Calamansi Fruit Juice

Step 1 (Harvesting of Calamansi Fruits)

The major ingredient that used in production is the Calamansi. The
Company will get the supply of Calamansi for the production of juice in the
farm that owned also by the company. The First step is to harvest the
needed Calamansi Fruits from the farm as one of the main ingredients for
the production of Calamansi juice.

Step 2 (Deliver to the Production Area)

The 2nd step is to deliver the harvested Calamansi fruits to the production
site, to use for the production.

Step 3 (Sorting and Washing)

The 3rd step for production is washing the Calamansi fruit on the double
sink stainless steel movable. Then after washing, remove the water so that
the Calamansi will dry, after that sort or organize and the Calamansi fruit to
the plastic crates.

Step 4 (Extracting and Filtering)

The 4th step for the production of Calamansi juice is to put the Calamansi
fruit in the extracting and filtering machine which is the Hydraulic Press and
put the Calamansi extract in the Stainless Steel Bucket.

Step 5 (Mixing)
The 5th step is to put all of the ingredients such as, Calamansi extract,
Sugar, and Water in the steam and mixing machine which is the Steam and
Mixing Kettle.

Step 6 (Pasteurizing)
Heating the juice to a high temperature then swiftly cooling it before
bottling, it enabled the juice to remain fresher for an extended period of
time. This process slows spoilage caused by microbial growth.
Pasteurization is not intended to kill all micro-organisms in the food.
Instead, it aims to reduce the number of viable pathogens so they are
unlikely to cause disease (assuming the pasteurized product is stored as
indicated and is consumed before its expiration date).

Step 7 (Filling)
In this step the worker will transfer the concentrated juice to the filling and
sealing machine. Then after transferring, the worker will place the bottle to
the machine to be filled and sealed automatically.

Step 8 (Packaging)
The final process is to label the finish product by the worker that includes
the Name of the Product, Tag Line, Ingredients, Nutritional Facts,
Manufacturing Company, and the Manufacturing and Expiration Date.
Lastly after labeling the worker will put the finish product in the box and
sealed it, and then the juice gets stored in cold storage facilities. So that it
will be ready for delivery
The technology that will be use in production, the CC Company will adopt a
commonly used processing technology in processing Calamansi like
Hydraulic Press, Mixing Kettle Machine and Filling/Sealing Machine.
For the fruit processing, a hydraulic press type, all stainless steel parts in
contact with the juice with maximum of 5 kgs capacity per load powered by
2 horse power motor, 3 phase, 220 volts, variable operating pressure juice
extractor will be used. This machine is available through the Industrial
Technology Development Institute Food Processing Division of the
Department of Science and Technology.
A Mixing Kettle Machine design and manufacture stainless steel cooking
kettles from 250L to 2000L capacity. Our food equipment, beverage
equipment and cooking kettles are primarily used for cooking and cooling
for Calamansi Juice.
Filling/Sealing Machine. This machine is a turning plastic bottle infusion
filling & sealing equipment. It can be suitable for 100ml, 250ml, 500ml
various sizes plastic bottle infusion producing. It can automatically finish
procedures such as infusion bottle filling, bottle feeding, cap sealing, etc.

https://citruscalamansicom.wordpress.com/2014/10/27/8-steps-in-the-
production-process-of-calamansi-juice/

Calamansi Production Guide

Prized for its fruit and ornamental value, the calamansi
(Citrofortunellamicrocarpa) is one of the most important citrus species in
the Philippines. Its potential lies in its varied uses. Once familiarity of the
fruit is established in other countries, the scope for increasing export and
production is large.

Description
The calamansi tree is evergreen and small, attaining a height of 2-7.5 m at
maturity. Its broadly egg-shaped leaves are dark green above and pale
green below. The small, white fragment flowers are grouped in clusters.
The calamansi fruit is round, with greenish yellow to orange skin which can
be easily peeled. There are six to ten segments in a fruit with an orange
colored, very acidic juice and each fruit has 4-11 seeds.
Variety
The calamansi seed produces plants which originate mainly from the
mother tissues giving rise to seedlings which have the same characteristics
as the mother tree. For this reason, the calamansi trees in the country are
believed to belong to only one variety.
Uses
Due to its varied uses, the calamansi is grown on a large-scale in the
country. The fruit is commercially processed into bottled concentrate, as a
ready-to-drink juice in tetra packs, and as a marmalade. The juice is also
very popular as a flavor enhancer for native dishes. As a cleanser and
hygienic substance, it can be a stain remover, body deodorant, skin bleach,
and hair shampoo.
Calamansi can be used for medicinal purposes. Rubbing the juice on insect
bites eliminates itching and irritation. It is taken orally as cough remedy, as
a laxative to loosen the bowels, and is combined with pepper to expel
phlegm. The roots are used for treatment at childbirth and leaves to cure
gas pains. Calamansi is also popular as a potted ornamental plant.

