1. Reconstituted Juice Dilution Line can also be called the juice repacking line, it uses fruit and vegetable concentrated juice or puree as raw material, blended with water, sugar and other flavor agents to make it into drinkable juice.
2. The capacity of the juice processing line can be 500LPH-10000LPH, and the end products can be filled into small bottles, pouches, tin cans or cartons according to client requirements.
3. The ingredients that can be added to the juice is milk, sugar, coffee powder, Flavors and fragrances, fruit and vegetable compound juice, vitamin, mineral matters, herb plants, emulsifier, sour agent, etc.
4. The blended juice usually adopts primary plate or tubular pasteurizing + hot filling + secondary tunnel hot water spray pasteurization technology to extend the juice’s shelf life.
5. All the processing machines are made of food-grade SUS304 material and CIP capable, which ensures the production of premium juice.
6. The auxiliary equipment for the processing line is RO water generating system(for diluting the concentrated juice and dissolving solid powder), CIP system(for cleaning the tanks, pipelines and filling machine), steam boiler(providing hot water to the dissolving tank, blending tank and sterilizer).
7. The reconstituted juice production process involves taking concentrated juice and blending it with water, sugar, preservatives, and natural or artificial flavors, pasteurizing, homogenizing and degassing the mixture to kill bacteria and extend shelf life, filling into containers in a sterile environment, and finally, labeling and packaging the product.

The reconstituted juice dilution line also called small package juice processing line, juice repacking line. It uses concentrated fruit puree or fruit juice powder(apple, mango, citrus, pineapple, guava etc.) as raw materials. Production starts with blending puree and/or concentrates and adding water while heating in a blending tank, then other ingredients and aromas sugar powder is dissolved in high shear emulsification tank. At last all the materials and ingredients will be blended together in a mixing tank for about 30 minutes. Then well-mixed juice will be homogenizing and degassing and sterilizing, finally, it will be filled into small packages like bottles, pouches or cartons. The whole production line includes sugar powder dissolving system, juice mixing system, homogenizing degassing and sterilizing system, filling and packing system, CIP cleaning system.

100% NFC juice drinks: Use non-concentrated fruit puree or fresh fruit as raw materials, can be produced with or without the addition of sugar and water. Fruit content is 100% or less.

Mixed Juice drinks: Use single fruit or mixed fruit juice concentrates/juice powder as raw materials, then blend with water other ingredients and obtained the mixed fruit juice drinks. This type of juice drinks are clear and without pulp, fruit content is above 10%.

Fruit Nectar drinks: contain fruit pulp, the fruit content 30%-50% with high acidity and less juice like mango nectar. This type of drink does not contain any colorings or preservatives.

Fruit flavor drinks: Using pure water as the main material, add about 5% fruit content and mix with flavoring and sweeteners.

The hot water treatment system is composed of one plate heat exchanger, one hot water tank, one water pump and a steam valve group. The main function is heating pure RO water to 80-90℃ and supplying the hot water to sugar/powder dissolving tank and blending tank for ingredients dissolving and blending. The whole system is made of SUS304 material, and the heating method can be steam or electricity.

The blending tank is also called a mixing tank, it is suitable for all kinds of fruit juice mixing, it can be designed one layer mixing, double-layer insulation mixing tank or triple-layer heating mixing tank according to clients’ customized technological requirements for hot or cold mixing.

In the blending tank, the concentrated juice/pulp, dissolved powder agents and RO pure water will be fully mixed to fix the final volume of the end products. Also the flavor of the end products is also formed at this stage.

The standard configuration of the blending tank: Liquid material inlet and outlet, airtight side manhole, anti butterfly and air vent, thermometer, temperature sensor, agitator(paddle, anchor, propeller, frame type), sample valve and CIP cleaning ball.  The whole tank uses SUS304/316L material.

