarding packaged fruit juices, 62% of consumers choose fruit drinks, while
only 60% choose carbonated drinks. Notably, more than half of those surveyed have a habit of
consuming fruit drinks daily.
The choice of these products is driven by:
- Quick, health-beneficial products
- Fruit juice products rich in essential nutrients, vitamins, etc.
- Products with clear origins."
1.2 Current fruit juice product
1.2.1 Classification:

Based on the level of naturalness, fruit juices are classified into the following types:
 Natural Fruit Juice: Made from a single type of fruit, with no added sugar, essential
oils, or colorants.
  Natural Fruit Juice for Direct Consumption or for Processing: Can be consumed
directly or used to make soft drinks and liqueurs. For very sour fruit juices, sugar is often
added before drinking. To enhance the flavor, sometimes part or all of the natural sugars
in the juice are fermented.
 Blended Fruit Juice: Created by mixing different types of fruit juices, with additional
fruit juice not exceeding 35% of the main fruit juice.
 Sugar-Sweetened Fruit Juice: To improve flavor, sugar is often added to certain juices
like lemon, orange, and mandarin.
 Concentrated Fruit Juice: Produced by concentrating natural fruit juice through heating
(evaporation) or freeze concentration. Concentrated juice is advantageous in terms of
reduced packaging, storage, transportation costs, and lower susceptibility to microbial
spoilage.
Based on preservation methods, fruit juices are classified as follows:
 Pasteurized Fruit Juice: Packaged in sealed containers and pasteurized by heating either
before or after sealing.
 Chilled Fruit Juice: Stored at temperatures between 0 - 2°C.
 Carbonated Fruit Juice: Infused with CO₂ to inhibit microbial activity and enhance
refreshment properties.
 Sulfited Fruit Juice: Preserved with SO₂, typically used as a semi-processed product.
 Alcohol-Preserved Fruit Juice: Alcohol is added to inhibit microbial activity, and it is
stored in sterilized packaging.
Based on the clarity of the product, fruit juices are divided into the following types:
Clear fruit juice: a type of juice without any insoluble particles. Clear fruit juice is extracted or
pressed from fruit and then clarified using various methods to remove all cloudy particles, even
the smallest ones, including colloidal systems. There are two types of clear fruit juice:
Clear fruit juice: juice without cloudy particles, but still containing colloids that can
denature and form sediment, causing cloudiness after a period of storage.
Transparent fruit juice: a type of juice that is not only free of solid particles causing
cloudiness but also free of denaturable colloids. To achieve this type of juice,
clarification requires removing all colloids such as pectin, proteins, and dissolved starch.

Cloudy fruit juice: a type of juice that still contains solid particles that cause cloudiness. There
are two types of cloudy fruit juice: pressed cloudy juice and nectar.
Pressed cloudy juice: obtained by pressing the fruit pulp and filtering out most of the
pulp particles, allowing a certain amount of solid particles to remain.
Nectar juice: prepared by mixing fruit puree with sugar syrup at a fruit puree ratio of
20% to 75% of the total weight, depending on the fruit type. Typical products widely
produced in Vietnam include banana juice, mango juice, and soursop juice.
· Fruit juice without pulp has an appealing appearance and is less prone to spoilage during
storage than juice with pulp. Fruits rich in carotene, such as apricots and tangerines, or those
with soft pulp, like bananas and papayas, should only be processed as juice with pulp because
carotene is not water-soluble, and the soft pulp makes it impossible to extract pure juice by
pressing.
1.2.2 Current commercial Nectar product:

Guava nectar Passion fruit nectar

Mango nectar Peach nectar

By choosing mango as the fruit for nectar processing comes with many advantages:
· Nutrient-rich product, high in vitamin C, etc.
· Quick and convenient, ready to consume without needing additional preparation time.
· Health benefits: good for skin, aids digestion, etc.
· Simple storage at room temperature, with a long shelf life of 12-18 months
· Reasonable price.
· Simple production process.
· This is a canned food product, allowing people to enjoy dishes that might not be available in
their own country, contributing to the broad exchange of culinary culture through import and
export.

1.2.3 Overview of the mango nectar

Mango nectar is a type of fruit drink with pulp that is non-fermented and processed by extracting
the pulp, which includes the juice and the flesh of the fruit, and adding sugar syrup and citric
acid. To stabilize the state of the mango nectar, certain suitable additives are often included.
The product has a thick texture with fruit pulp, a bright yellow color, and a characteristic
fragrant aroma of mango. It is typically consumed directly and does not undergo further
processing.
Ripe mangoes contain a lot of carotenoid pigments, which are insoluble in water but soluble in
oil. Since this drink contains fruit pulp, the product has a high carotenoid content, and the
production process includes pasteurization, significantly increasing the absorption rate of
carotenoids into the body. The product is rich in nutrients, vitamins, and fiber, especially
antioxidants that are essential for health, preventing diseases, and maintaining beauty.
However, because the product contains fruit pulp, it may separate during long-term storage
(even after homogenization), which can affect its sensory quality.
Current mango nectar product on the market:
Mango nectar Le fruit:
 Classification:
- 1 Liter / Multilayers Packaging
(Price: 69.900đ NamAn market)
- 250 ml / Glass Packaging
(Price: 42.900đ – NamAn market)
 Ingredients:
- 30% mango, 2% cherries, sucrose, water
 Flavoring:
- With the mild sour taste of mango, aroma
of mango and cherries flavor
- A bit viscous
 Preservation:
- 12 months
- Store at 20-25oC
 TH true juice nectar:
 Classification:
- 350ml / Plastic Bottle Packaging
(Price: 15.000đ)
 Ingredients:
- Water, puree mango
(25%), sucrose, stabilizer
(E 440), mango flavoring,
acidity regulator (E 330) –
No preservatives
 Flavoring:
- Light sour, aroma of
mango
- Texture not too much
viscous
 Preservation:
- 6 months
- Store in dry condition. Once opened,
refrigerate at 4-10°C and use up within
24 hours

We can see that Vietnam has a large annual mango production, with most mangoes being
consumed domestically or exported primarily as fresh fruit. Since mango is a climacteric fruit
with a short shelf life, and especially due to the limitations in post-harvest preservation
technology in Vietnam, mangoes are prone to spoilage, darkening, and rotting, which reduces
the quality of fresh mangoes.
Although mango exports have seen impressive growth in recent years, they remain modest
compared to global levels due to strict quality standards (size, color, pesticide residue, etc.). For
these reasons, during the peak season, a significant quantity of mangoes accumulates, leading
businesses to address this by producing mango-based food products, which not only add value to
the fruit but also extend its shelf life. Major mango-based products include dried mango, mango
jam, mango juice, mango in syrup, mango concentrate, and mango nectar—a unique product
that can meet these demands.

1.3 Mango production state: Worldwide and Vietnam

1.3.1 Mango production: worldwide

Mango is one of the common fruits in most continents, particularly in Asia, Central and South
America and Africa, and is ranked fifth in production among major fruits. Mango is produced in
over 90 countries worldwide. FAO estimated that the mango harvest will be around 28 million
tons in 2014, that is, 35% of the production of the world’s tropical fruit. Asia accounts for
approximately 77% of global mango production, and the Americas and Africa account for
approximately 13% and 9%, respectively. Most of the major mango-producing countries like
India, China, Thailand, Indonesia, Pakistan, the Philippines, and Bangladesh are in Asia;
however, the cultivation has spread to countries such as Mexico, Brazil, Madagascar, Tanzania,
Dominican Republic, Haiti, Brazil, and Australia .