Soil and Climatic Requirements

The calamansi thrives in warm to cool climates with an evenly distributed
rainfall of 1,500-2,000 mm/year. It is generally grown in the lowlands.
Calamansi can grow over a wide range of soil types from clay loam to
limestone to sand. However, it grows best in a slightly acidic, well-drained
sandy or clay loam soil rich in organic matter.
Cultural Management
Propagation. The calamansi may be propagated by seed. However, for
large scale multiplication of superior trees, propagation by shield budding
using calamandrin as rootstock is practiced. Other methods of propagating
calamansi are by stem cuttings,marcotting, anf grafting.
Planting/Transplanting. Sow seeds in a seedbed, 1-2 cm apart at a depth
of 1cm. transplant to individual containers after four to five months when
seedlings are 10-15 cm tall. Field planting should be done during the rainy
season. Set the plants at a spacing of 4-6 m apart.
Irrigation. Irrigate during the first dry season after which the trees may
depend entirely on rain for their water requirement. If early of-season
flowering is desired, heavily water the trees one to two months before
normal flowering time. Commercial orchards may employ a drip irrigation
system.
Fertilization. During the first year, apply urea at 50-100 g/tree and 200-300
g/ tree during the second year. In the third year when the tree starts
bearing fruit commercially, apply 350-400 g complete fertilizer/tree.
Correspondingly increase the amount as the tree gets older. Evenly
distribute the fertilizer in two applications, one at the onset of the rainy
season and another towards the end of the rainy season.
Pruning. Remove diseased, dead interlacing branches.
Pest and diseases. The common pest of calamansi is the fruit fly. The
most serious disease is leaf mottling which is transmitted by the insect
carrier, Diaphorinacitri better known as citrus psylla or jumping plant lice.
As a preventive measure, use certified disease-free planting materials and
spray trees regularly with an insecticide. Totally remove and burn infected
trees.
Harvesting and Post harvest Handling
A three-year-old tree produces. 75 kg fruit; at six years, 10 kg; and at ten
years, 50 kg. on the average, calamansi produces 20 t of fruit/ha per year.

Though fruits are available throughout the year, the peak season is from
August – October.

Harvest fruits by hand or by clipping with shears.

Pack calamansi fruit in kaings or bamboo baskets lined with banana leaf
sheaths or newspaper.

The fruit will keep in good condition for two to three weeks at 8?-10C and
90% relative humidity.

Reference: Philippine Council for Agriculture, Forestry and Natural

Resources Research and Development (PCARRD)

How To Make Calamansi Juice Concentrate

Calamansi is commonly used as a condiment for dishes. However, it can

also be used in making calamansi juice concentrate which prefers by
most parents in preparing nutritious juice drink for their family. Like other
citrus fruits, the calamansi is high in vitamin C.
Calamansi Concentrate Ingredients:
70 pcs. calamansi (medium size)
Sugar (if desired)
“Sodium benzoate”
Utensils:
Kitchen knife, Mixing bowl, Cheesecloth, Casserole for cooking,
Spoon, Cooking stove, Bottles (8 oz.), Measuring spoon, Measuring cups,
Chopping board, Strainer
Procedure:
1. Carefully wash the fruits with water.
2. Cut crosswise and squeeze the juice through a cheesecloth.
3. Add sugar if necessary. The amount of sugar added is according to
taste.
4. For every 4 1/2 cups of calamansi juice, and 1/4-1/3 tsp. sodium
benzoate dissolved in water.
5. Heat the mixture up to 75oC or until the mixture is about to boil. Continue
to maintain at this temperature for about 5 minutes while stirring constantly.
6. Transfer while hot to sterile bottles. Cover the bottles.
7. Boil for 20 minutes. Close tightly and let cool in an inverted position.
8. Wipe dry and store in a cool place.
Source: Food and Nutrition Research Institute (DOST)

Fruit Juice Processing and Equipment

All the processes for fruit juice products require that the juice or pulp is first
extracted from the fruit. The following are the manufacturing stages:

Juice Extraction
In the case of citrus, this is easily done with a hand presser or a revolving
citrus ‘rose’, Figure 1. Other fruits such as mango, guava, soursop, etc
require pulping – that is, after peeling and stone removal, the flesh of the
fruit is pushed through a perforated metal plate.

For this process, there is a range of equipment available from the small
‘Mouli Legume’ and several versions of handpowered pulper/sieves, all of
which force the fruit pulp down through interchangeable metal strainers,
Figures 2 and 3.

At slightly higher production levels, it is necessary to use a power source,

and the multi-purpose Kenwood Chef food mixer, is strongly
recommended. This has a pulping attachment rather similar to the Mouli
Legume and in addition can be used for liquidizing etc.