Juice manufacturers can dilute and dissolve the hard-to-melt solids powder or liquids in a high-shear dissolving tank according to the ingredient list. The high-shear dissolving tank can dissolve sour agents, sugar, sweeteners, emulsifiers, milk powders, starch, stability agent, colloids, and some other solid or high-viscosity liquid ingredients with high speed. The stirring speed is 1450-2900rpm adjusted. It divides into the bottom shear and top shear types.

When there are large quantity of solids or powder products that needs to dissolve, usually above 3-5 tons per hour, the high-speed water powder mixer is used thanks to its high efficiency.

The blended juice will be heated to 50℃ for the homogenizing, the homogenizer can miniaturize the particles in the juice, inhibit the precipitation of the juice beverage, and enhance the stabilizing effect. After homogenizing, use hot water to heat the juice to 95-98℃ holding for 15-60S for pasteurizing, then the pasteurized juice will be sent to degassing tank for air removal. Plate type or tubular type sterilizer is adopted to process juice according to viscosity value. Usually fruit nectar juice or pulp juice will use tubular type sterilizer and clear fruit juice drinks will use plate sterilizer.

When for hot filling juice, the juice can be pasteurized. Pasteurization is low-temperature sterilization, the temperature is lower than 100 ℃, and the pasteurization time lasts from a few minutes to tens of minutes. This method can kill pathogenic bacteria, but non-pathogenic bacteria such as heat-resistant bacillus cannot be killed under pasteurization conditions (heat-resistant bacillus can be killed by 121-126℃/15min) . However, when sterilizing fruit juice, because the acidity of fruit juice is relatively high (pH value below 3.8), under this condition, the acidity can inhibit the growth of Bacillus, so when sterilizing acid juice, even if it is pasteurized below 100 ℃, steady shelf life is still available for products that are filled and sealed into containers.

According to different filling technological processes, the sterilizing temperature is also different. if hot filling, then lower temperature pasteurizer will be OK; but if for aseptic filling, then it needs UHT sterilizer.

After the juice is pasteurized or sterilized, the juice drinks should fill into containers immediately to avoid the air come into juice. The most popular package for blended juice drinks is PET or glass bottles, some juice processing plants also fill into pouches or tin cans, it depends on the local market consumer consumption habits. No matter what kind of packaging is used, the filling method is hot filling at 89℃. After the filling is completed, the container should be transported to the next station immediately for sealing, to ensure there is no air in the juice container, the vacuum sealing method or injecting liquid nitrogen into the container after the filling is used.

Some manufacturers also have the demand to fill the reconstituted juice into the carton box. When using this type of package, the juice needs to be UHT sterilized and then filled into the aseptic cartons box aseptically and no need for further sterilizing/pasteurizing process after filling.

Because the pasteurization before filling only kills the pathogenic bacteria, and during the hot filling process, air may be mixed in, which will cause the bacteria to multiply again. Therefore, after the filling is completed, we need to carry out secondary sterilization on the packaged juice. This pasteurizing process is using 95-98℃ hot water to spray on the surface of the bottles or put the pouches into hot water for 20-30 min, then cool down to room temperature for date coding and packing. There are two pasteurizers that can be used, for the bottles and tin cans, we use spray-type pasteurizing cooling tunnel, and for the pouches, we use the water bath-type pasteurizer cooling tunnel.

A Clean-in-Place (CIP) system is an essential component of a juice production line to ensure proper cleaning and sanitization of equipment. CIP systems are designed to automate the cleaning process, it can significantly save time and labor while maintaining hygiene standards.

CIP system is used for cleaning all the tanks and pipelines and filling machines in the juice dilution line.  The tank number and cleaning pressure routes will depend on the capacity of the juice production lines.  Basically, single to five-loop cleaning pressure lines can be chosen. The tank number is also from 3 tanks to 5 tanks available(alkali tank, acid tank, hot water tank, clean water tank, water recovery tank).

Use RO equipment to remove the bacteria in water and soft the water, RO water treatment system is the core equipment, because in blending juice processing line, the proportion of pure water accounts for more than 50%，Therefore, the quality of water directly affects the quality and taste of the final packing juice.