Table 1 1 World's ten

major mango
producing
countries for
selected years
since 2000 (million
metric tons).

Mango is the
second-most
popular fruit in
Vietnam (after
banana),
commonly grown in 59/63 provinces. In 2022, Vietnam has the mango plant area of 1,142
thousand hectares with an output of about 996 thousand tons, of which nearly 600,000 tons of
mangoes are exported to 40 international markets, an increase of 42% compared to 2020. The
mango has grown most in the provinces of the Mekong River Delta such as Tien Giang, An
Giang, Dong Thap, Vinh Long, Can Tho, Ben Tre made up 45.3% in 2018, next is Southeast
(table 1.2). Vietnam ranks 13th in mango production in the world but the export quantity is still
modest.
Table 1.2 Mango planted area, Viet Nam, 2009-2018.

Hectares (per annum) Propo Averag

rtion e
Region (%) growth
2009 2010 2015 2016 2017 2018 rate
(2018)
(%)
Whole 87,60 87,500 83,70 86,60 92,70 99,60 100 1.4
country 0 0 0 0 0
Red River 1,900 1,800 2,200 2,200 2,400 2,400 2.4 2.5
Delta
Northern 8,500 8,400 8,300 8,700 12,20 15,90 16.0 7.2
Figure 1.1 Production volume of mangoes in Vietnam from 2016 to 2022. Source: Statista
midlands and 0 0
mountain
areas
North Central 14,20 13,800 14,20 14,20 14,70 15,20 15.3 0.8
and Central 0 0 0 0 0
 coastal area
Central 2,100 2,200 2,700 2,400 2,900 3,200 3.2 4.9
Highland
Southeast 17,40 18,100 17,40 17,20 17,80 17,80 17.9 0.3
0 0 0 0 0
Mekong River 43,50 43,200 39,00 41,90 42,70 45,10 45.3 0.4
Delta 0 0 0 0 0

Figure 1.2 Production volume of mangoes in Vietnam from 2016 to 2022. Source:
Statista
There are four leading provinces where have the largest mango production areas in the Mekong
Delta; they are Dong Thap, Tien Giang, An Giang and Vinh Long (Table 1.3). These provinces
account for 72.8% of the total mango area and 72.7% of total mango volume in the MD.
Dong Thap province has the largest mango production areas of any province in the MD 9200
hectares in 2013). This area increased gradually by an average of 3.5% per year between 2009
and 2013. The average yield was 14.89 tons per hectare in 2013. According to provincial
statistics, mango production in Dong Thap totaled 123,870 tons in 2013 (average 59,730 tons
per crop)
Table 1.3 Area and volume of mango production in the MD in 2013

Provinces Cultivated Harvest % of Volume % of Yield

Area (ha) Area area (tons) volume (tone/ha)
(ha)
Dong
9,200 8,319 28.4 123,870 29.7 14.89
Thap
Tien
4,894 4,591 15.7 61,290 14.7 13.35
Giang
An Giang 4,664 4,217 14.4 64,251 15.4 15.24
 Vinh
4,857 4,204 14.3 54,230 12.9 12.89
Long
Others 18,185 7,985 27.2 113,627 27.3 14.23
The MD 41,800 29,316 100.0 417,268 100.0 14.23
Most mangoes produced are consumed domestically. According to FAO statistics, 1.53 million
tons were exported globally in 2011 (compared with 43.6 million tons produced that year). The
volume of exports is increasing, however, by an average of 5.5% per year in terms of volume
and 12.2% per year in terms of value between 2005 and 2012.
1.4. Mango characteristics and variety
Mango (Mangifera indica Linn.), a commercially important tropical fruit, is a large fleshy drupe
containing edible mesocarp of varying thickness. It varies in size, shape, color, and flavor. The
exocarp (peel) is thick and glandular. The mesocarp (pulp) can be fibrous or fiber-free with
flavor ranging from turpentine to sweet. The mesocarp provides edible pulp, which is firm
containing a sweet, well-flavored juice. The endocarp is woody, thick, and fibrous, forming a
thick, tough, leathery glandular covering of the seed, termed as husk. The seed is albuminous. It
is solitary, large and flat, and ovoid oblong and is surrounded by the endocarp at maturity. The
testa is thin and papery. The outer skin is smooth and is green in unripe mangoes but turns into
golden yellow, crimson red, yellow, or orange–red when ripened depending upon the cultivar
type [2].
The mango fruit is an essential part of human nutrition. Mango is used as food in all stages of its
development. During the ripening process, the fruit is initially acidic, astringent, and rich in
ascorbic acid. Mango fruit contains amino acids, carbohydrates, fatty acids, minerals, organic
acids, proteins, and vitamins. The ripe mango contains about 15% sugar. Sugars present in
mango comprise sucrose, glucose, fructose, and maltose. Sucrose is the principal sugar in ripe
mango. Mango fruit contains 0.5–1.0% protein on a fresh weight basis. Total lipid content in
seven commercial mango cultivars ranged from 0.26% to 0.67% at harvest.
Mango fruit is particularly a rich source of vitamin C. Literature reports indicate great variation
in ascorbic acid contents, ranging from 9.79 to 186 mg per 100 g of mango flesh. Daily
consumption of mango fruits by population groups of all life stages can meet the recommended
dietary requirements of vitamins A and C.
Table 1.4 Food value per 100g of ripe mango pulp [3]

Calories 62.10-63.70 Cal

Moisture 78.90-82.80 g
Protein 0.36-0.40 g
Fat 0.30 – 0.53 g
Carbohydrates 16.20 – 17.18 g
Fiber 0.85 – 1.06 g
Ash 0.34 – 0.52 g
Calcium 6.10 – 12.80 mg
 Phosphorus 5.50 – 17.90 mg
Iron 0.20 – 0.63 mg
Vitamin A (carotene) 0.135 – 1.872 mg
Variety of mango in Vietnam
Mango trees are widely grown from the North to the South of Vietnam. Vietnam has 46 varieties
of mango. Mango varieties with commercial value include Cát Hòa Lộc mango, Cát Chu mango,
Cát Bồ mango, Xiêm mango, Thanh Ca mango, … In the southeast of the Mekong River Delta
(MRD), Cát Hoà Lộc and Cát Chu are the most popular. Cát Hoà Lộc is recognized as the best
mango variety in Vietnam due to its taste, aroma, sweetness, quality, and appearance. It was first
grown in the Cái Bè district of Tien Giang province.
The drawback of these mango varieties is that mango fruit is hard to bear, especially for Hoa
Loc mango and in rainy season of mango production. On the other hand, due to the thin shell,
transportation and preservation of Hoa Loc mango and cat chu mango have limited obstacles to
export.
Table 1.5 Main mango varieties in Mekong River Delta, Vietnam, 2019

Variety Cat Hoa Loc Cat Chu Tuong

Son La province,
Main planting Tien Giang, Dong South of Dong Thap Dong Thap
area Thap, Ben Tre province Province, Binh Dinh
province.
Oval, long, pointed
Shape Oblong shape Oval, rounded tip
tip
Weight 450-600g 350-450g 1,000-2,000g
Natural Green but Natural Green but
Flesh color Yellow/Yellow turns into Pale yellow turns into Pale
when ripe yellow when ripe
Tangy and sweet. - Sour and crunchy
Sweet and
Mango flesh is less when young.
fragrant, pleasant
Flavor with fiber, but slightly - Tangy and sweet
aroma, good
chewy, tangy sweet, when ripe. Mango
aftertaste
pleasant aroma flesh is less with
 fiber, crunchy, tangy
sweet, pleasant
aroma
Yield/tree (at
10-12 tons/ha ≈ 25 tonnes/ha 20-25 tons/ha
10 yrs.)
Main seasons April- June March- May May- July
Flower
August- March August- February August- December
manipulation
Flesh (%) 70-82 78 90
Brix level 22 18 10-15

Types of mango products in Vietnam

Mango fruit is processed and used at every stage of its growth. Mango is processed at two stages
of maturity. Green fruit is used to make chutney, pickles, curries, and dehydrated products. Ripe
mangoes are processed as canned and frozen slices, puree, juices, nectar, and various dried
products. Mango juice, nectar, and squash are some of the important beverages prepared on a
commercial scale. The pulp was extracted from fully ripe fruits, canned, and used for preparing
nectars and juice. Mango-based carbonated beverages and wine are also available in the market.

