Coconut Water Processing Introduction

The coconut water is extracted from tender coconut fruits and coconut water is fat-free and rich in vitamins and minerals, it is an ideal electrolyte drink for the human body to replenish water.

The coconut water can be produced into the pure coconut water, sparking coconut water, coconut beverage, concentrated coconut water according to the client’s requirements. We offer a flexible option for coconut water processing projects.

The coconut water production process involves selecting and harvesting young green coconuts, drilling a hole to extract the clear liquid, filtering and cooling the coconut water, fat separating coconut water, adding preservatives and flavored agent(if desired), sterilizing, coconut water and CO2 mixer(for sparking coconut water production), bottling or canning the product in a sterile environment, and finally, labeling and distributing it to retailers for consumption as a refreshing and hydrating beverage.

The coconut water can be packed into metal cans, PET/glass bottles, Tetra Pak aseptic cartons, and aseptic bags, and the capacity of the coconut water processing plant is from 500L/H to 10000L/H available for clients to choose from.

Coconut water is a fragile product, so when it is extracted from coconuts, it needs to be cooled down to 4℃ or pasteurized instantly and stored in fully closed stainless steel tanks to prevent liquid oxidation and deterioration.

The coconut water processing machine is made of SUS304 material and the whole system will equip the CIP system to keep all the processing machines in hygienic condition.

Coconut water is extracted from tender or mature fresh coconuts, and for high-quality RTD coconut water, the best is to choose young tender coconuts. There are two methods for extracting coconut water.

The first method is that one sharp stainless steel drill is fixed on the platform, and under the platform, there is one coconut water receiving vat. Coconut water is obtained by drilling a hole near one of the three eyes of the coconuts where the coconut shell and meat is the thinnest. It is designed to minimize contamination and streamline handling.

The second method is cutting half of the fresh coconuts, and then coconut water is collected in the tank. This system is composed of one coconut elevator, coconut holding and cutting machinery and coconut water collecting tank. The fresh coconut is lifted by the elevator to the coconut holding and cutting device, where the sharp knives are installed, once the device detects the coconuts, it will cut the coconuts into halves and the coconut water will be collected after the cracking and cutting of the coconuts. This method has less hygiene condition than the first method but the labor intensity is lower.

When cracking the coconut to obtain the coconut water, some coconut fiber or coconut meat will be mixed and collected with coconut water, so we need to use one filter to remove the excess coarse solids. There are many machines that can be used for filtering coconut water.

The most common machine used is the sieve screen filter, the coconut water will go through the 100-150mesh sieve, the solids that more than 100-200μm will Intercept on the sieve and the water will go through the sieve and is collected into the sanitary tank. The sieve screen can be integrated into the production line to ensure production continuity.

The plate and frame filter can also be used for filtering the coconut water. The coconut water is pumped into the plate and frame filter, through the filter cloth the solids will be held and the pure coconut water can be collected. The filter cloth filter precision can be customized according to client’s requirements.

We can also equip the disk/stack centrifuge separator to separate the solids and fats in coconut water. Some manufacturers want to produce zero-fat coconut water, in this case, the three-phase disk separator will be used.

After the coconut water is filtered, it needs to be pasteurized or cooled down instantly. Whether the coconut water needs to be cooled or pasteurized depends on the processing capacity.

If for the small capacity, when the coconut water is collected and can be sterilized and packed in 5-8 hours, then the coconut water can be cooled to 4℃and stored in batch tanks. We can either use the plate cooler to quickly cool down the water or use the jacketed tank feeding chill water to cool down the coconut water in the tanks.

If the coconut water needs to be stored in tanks for more than 12 hours or one day for subsequent processing and packing, then the prepasteurization is preferred to use, the main purpose is to inactivate the enzymes in coconut water and avoid the oxidation. The plate pasteurizer is for the heat treatment of coconut water and after pasteurization, the coconut water will be cooled down to 4-10℃ and kept in the insulation tanks.

To make the coconut water has the same flavoring and nutrient, the standardizing tank is a must process. In standardizing tank, you can add the ingredients and flavor agents to make the water the same. The tank is equipped with an agitator to mix fully and evenly of the products, a manhole to feed the ingredients, and a sample valve to check the product’s quality consistency.

As fragile products, sterilizing or pasteurizing process of coconut water is vital in coconut water processing plants. There are many sterilizers that can be used for sterilizing coconut water.

The most common equipment will be the UHT sterilizer, which is divided into indirect heating and direct heating(DSI). The UHT sterilizer is connected with an aseptic brick carton filler or an aseptic bottle filler to produce the aseptic pure coconut water products. This kind of sterilizing and filling system is for producing high-quality products and is aimed at the high-end market due to the less heating time.

The second method is in-container pasteurizing. The coconut water will be hot-filled into bottles or aluminum cans, then the package will be transported to the spray pasteurizing tunnel or retort sterilizer for in-container heat treatment. This kind of filling and packing method is suitable for producing coconut water beverages, which will include additives and water in products, it is for low-end market products.

The third is HPP treatment. The coconut water will be standardized, and then filled into plastic bottles at room temperature, and then the bottled coconut water will be fed into HPP system for high-pressure pasteurization. This method is suitable for small-scale coconut water processing plants and aimed at very high-end market consumers due to no heat treatment during the whole process.