For large-scale production, an industrial pulper-sieving machine is

necessary. This also acts by forcing the fruit pulp through a fine cylindrical
mesh. These cost, however, is quite expensive.
Preparation

When the juice or pulp has been collected, it is necessary to prepare the
batch according to the chosen recipe. This is very much a matter of choice
and judgement, and must be done carefully to suit local tastes. Juices are
sold either pure or sweetened. Fruit squashes would normally contain
about 25% fruit material mixed with a sugar syrup to give a final sugar
concentration of about 40%. These are diluted with water prior to use and
as the bottle is opened, partly used and then stored, the addition of a
preservative is necessary (for example 800ppm sodium benzoate).
Cordials are simply crystal clear squashes.
Another range of products that has proved popular is fruit nectars which are
consumed on a ‘one shot’ basis. Essentially, these consist of a 30% mix of
fruit pulp and sugar syrup so as to give a final sugar level of about 12-14%.
All fruits contain sugar, usually around 8-10%, with variations not only from
fruit to fruit but also in the same fruit grown in different parts of the world.
The addition of sugar to give the recommended levels must take into
account the sugar already in the juice. However, the amount of sugar
added in practice is finally decided by what the purchasers actually want.

In all cases, sugar syrups should be filtered through muslin cloth prior to
mixing to remove
particles of dirt which are always present.
Pasteurization

All the products mentioned above need o be pasteurized at 80-95°C for 1-

10 minutes prior to filling hot*. At the simplest level, this may be carried out
n a stainless steel, enameled or aluminum saucepan over a gas flame, but
this can result in localized overheating at the base of the pan, with
consequent flavor changes.
To avoid the use of large expensive, stainless steel pans, a large aluminum
pan can be used to boil sugar syrup. A given amount of the syrup is then
mixed with fruit juice in a small stainless steel pan and this increases the
temperature to 60-70°C. The juice/syrup mixture is then quickly heated to
pasteurizing temperature.

The next industrial jump in pasteurization is, unfortunately, expensive in

that it involves the purchase of a double-jacketed steam kettle in stainless
steel and a small boiler.

Filling & Bottling

In all cases, the products should be hot-filled. A stainless steel bucket,
drilled to accept a small outlet tap, has proved to be a very successful filler.
Output can be doubled quite simply by fitting a second tap on the other side
of the bucket. This system has been used to produce 500-600 bottles of
fruit juice per day.

After filling hot, the bottles are capped and laid on their sides to cool prior to
labeling.
*Care is needed when producing pineapple juice due to a heat resistant
enzyme in the juice. The enzyme damages skin after prolonged contact
and workers should therefore wear gloves to protect their hands. The juice
must be heated to a higher temperature for a longer time to destroy the
enzyme (eg boiling for 20 minutes).

Quality Control
As in all food processing enterprises it is necessary to ensure that the fruit
products are correctly formulated and priced to meet the customer’s
requirements, and that production costs are minimized to ensure that a
profit is made. The quality of each day’s production should be monitored
and controlled to ensure that every bottle of juice has the correct keeping
and drinking qualities. In particular the following points should be observed:

o Only fresh, fully ripe fruit should be used; mouldy or insect damaged
fruit should be thrown away. All unwanted parts (dirt, skins, stones etc)
should be removed.
o All equipment, surfaces and floors should be thoroughly cleaned after
each day’s production.
o Water quality is critical, if in doubt use boiled water or add one
tablespoon of bleach to each gallon of water to sterilize it. If water is
cloudy, a water filter should be used.
o Pay particular attention to the quality of re-usable bottles, check for
cracks, chips etc and wash thoroughly before using. Always use new
caps or lids.
o The concentration of preservative should be carefully controlled for
correct preservation of squashes and cordials, and may be subject to
local laws. Check first and use accurate scales to measure the
preservative.
o The temperature and time of heating are critical for achieving both the
correct shelf life of the drink and retaining a good color and flavor. A
thermometer and clock are therefore needed.
o The correct weight should be filled into the bottles each time.
These factors are important because a customer will stop buying the
products if the quality varies with each purchase.

Checklist of Required Equipments

o Kenwood chef major and continuous juice separator

o Boiling pans should be made of aluminum, enameled metal or stainless
steel. For larger quantities it is necessary to buy equipment which does
not cause burning or sticking of the product to the bottom of the pan.
o Stainless steel steam jacketed kettles, that is, a double walled pan are
suitable and can be obtained with capacities from 5-500 liters
o Checklist for equipment required
o Peeler
o Knives (stainless steel)
o Cutting boards
o Juice extractor
o Thermometer
o Analytical balance
o Stainless steel saucepan
o 10kg scales
o Measuring cylinder
o Capping machine
o Wooden spoons
o Plastic funnels
o Plastic buckets
o Strainers
o Cleaning equipment (brushes, scourers, cloths, hosepipes etc) 2 gas
cylinders, 2- or 3- ring burners.
Building with large preparation table, smaller table for gas burners, shelves
for products, sink, draining board, taps, cupboard for labels and dry
ingredients.

The working area should have the following features:

o Sloping concrete floor and proper drainage for washing down each day.
o A potable water supply.
o Preferably electricity.
o Screened windows and doors to reduce insects.
o No horizontal ledges, window sills, or rafters where dust, bird droppings
etc can collect.
source: practicalaction.org, photo from enzymeindia.com