Smoothie Base Smoothie Mango

Dried mango Banana
Mango nectar

Mango Jam Mango & Cinnamon Pickle Mango Chutney sausage

Spread

1.5. Economical meaning of mango nectar:

With the economic development of our country, the quality of life is increasingly improving.
Especially during the COVID-19 pandemic, beyond the basic nutritional needs in daily meals,
people are paying more attention to essential micronutrients for health, derived from fruits and
vegetables. Due to the convenience and industrialization of fast food products, both domestic
and international markets are expanding.
With the advantage of an abundant supply of fresh mangoes that cannot be fully consumed in
fresh form, processing mango into unique fruit products, especially mango nectar, offers a
solution to the issue of surplus mangoes during the harvest season. Building a mango nectar
production plant is essential and important to help consume large amounts of fresh mango,
promote agricultural economic growth, add value to mangoes, improve people's livelihoods, and
enhance the material well-being of citizens.
Moreover, mango fruit products will bring a new variety to the Vietnamese market and offer
convenience and nutrition for the international market as well. Beyond consuming fresh mango
or mango smoothies, mango nectar will be a new choice for consumers while still meeting their
nutritional needs.
Additionally, the economic efficiency of producing mango nectar is significantly higher than
selling fresh mangoes. Compared to selecting uniform fruits by size, ripeness, and high quality
for export, processing mango into fruit juice allows for the use of raw materials with less
reliance on size, reducing the cost of raw material procurement.
Thus, processing mangoes into nectar not only addresses the raw material surplus but also
diversifies products on the market, serving the population’s needs and increasing economic
efficiency.

[Link] the location to build the factory.

[Link]
Tien Giang is one of the Southern Key Economic Zone located 70 km south of Ho Chi Minh
Figure 1.3 Location of Tan Huong Industrial Park, Tien Giang Province City. The North
and the Northeast are near by Long An and Ho Chi Minh City, the West nears Dong Thap, the
South nears Ben Tre and Vinh Long, the East nears Biển Đông.
Tan Huong Industrial Park, Chau Thanh District, Tien Giang Province is 12 km from My Tho
City, 50 km from Ho Chi Minh City, next to National Highway 1A and the Ho Chi Minh City -
Trung Luong Expressway. With the border with the above-mentioned southwestern provinces, it
is a favorable condition to satisfy the demand for supplying raw materials, an essential issue
when building a factory.
Area of the industrial park: 197.33 ha
1.6.2. Climate
- The climate is tropical monsoon, divided into two distinct seasons: the rainy season and the
dry season.
- Main wind direction: Southwest - Northeast.
- Average annual rainfall: 1467mm.
- The average temperature of the year is 28oC, the lowest temperature of the year is 26oC, the
temperature difference between months is not large, about 4oC.
- Average annual humidity: 80 - 86%
1.6.3. Raw material area
The Mekong River Delta has the largest volume of mango production in Vietnam, and it is also
the key region for tropical fruit production in Vietnam. Within the region, the largest mango
areas are in Dong Thap and Tien Giang, following by An Giang, Vinh Long (both are near Tien
Giang province). Moreover, Cát Hoà Lộc is also the flagship fruit in TG provinces. With the
abundance of raw materials mentioned above, it is suitable for the goal of building a factory
here.
1.6.4. Electricity systems and water systems
The electricity grid in Tien Giang is invested increasingly, ensuring timely response to business
and production requirements of enterprises. Power is supplied from the 22KV power line of the
national grid, with a capacity of 40 MVA.
Currently, the province has 13 surface water extraction plants and many underground water well
drilling stations, supplying urban areas with a total capacity of 160,600m3/day. At the same time,
there is a water company built inside the industrial park, which is invested and provided on a
large scale with a large capacity of up to 12,000m3/day.
1.6.5. Waste management system
This is a food processing factory, so the wastewater mainly contains organic substances, which
are the environment for micro-organisms to grow, making it easy to infect tools, equipment and
raw materials entering the factory, which will affect the environment. All production wastewater
and domestic wastewater must be treated according to regulations before being discharged into
the common wastewater system.
The scrap from the factory should be treated to avoid polluting the working environment as well
as the surrounding environment. With mango as the raw material, the scraps from them can all
be used as microbial fertilizers, ... Therefore, these scraps can be sold to other factories, both
hygienic and functional economy.
1.6.6. Traffic system
 Block of transportation system in Tan Huong Industrial
- 4-lane main shaft system 27 & 33m wide in the industry park
- Internal transportation system with 2 lanes, 19.5m wide
 The industrial park is in the southern key economic region as well as a traffic hub between
the Mekong Delta and the center of Ho Chi Minh City.
- Provincial road 827 and National Highway 50 are the main external transport axis of the
district connecting economic regions together.
- Go through National Highway 1A
- Near the highway Ho Chi Minh City - Trung Luong.
- To Ho Chi Minh City: 50km to the Southeast along National Highway 1A, 37km to the
Northwest by Ho Chi Minh City - Trung Luong Expressway
 Railway
- Distance to the nearest railway station: 60km from Saigon station
 Waterways of about 500 - 600 tons to transport goods from the industrial park to My Tho
Port and Hiep Phuoc Port.
- Distance to the nearest river port: 15km from My Tho port
- Distance to the nearest seaport: 45km from Hiep Phuoc port and 50km from Cat Lai port.
1.6.7. Human resource
Tien Giang province has an abundant labor source, the labor rate increases gradually over the
years, due to the rapid development of industrial zones which has attracted labor from other
provinces.
- Workers are mainly recruited locally to reduce the cost of building worker dormitories. Most
of the recruited workers have an education level from 12th grade, so they can respond to the
manual stages.
- Management scientific and technical staff: with staff with many years of experience in
addition, the factory will receive engineers from universities across the Mekong River Delta
and be trained to apply new scientific and technical achievements of advanced countries in
the world, this is the core force of the factory.
1.6.8. Market
With the factory location located in Tan Huong industrial park, it is very convenient for traffic
to the gateway to the traffic hub in the economic quadrangle area of Dong Nai - Binh Duong -
Vung Tau - Ho Chi Minh City. Besides, Ho Chi Minh City is a large urban area with a high
population rate that will attract the attention of many consumers. Therefore, Nectar mango
products of the factory will be distributed mainly in the southern provinces and especially Ho
Chi Minh City.
Not only that, with the advantage of being located near Ho Chi Minh City, through 1A highway
with the route running along the North-South route, the factory's products will be marketed to
major markets in the North and Central regions such as Hanoi, Hai Phong, and Da Nang, etc.

CHAPTER 2. SELECTION AND EXPLANATION OF TECHNOLOGICAL PROCESS

1 Selection of technological process
2 Sorting and selection
Table 2.1 Advantages and disadvantages of sorting and selection methods and equipment

Methods Advantages Disadvantages

Save costs on
Ripeness by color Time- consuming and
machinery and
(Manual method based sometimes inaccurate
equipment and can
on experience to manual and eye
take advantage of
Sorting identify) classification
human resources.
based
on Ripeness according to
ripenes density: put fruits in a
Accuracy is only
s water tank, then green Can combine
relative, and the
fruits float, ripe fruits material washing to
materials used for this
sink: sink deeper or save time
method are limited
shallower depending on
mature meter
Sorting Using sieves: Includes
based mesh tape systems
on fruit where the mesh holes
Can sort fruits Not popular, usually
size of each conveyor have
quickly apply to round fruits
a certain size. This
conveyor can divide
fruits into 2-4 groups.
Cable belt: includes a Can divide fruits High-cost equipment
 cable conveyor system
where the distance
between the cables
increases with the into many same
movement of the tape. size groups
Where there is a greater
gap between the cables,
the fruit will slip down.
Sorting - Save labor.
- High productive. Do not classify the
based
Weighing machine - Suitable for ripeness and the
on fruit many fruits deterioration of mango
weight including mango
 The manual method according to the mango color based on the worker experience are
chosen for the mango nectar technology process, because workers can detect rotten and
spoiled fruits and sort them by ripeness, helping to ensure consistency in the sensory and
nutritional quality of the mango nectar product.
3 Soaking and cleansing
a. Wash on the sink
• Procedure: This step is conducted manually by workers on the big tank with water at 25°C
and one more time to remove unsatisfactory fruits.
• Advantage: + Avoid the breaking of fruit
• Disadvantages: + Labor consuming
+ Time consuming
b. Use an air blow-washer
 Procedure: Use clean water at room temperature to wash, using air blower device
 Advantages: + Materials are cleansing quickly
+ Large quantity of fruit in a batch
 Disadvantage: + Expensive
+ Need the engineer to operate the machine
 The technology choosing to use in factory:
Using the air-blow washer machine:
- Because mango fruit has a smooth, slippery surface, without much dirt.
- To avoid leaving unwashed mangoes, wash them more evenly. Besides, it also saves
time and labor.
4 Thermomechanical treatment
Table 2.2 Advantages and disadvantages of thermomechanical treatment method

Method Advantages Disadvantages

 Tear, grind too small or too
Tear, coarsely crush Increased pressing efficiency
big will not let the fluid out

Heat treatment Performance will be It is easy to lose aroma,

(Blanching, Steaming, significantly increased. Kills change taste, color, and
Grilling) the activities of enzymes consume vitamins

Pectin hydrolyzed The quality of the juice

significantly reduces the obtained is lower with other
Enzyme treatment
viscosity, increasing the methods
yield of juice
 In the process of producing mango nectar, which is easy to change color, heat treatment
(blanching) with a conveyor blanching device is chosen.
4.1.1 Separation of fruit flesh
Table 2.3 Advantages and disadvantages of separation of fruit flesh methods

Method Advantages Disadvantages

Peel off Peel the fruit manually Save, careful For low
productivity
Peel the fruit Fast peeling time Equipment costs
mechanically are high.

Remove Punching method Used to remove relatively small nuts

seeds such as apricots, plums, cherries, etc.

Method of dredging This is a method of getting seeds from

nuts, but the fruit size is relatively
large such as pears, peaches, apples,
passion fruit.
 The method of separating the fruit flesh based on the labor of the workers is chosen in
this process. Workers use knives to cut, collect the flesh, remove seeds and shells.
4.1.2 Receiving fruit flesh
Table 2.4 Advantages and disadvantages of fruit flesh collection methods

Method Advantages Disadvantages

Crushing Isolate the fruit flesh It has not been completely
from the raw material obtained.

Compress For high productivity Strong pressure will cause the

 seeds to remain in the juice.
 The technology chosen in the factory is the crushing method.
4.1.3 Mixing
In fruit processing, the mixing stage is conducted in the production processes of products such
as fruit juices, fruit purees, etc.
It is necessary to calculate the amount of sugar needed to be mixed into the sugar solution so
that when mixing a definite amount of sugar syrup with the fruit, the required dry matter content
of the product is achieved.

5 Homogenization
This is a major step that determines the quality of the product. Homogenization is intended to
break down the pulp particles to the required size, the smaller the particle size, the more stable
the juice state.
A mechanical force must be applied to them according to two principles:
- Using mechanical methods to crush and tear the flesh directly: often use rotor homogenizers,
glue grinders, ultrasonic homogenizers…
- Create a sudden high-pressure difference so that the undissolved particles break down on their
own. Homogenization in this way is widely used in the production of juices, fruit purees and
milk.
 In order to reduce the time and create high efficiency, the second principle for the
homogenization stage in the process and use high pressure homogenizer is chosen in the
factory.

6 Deaeration
Deaeration methods:
- Deaeration by heat: put in the box of the product has been heated. The simplest and most
convenient way to degas by heat is to put the product in the packaging while it is still hot
(Hot Filling). Put the product into the package when it has been heated to about 85-90 oC
and then seal it immediately.
- Mechanical deaeration: A vacuum pump is used to suck the air out of the box in a
compartment of the closed laminator. Although the mechanical degassing method
(vacuum degassing) is a simple and easy to use method, it has some disadvantages when
applied to this type of canned food only 85.5%. Therefore, not removing all the air in the
tissue will easily cause vacuum expansion and vacuum absorption.
- Combined air release: To achieve the best air removal effect, combine hot pouring
method with vacuum suction method is often chosen.
In addition to the above methods, technology also conducts air removal by steam injection.
Using hot steam to spray the space in the can, before sealing, the steam pushes the air out. After
sealing and cooling, that steam condenses and creates a vacuum in the box. This method only
applies to liquid canned goods, and solid products will deteriorate the appearance of the product.
  In the production of mango nectar, centrifugal defecator method is used.

7 Filling and seaming

8 Filling the bottle
Filling the product into the package is done according to two principles: Weight and volume.
The advantages and disadvantages of these two principles are as follows:
Table 2.5 Advantages and disadvantages filling methods

Method Advantages Disadvantages

Weight: put a quantity of Accurate Not actively controlling
product into the package to the size of the packaging
a specified amount, then
stop
Volume: the product in the Regardless of the shape There may be loss or
package will stop when the of the elements in the excess in volume
product in the box reaches product block
the specified volume
 The nectar products are filled into a glass bottle, so the principle of pouring by volume is
applied because these products are liquid, the volume does not depend on the shape of the
elements in the product mass.

9 Seaming
Table 2.6 Advantages and disadvantages of seaming methods

Method Advantages Disadvantages

Manual Save machine costs, make - Only applicable to
full use of human products with screw
resources caps, containers with
lids, etc.
- Low productivity
Machine - For high productivity. Machine cost
- Packaging is secure

 Mango nectar production uses an automatic seam machine located on the filling line that
will save labor and give high productivity.

10 Pasteurization
Pasteurization is the process of killing or inhibiting the activity of microorganisms and enzymes
in food. The pasteurization mode is based on the pH, the biome presents in the product as well
as the structure of the product.
Pasteurization can be done by different methods. Currently, the most widely used and
convenient method is heating pasteurization. There are several types of heat pasteurization:
- Pasteur is pasteurization at a temperature of 100℃ or less. This method is intended to kill
microorganisms in their growing form and are not thermally stable. This pasteurization method
is often used for products with high acidity such as: fruit juices, concentrated products.
- Tyndallization is pasteurization but done many times. This method is not used much in
production because it has the disadvantage that the heat effect is long, affects the quality of the
product, and requires a lot of time to manipulate, so it is not suitable for the requirements of
industrial production. Industrial pasteurization is pasteurization at temperatures above 100 ℃.
Most food products with high pH are practiced this way.
 Pasteur pasteurization will be applied due to many advantages and the suitability of
nectar products.
11 Flow chart

Mango fruits

Sorting and selection

Weighing

Sugar, Citric acid,

modified starch
Soaking and Cleansing

Weighing
Blanching

Mixing Ascobic acid

Peeling and seed removing

Heating
Crushing Weighing

Sugar syrup Mixing Bottle, Lids

Homogenization and heating Cleaning

Dearation and filling Pasteurization

Pasteurization

Cooling

Storage, labelling, packaging and

inspection
12 Material
13 Mango
14 General information
The main mango variety of Vietnam is Cat Hoa Loc. Cat Hoa Loc mango has been granted a
certificate of trademark registration by the National Office of Intellectual Property (Ministry of
Science and Technology). At the same time, in 2012, Hoa Loc Cooperative organized
production according to GAP, with 20.73 hectares certified to meet Viet GAP standards. Also in
2012, Hoa Loc sand mango was granted a national certificate of geographical indication. By
2014, farmers produce with a higher process and are Global GAP certified. After GAP
certification, this product is exported to markets such as: China, Taiwan, Japan, Korea, Canada,
Russia... and for domestic consumption in Ho Chi Minh City, Ha Noi.
The type of mango selected to produce mango nectar is Cat Hoa Loc mango due to the type of
mango with the best flavor, the most flesh, low fiber, etc., from which good fruit quality and
economic efficiency can be obtained.
15 Quality criteria of mango
The mango variety used must be of good quality, delicious aroma, and have moderate and
uniform ripeness. Mangoes must be intact, not crushed, or damaged. Harvest the mango when
the fruit has just begun to turn light yellow. When the fruit turns yellow, there is a thin layer of
chalk around the fruit, this time ensures that the mango reaches the largest size, high dry matter
content, after that be stored, when reaching uniform technical maturity, put into production.
The quality of the mango must be met the TCVN 9766:2013 for mangoes.
16 Other ingredients
17 Sugar
During the processing process, sugar is added with the purpose of adjusting the taste and
increasing the sensory value of the product, while also serving as a preservative. At high
concentration, sugar molecules bind tightly with water, reducing the a w of the product making it
impossible for microorganisms to grow. In addition, high sugar concentration creates osmotic
pressure which inhibits microbial growth.
Sugar which is used in the production is sucrose. Sucrose is a disaccharide, made up of glucose
and fructose, these two monosaccharides linked together by their -OH glucoside bond, so
saccharides are not reducing.
Regarding the requirements, the sugar species used must create a colorless or light-yellow
solution without strange odors affecting the natural taste of the product and according to the
following sensory and physical and chemical criteria.
Table 2.7 Sensory criteria of sugar (according to TCVN 6958:2001)

Criteria Requirement
Appearance Uniform crystals, relatively even size, dry and not lumpy
Flavor Sugar crystals or a solution of sugar in water have a sweet taste, without
any strange taste.
Color Iridescent white crystals. When mixed with distilled water, the solution is
transparent.
Table 2.8 Physiochemical criteria of sugar (according to TCVN 6958:2001)

Criteria Level
Pol degree, (oZ) ≥99,80
Reducing sugar content, mass % (m/m) ≤0,03
Conductive ash, mass % (m/m) ≤0,03
Weight loss on drying at 105oC for 3h, % mass (m/m) ≤0,05
Color degree, ICUMSA units ≤30
18 Water
The water used in the production process must meet the requirements according to QCVN 01-
1:2018/BYT on the quality of domestic water.
Table 2.9 Water criteria in production

Maximum
Criteria Ingredient Unit
allowable limit
Flavor Tasteless, scentless -
Physical
Turbidity 2 NTU***
criteria
Color 15 TCU****
pH 6,0 – 8,5 -
Hardness mg/l
(Calculated in 300
CaCO3)
Chemical
criteria Aluminum 0,2 mg/l
Amoni 3 mg/l
Asen total 0,01 mg/l
Clorua 250 FCR**
 Florua 1,5 mg/l
Hydro Sulfua 0,05 mg/l
Total Iron 0,3 mg/l
Pb 0,01 mg/l
Mangan total 0,3 mg/l
Total mercury 0,001 mg/l
Nitrate 50 mg/l
Nitrite 3 mg/l
Sodium 200 mg/l
Sunfat 250 mg/l
Zinc 3 mg/l
CFU*/100
Total coliform <3
Microbiological mL
criteria Heat-resistant E. CFU*/100
<1
Coli or Coliform mL
* CFU stands for "Colony Forming Unit".
**FCR stands for “Free Chlorine Residual.”
***NTU stands for “Nephelometric Turbidity Unit.”
****TCU stands for “True Color Unit”.
19 Acid ascorbic E300
Ascorbic acid, also known as vitamin C, is found abundantly in fruits, and is an essential
nutrient for living things. In the field of biochemistry, it is an antioxidant, participates in enzyme
synthesis, and increases resistance.
In fruit juice, adding vitamin C will help limit oxidation and discoloration of the product.
The amount of vitamin C added when mixing should be enough to inhibit the enzymes that
catalyze the reaction. The doses of the additive: ascorbic acid- E300 used to follow the
Vietnamese standard: Thông tư 24/2019/BYT (maximum concentration of ascorbic acid in fresh
fruit is: 500 mg/kg)
 Criteria Level
Content of C6H8O6, % dry matter ≥99,0
Mass loss on drying, % mass ≤0,4
❑
Extremely unique angle, [ α ]
❑ +20,5° to +21,5°
pH (solution 1/50) 2,4 - 2,8
Sulfate ash content, % mass ≤0,1
Pb content, mg/kg ≤2
Table 2.10 Physical and chemical criteria of ascorbic acid (TCVN 11168: 2015)
20 Citric Acid E330
Citric acid is an organic acid which is found in citrus fruits. Acid citric is a natural food
preservative and is often added to foods and beverages to give it a sour taste. It is a colorless,
semi-transparent, crystalline powder, odorless. Citric acid shows activity against some molds
and bacteria. Organic citric acid reduces the pH value of the product, thereby inhibiting the
growth of microorganisms with pH in the neutral or alkaline region.
Function: added in the process of cooking sugar syrup to perform an inverse reaction of sugar,
help increase solubility and increase sweetness, create a balance between acidity and sweetness
or adjust the ratio of sugar/sugar. acids in food. It also has a preservative and antioxidant effect.
The doses of the additive: citric acid - E330 used to follow the Vietnamese standard: Thông tư
24/2019/BYT (maximum concentration of citric acid in nectar juice is: 5000 mg/kg)
Table 2.11 Physical and chemical criteria of citric acid (TCVN 5516:2010)

Criteria Requirement
Very soluble in ethanol, sparingly soluble in
Solubility
water, able in ether
Citrate test Pass the test requirements
- Anhydrous form, % by mass, not more than
The water content 0.5
- Monohydrate form, mass % from 7.5 to 8.8
Sulfate ash content, % mass ≤0,05

Oxalate content, mg/kg ≤100

Substances that are easy to
Pass the test requirements
carbonize
Pb content, mg/kg ≤0,05
21
22 Modified starch (E1422)
Modified starch is a type of starch that has been modified by physical and chemical methods to
enhance or adjust specific properties such as viscosity, gelatinization temperature, etc. compared
with natural starch.
During the production of mango nectar, because the mango juice already has a certain viscosity,
modified starch should be added to the sugar solution to increase the viscosity of the product and
keep the stabilization of the product.
Table 2.12 Physical and chemical criteria of modified starches (TCVN 511471:2016)

Criteria Requirement
Insoluble in freezing water (without pre-
gelatinization), forming typical colloidal
Solubility
solutions in hot water; insoluble in
ethanol.
Sulfur dioxide content
- For modified cereal starch, mg/kg ≤50
- For other modified starches, unless
≤10
specified in Table 2, mg/kg
Pb content, mg/kg ≤2
Addition requirements of purity with
Starch Acetate: Esterification with acetic The content of acetyl groups is ≤2.5%.
anhydride or vinyl acetate
23 Explanation of the technological process
24 Sorting and selection
25 Purpose
Mangoes should be sorted and selected according to ripeness, integrity...to remove damaged and
immature mangoes. The quality criteria of mangoes meet Vietnamese standards TCVN as
mentioned in chapter 1.
- Ripeness: Mangoes need to reach maturity (fully ripe). At this ripeness, the peel is yellow, the
pulp has moderate firmness, soluble solids are the highest, the best color and flavor parameters,
and the content of sugars and acids, pectin is stable.
- Integrity: before processing, it is necessary to eliminate the fruits showing signs of rot,
crushed, partially damaged fruit can be utilized by removing the bruised part, the rest can still be
preserved use. Bruised mango flesh has active enzymes and can degrade the final product even
in the short time prior to entering the thermal break or the sterilizer, where the enzymes are
mostly denatured and deactivated.
26 Procedure

Figure 2.1 Conveyor belt

Fruit materials are put on roller conveyors, workers select by observing and removing
unsatisfactory fruits.

27 Soaking and cleansing

Mangoes are soaked in clean water for 5-10 minutes to remove dirt on the surface and increase
washing efficiency. Soak with the ratio of mangoes: water is 1:1.5-2.0.

28 Purpose
To eliminate impurities, dust, and sand around the raw materials and at the same time reduce a
significant number of microorganisms on the surface of the raw materials. In addition, it also
aims to clean up some harmful chemicals which are left over from the cultivation process such
as fertilizers, pesticides, etc.

29 Requirements
- Changes of raw materials:
+ Mechanical: the surface of the mango is smooth and does not stick to dirt
+ Biochemical: a part of microorganisms on the surface of the fruits is removed
30 Procedure
Use clean water at room temperature to wash, using air blower device
Structure of air blow washer:
1. Inlet trough; 2. Conveyor belts; 3. Air blower tubes; 4. High pressure water jet.
31 Figure 2.2 Air blow washer Blanching
32 Purpose
After cleaning, the fruits are blanched in hot water at 85-90oC for 2-3 minutes to:
- Inhibit, inactivate enzymes (especially oxidizing enzymes) to avoid discoloring materials.
- Soften the fruit tissue; facilitate the peeling and pulping process.
- Kill microorganisms on the peel, especially yeast and mold.
- Remove a part of the intercellular air, especially oxygen to protect the easily oxidized
substances and vitamins.

33 Requirements
- Mechanics: Reduces the firmness of the fruit
- Physical: If blanched for too long, the product will lose color and taste.
- Chemistry: At high temperature, vitamins are decomposed, dry matter content is partially
lost (to minimize this loss of dry matter, adding a small amount of sucrose (0.5 -2%) to
prevent osmosis of the dry matter from the raw material to the solution) ⇒ Volume and
weight are changed.
- Biological: inhibit biochemical processes, deactivated enzymes.

34 Procedure
Put the mangoes through the conveyor blanching machine at a temperature of 90°C within 3
minutes according to the ratio of the blanching water volume to the material is 2:1.
 Figure 2.3 Conveyor blanching machine
Structure: 1. Bucket blanching; 2. Conveyor belts; 3. Steam pipes; 4. Faucet for washing water

35 Peeling and seed removal

After blanching, remove peel and seeds. This process requires to do quickly as possible to limit
microbial contamination from outside.

36 Procedure
Workers use knives to cut, collect the flesh, remove seeds and shells.

37 Requirements
The fruit pulp is not crushed, causing loss of nutrients, and no impurities.
Changes of material:
- Mechanical: a very small amount of nutrients escape.
- Chemistry: the surface of the fruit is easily oxidized.
- Biology: microorganisms have conditions to grow.

38 Crushing
39 Purpose
- Preparation: make the ingredients smaller to prepare for the process of mixing
- Collecting juice containing fruit juice and fine fruit pulp on a sieve in a puree form,
removing parts with no or poor nutritional value from the mass of materials such as fiber...

40 Procedure
Put the ingredients into the scrubber.
Figure 2.4 Mango pulper machine
Structure:
1. Twisting trough for material loading 2. Feed hopper
3. Swim and paddle to transfer materials 4. Wings beat
5. axis of rotation 6. Sieve face
7. Waste door

41 Requirements
Proceed quickly, pure, and uniformly.
Changes of material:
- Physical: the fruit pulp is reduced in size, the cell is broken, causing the cell fluid to escape
from the raw cell; slight increase in temperature due to friction
- Chemistry: There is a lot of contact between the product and the air, so the product is easily
oxidized, changed color, so it is necessary to go through the next stage quickly and add
antioxidants such as vitamin C with a concentration of 0. 1% by weight of fruit pulp.

42 Mixing
The fruit is mixed with sugar syrup and 0.3% citric acid with the ratio of fruit: sugar syrup is
1:1-1.5; The product after mixture has a dry matter content of 15oBx and 0.3% citric acid. In the
sugar solution, additives can be added to increase the viscosity and limit layering of the product
(modified starch 1.5-2%)

43 Preparation of sugar syrup

From a homogeneous mixture of sugar, citric acid, modified starch, and water to create sugar
syrup for mixing.
Procedure: Determine the Brix, acidity of the juice from which to build the amount of acid and
sugar to add. Then put the mixture into sugar syrup using a double-shell pot device.
Concentration: 1.5% modified starch of total weight of the juice
Purpose: + increased stability, good water-holding capacity
+ increase the viscosity

44 Mixing
Purpose: processing to create a specific flavor, adjusting the chemical composition of the
product to create product homogeneity, changing the sensory criteria.
Change:
- Physico-chemical: change the concentration of dry matter, state of raw materials
- Chemistry: change the chemical composition of the mixture, hydrolyze sucrose into fructose
and glucose.
Procedure: Mix sugar syrup and puree by mixing device with mixing tank

Figure 2.5 Double jacketed mixing tank

Requirements: the amount of modified starch is equal to 2% of the total weight of fruit juice;
The ratio of fruit pulp: sugar solution = 30:70, the fruit juice after mixing has a Brix of 15 oBx
and an acidity of 0.3%

45 Homogenization and heating

46 Homogenization
- Purpose: Break down the pulp particles to the required size, the smaller the particle size, the
more stable the juice state, the product has the appropriate consistency, increasing the
dispersion and suspension of the fruit. fruit pulp, increase product homogeneity, minimize
layering and stratification during storage. It also increases taste, smoothness and
digestibility when used.
- Requirements: The product must achieve uniformity, required size, increase digestibility
when ingested and less stratified when storing later.
- Change:
+ Physical: reducing the size of the dispersed phases in the puree to limit phase separation
during storage, the puree becomes homogeneous.
+ Physico-chemical: increases the contact surface area between the two dispersed and
continuous phases, causing temperature and oxygen to darken reactions, thickening additives
to expand the dispersed particles are evenly distributed in suspension.
- Procedure: Using homogenizer

1. Main drive motor

2. V-belt transmission
3. Pressure indication
4. Crankcase
5. Piston
6. Piston seal cartridge
[Link] stainless steel pump
block
8. Homogenizing valve
assembly

Figure 2.6 The homogenizer is a large high-

pressure pump with a homogenizing device

47 Heating
- Purpose: To reduce the time of pasteurization, deaeration, destroy a part of
microorganisms, and stabilizing the juice.
- Procedure: The homogenized juice mixture is heated to 80- 90 oC and hot poured into the
bottle.

48 Deaeration
The extra air makes the product much more susceptible to oxidation, which leads to browning
and increased acidity. To prevent oxidation, air can be removed in a deaeration chamber or by
heat.
Procedure: using a vacuum degassing device
Specifications:
- Vacuum pressure 700mmHg
- Maximum flow 10m3

49 Filling
After deaeration mixture of mango juice are filled to the clean jars to get volume of juice and
closed the lids before taking to the pasteurization.
- Procedure: using automatic bottle hot filling and capping equipment

50 Pasteurization
- Purpose:
+ The goal of pasteurization is to bring the microbial load down to a level that will not
induce damaging bacterial or fungus growth in the product at any point in its future life.
+ Sterilize according to the formula 12 − 15 – 12 in 90 oC. The purpose of the pasteurization
process is to destroy or inhibit the maximum microbial activity to prolong the storage time.
- Requirements: Both ensure the destruction of the remaining harmful microorganisms, which
are so small that they cannot grow to cause damage and do not harm the health of consumers,
and at the same time ensure the quality of canned goods. good in sensory and nutritional
value.

at 90𝑜𝐶 then refrigerate for 20 minutes.

- Procedure: using a conveyor belt sterilizer, pasteurization mode 12-15-12 within 15 minutes

51 Cooling
After pasteurization, the bottle is taken out, cooled with water to room temperature, then drying.

52 Inspection
After the product is cooled, it is kept for 7-10 days in 25-30 oC. To detect and remove spoilage
products due to residual microbial activity in the form of spores. Products are checked to remove
unsatisfactory boxes, such as bulging boxes, open eyelids, etc.

53 Storage
After cooling, the product is stored to detect and remove defective and damaged products. The
product is stored in the refrigerator.
 CHƯƠNG 3: CÂN BẰNG VẬT CHẤT

3.1 Kế hoạch sản xuất

Để chủ động trong sản xuất cần phải lập kế hoạch sản xuất thông qua biểu đồ nhập
nguyên liệu và biểu đồ sản xuất.

Sản phẩm nectar xoài được đóng chai thủy tinh 350ml.

3.1.1 Biểu đồ thu nhận nguyên liệu

Căn cứ vào thời vụ thu hoạch của xoài ta lập được biểu đồ cho kế hoạch thu mua nguyên
liệu để sản xuất như sau:
Bảng 3.1 Biểu đồ thu hoạch nguyên liệu

Thán 1 2 3 4 5 6 7 8 9 10 11 12
g

Xoài - + + + + + + + + - - -

(Xoài được thu hoạch từ tháng 2 đến tháng 5 ở miền Nam; từ tháng 5 đến tháng 9 ở miền
Bắc.)
3.1.2 Biểu đồ sản xuất của phân xưởng.

Dựa vào bảng thu nhập nguyên liệu của phân xưởng và số lượng nguyên liệu nhập vào, ta
có thể lập ra kế hoạch làm việc trong 1 tháng, số ca làm việc trong một ngày. Mỗi ngày
làm việc 2 ca, mỗi ca làm 8 tiếng, ngày chủ nhật và ngày lễ được nghỉ.

Bảng 3.2 Biểu đồ sản xuất của phân xưởng

Tháng 1 2 3 4 5 6 7 8 9 10 11 12 Cả
nă
m

Số ngày làm việc - 25 27 26 26 26 27 27 27 - - - 211

Số ca làm việc - 50 54 52 52 52 54 54 54 - - - 422

3.1.3 Kế hoạch phân bố sản lượng hàng tháng

Dựa vào yêu cầu: sản xuất nectar xoài năng suất 30 tấn sản phẩm/ngày, (mỗi ca làm
việc trong 8 giờ => 3,75 tấn sản phẩm/giờ) dựa vào kế hoạch sản xuất ta lập được biểu đồ
phân bố sản lượng như sau:

Bảng 3.3 Biểu đồ phân bố sản lượng

Tháng 1 2 3 4 5 6 7 8 9 10-12 Cả năm

Sản
lượng
_ 330 470 580 560 660 680 600 340 _ 4220
(tấn)

3.2 Cân bằng vật chất cho phân xưởng sản xuất nectar xoài

Năng suất của dây truyền: 30 tấn sản phẩm/ngày

 Dựa vào việc cân, đo phân tích từng công đoạn trong sản xuất, qua thực tế thí nghiệm
và tra cứu số liệu ta lập được bảng tiêu hao nguyên liệu qua các công đoạn:
Bảng 3.4 Tỷ lệ tiêu hao nguyên liệu qua các công đoạn

Lượng nguyên liệu chính, phụ cần thiết để sản xuất một tấn sản phẩm được tính theo

STT Công đoạn Hao hụt (%)

1 Lựa chọn, phân loại 3

2 Rửa 0,5

3 Chần 1

4 Tách thịt quả, bỏ hạt 28

5 Chà 5

6 Phối chế, gia nhiệt 1

7 Đồng hóa 1

8 Bài khí 0,5

9 Rót chai 0,5

10 Thanh trùng 1

11 Bảo ôn 0,5

công thức:

𝑛
𝑆 𝑥 100
𝑇 = 100−𝑋 100−𝑋 ...(100−𝑋 )
𝑛
( )( )
1 2
Trong đó:
- T: là lượng nguyên liệu cần để sản xuất 1 tấn sản phẩm.
- S: là lượng nguyên liệu có trong 1 tấn sản phẩm.
 - X1, X2, … X3 là hao phí nguyên liệu ở các công đoạn 1, 2, 3, … n được tính bằng
phần trăm của lượng nguyên liệu hao phí so với lượng nguyên liệu đưa vào công
đoạn đó.
- n: số công đoạn tiêu hao
3.2.1. Tính lượng nguyên liệu cho vào 1 tấn sản phẩm

Ta có: Tỉ lệ phối trộn giữa puree xoài và dịch syrup là 30:70

Trong 1000 kg sản phẩm có chứa 300 kg puree xoài và 700 kg dịch syrup

Vậy lượng nguyên liệu cần để sản xuất 1 tấn sản phẩm là:

𝑇 =
11
300*100
= 480,242 (kg/tấn)
4 4
(100−3)* (100−28)* (100−0,5) * (100−1) *(100−5)
⇨ - Lượng nguyên liệu cần cho sản xuất trong một ngày(30 tấn sản phẩm) là:
30.480,242 = 14407.26 (kg/ngày)
- Lượng nguyên liệu cần cho sản xuất trong một giờ là: 14407.26 /8 = 1800,9075(kg/h)
- Lượng nguyên liệu cần cho sản xuất trong một năm là:
211. 1800,9075 = 379991.4825(kg) = 37999,14 (tấn)
3.2.2. Tính lượng nguyên liệu phụ cần để sản xuất ra 1 tấn sản phẩm.
Bảng 3.5 Tổn thất dịch qua các công đoạn
Công đoạn sản xuất Tổn thất (%)

Dịch đường 0
Phối trộn, gia nhiệt 1,0
Đồng hóa 1,0
Bài khí 0,5
Rót chai 0,5
Thanh trùng 1,0
Bảo ôn 0,5
Sản phẩm 0
Trong 1 tấn sản phẩm có 700 kg dịch nên lượng dịch đường cần cho 1 tấn sản phẩm là:

700 𝑥 100
6

(100−0,5) 𝑥 (100−1,0)
T= = 732,358 (kg/tấn)
3 3
Mặt khác, trong quy trình tạo siro, nguyên liệu dịch đầu vào lại có những tiêu hao:

Bảng 3.6 Tổn thất nguyên liệu dịch đầu vào qua các công đoạn:

Công đoạn sản xuất Tổn thất (%)

Nguyên liệu dịch 0

Cân 0,1
Phối trộn 0,5
Gia nhiệt 0,5
Lọc 0,5
Dịch đường 0

Vậy lượng nguyên liệu dịch ban đầu cần cho 1 tấn sản phẩm là:

4
732,358 𝑥 100

(100−0,5) 𝑥 (100−0,1)
Tđ = = 744,198 (kg/tấn)
3

● Tính nguyên liệu đường:

Yêu cầu thành phẩm : Độ Brix là: 13%
Nguyên liệu có: Độ Brix là: 16 %
Phương trình cân bằng tổng chất khô cho 1 tấn sản phẩm:
300 . 16% + 700 . x % = 1000 .13%
⇨ Độ Brix của đường : x = 11,714 %
Lượng nguyên liệu đường cần dùng cho 1 tấn sản phẩm là:
744,198 .11,714/100 = 87,18 (kg)
Lượng nguyên liệu đường cần dùng cho 1 ngày sản xuất là:
87,18.30 = 2615.4 (kg/ca)
Lượng nguyên liệu đường cần dùng cho 1 năm sản xuất là:
2615,4.211 = 551849,4 (kg/năm) = 551,8494(tấn/năm)
 ● Tính lượng acid citric có trong syrup đường

Ta có phương trình cân bằng nồng độ acid cho 1 tấn sản phẩm:

300.0,3% + 700.y% = 1000.0,25%

Trong đó: nồng độ acid của puree xoài: 0,3 %

nồng độ acid (acid citric) có trong dung dịch syrup đường: y %

nồng độ acid của sản phẩm nectar xoài: 0,25%

⇨ Vậy nồng độ acid của dung dịch syrup đường là: y = 0,23%

Lượng acid citric chứa trong dịch syrup cho 1 tấn sản phẩm là:

744,198.0,23/100 = 1,71(kg)

Do acid citric được thêm vào ở công đoạn gia nhiệt □ có tiêu hao:

+ Cân: 0,1%

+ Phối trộn: 0,5%

+ Gia nhiệt : 0,5%

+ Lọc: 0,5%

Lượng acid cần sử dụng cho 1 tấn sản phẩm là:

𝑇 =
𝑎
1,71 × 100
4
= 1, 738 (𝑘𝑔/𝑡ấ𝑛)
3
(100−0,5) ×(100−0,1)

=> Lượng acid citric cần dùng cho một ca sản xuất là: 30.1,738 = 52.14 kg/ngày
Lượng acid citric cần dùng cho 1 năm sản xuất là: 52,14 . 211 = 11001,54 (kg/năm)
● Tính lượng acid ascorbic:
Lượng xoài đi vào trong giai đoạn chà cho 1 tấn sản phẩm là :

480,242 𝑥(100−3)𝑥 (100−0,5)𝑥 (100−1)𝑥(100−28)

T= = 330,387(kg/tấn)
1004
Lượng vitamin C bổ sung vào giai đoạn chà là 50 mg% và có độ tinh khiết trung bình
khoảng 99,7%.
Vậy lượng nguyên liệu vitamin C cần dùng cho 1 tấn sản phẩm bổ sung trong giai đoạn
chà:

330,387. 0,05/99,7 = 0,166 ( Kg/tấn).

Lượng nguyên liệu vitamin C cần dùng cho 1h sản xuất:

0,166 x 10/8 = 0,2017 ( Kg/h).

Lượng nguyên liệu vitamin C cần dùng cho 1 ca sản xuất:

0,166 x 10 = 1,66 ( Kg/ca).

Lượng nguyên liệu vitamin C cần dùng cho 1 năm sản xuất:

1,66.422 = 700,52 (Kg/năm).

3.3. Tính tiêu hao qua từng công đoạn sản xuất.

Bảng 3.7 Khối lượng bán thành phẩm vào tại các công đoạn

Tổn thất Lượng Lượng

Lượng bán Lượng bán bán thành bán thành
(%)
Công thành phẩm thành phẩm phẩm phẩm
STT đoạn (kg/ tấn) (kg/h) (kg/ca) (tấn/năm)

Nguyên 0
1 liệu 480,242 600,3 4802,42 2026,62
 Lựa 3
chọn,
2 phân loại 465,835 582,291 4658,35 1965,83
3 Rửa 0,5 463,506 579,38 4635,06 1955,99

4 Chần 1 458,871 573,586 4588,71 1936,43

Tách thịt 28
5 quả 330,387 421,98 3303,87 1394,23

6 Chà 5 313,867 392,13 3138,67 1324,52

1 310,729 +
725,034 =

7 Phối trộn 1035,763 1294,704 10357,63 4370,94

8 Đồng hóa 1 1025,406 1281,76 10254,06 4327,23

9 Bài khí 0,5 1020,279 1275,35 10202,79 4305,59

10 Rót chai 0,5 1015,177 1268,97 10151,77 4284,06

Thanh 1
11 trùng 1005,026 1256,28 10050,26 4241,22

12 Bảo ôn 0,5 1000,0005 1250 10000,005 4220,02

0
13 Sản phẩm 1000,0005 1250 10000,005 4220,02
 Bảng 3.8 Tính toán các nguyên liệu trong sản xuất:

STT Nguyên 1 tấn sản phẩm 1 giờ 1 ca 1 năm

liệu
(kg/tấn) (kg/h) (kg/ca) (tấn/năm)

1 Xoài 480,242 600,3 4802,42 2026,62

3 Đường 86,18 108,97 871,8 367,8996

4 Acid
citric 1,738 2,17 17,38 7,3

5 Acid
ascorbic 0,166 0,2071 1,66 0,7

Tính số chai:

Sản phẩm được đựng trong chai có dung tích 350 ml, khối lượng tịnh 330 gam
Số chai cần cho 1 ca sản xuất : 10000/0,33 = 30304 (chai/ca)
Số chai trong thực tế luôn lớn hơn 5% so với số chai cần sản xuất.
Do đó số chai cho 1 ca sản xuất là:
30304+ 30304. 5/100 = 31820 (chai/năm).
Số chai cho 1 năm sản xuất là:
31820.422 = 13428040 (chai)
Tính số thùng:

Mỗi thùng đóng 30 chai nước quả nên:

Số thùng cần cho 1 ca sản
xuất: 30304:30 = 1011
(thùng).
Số thùng cần cho 1 năm
sản xuất: 1011.422 =
426277 (thùng).