Discussion on Technology of Hot Filling Barley Tea Beverage

In order to meet the needs of different levels of people's life consumption, the current market tea beverage has gradually expanded towards the pursuit of high quality and fashionable direction. Consumer demand for green and organic food tea beverages is also increasing.
"Compendium of Materia Medica" records: barley sweet, flat nature, with a flat stomach and thirst, in addition to heat, Qi to adjust the tone, wide chest and lower gas, consumer product to eat, make up bad, strong blood, real five internal organs, food Features. Therefore, barley tea, which is delicious and unique in taste, is widely welcomed in Southeast Asia, Hong Kong and Taiwan. Since the beginning of this year, China has gradually become popular with "hot wheat." The barley tea is made of high-quality six-row barley containing dietary fiber, vitamins, protein and other nutrients as raw materials, then baked in a fine fire, and extracted with a special process to prepare a dark brown tea soup. It contains the essence of natural wheat, giving off a rich flavor. The barley aroma has a natural moist texture and is particularly good for the body. The following is the author's discussion on hot filling barley tea beverage technology in practical work.
First, the hot filling of barley tea beverage process 1. Barley extraction process barley extraction → coarse filtration → enzymatic → cooling to <7 °C → settling → centrifugation → buffer tank → coarse filter → 0.45m fine filter → buffer Tank → RO → Sterilization → Packing into the cold storage 2. Filling and filling process

Second, the key control point barley tea drink pH> 4.5, belong to the low acidic beverage. The use of hot filling line production has certain risks. The key lies in the need to reduce the pollution that can be brought about by each link:
1. The leaching process is a key control point in the production of tea beverages and directly affects the quality of tea beverages. Barley extract pH> 4.5, rich in nutrients, bacteria can easily grow and reproduce, but also because of the origin of agricultural products, may bring into the difficult to inactivate the thermophilic spores;
2. The deployment process is susceptible to contamination by bacteria, and contamination should be minimized to prevent the proliferation of bacteria;
3. Sterilization is critical to the microbiological safety of the product;
4. The hot-filling line does not have strict aseptic filling lines for the processing of packaging materials, and may also lead to pollution sources; GMP control of the filling environment is also very important; therefore, ensuring the filling temperature is also critical.

Third, the process description and discussion 1. The main raw materials approved barley fried: the selection of a variety of healthy nutrients containing dietary fiber, vitamins, protein and other organic green barley as raw materials, prepared by fine fire roasted and baked and other special processes , golden color, rich aroma.
White sugar: physical and chemical indicators should meet the relevant requirements of GB317-2006 White Sugar. Purchasing from qualified suppliers, each batch should have a factory inspection certificate and an annual inspection of all items issued by the government authorities. Qualified report.
PET bottles: Meet QB/T2665-2004 "Polyethylene Terephthalate (PET) Bottles for Hot Filling" requirements, each batch has a factory inspection certificate, and is issued by the government authorities once a year. All projects passed the test report. If you can blow the bottle better.
Raw materials such as barley, white granulated sugar, and PET bottles, etc., which are frying, should all be sampled at the factory and filled in with the “Acceptance and Acceptance Record of Raw Materials”.
2. Leaching: (CCP1)
The quality of the extract will directly affect the quality of the tea beverage. This process is a key control point in the production of tea beverages. We used hot water extraction and enzymatic treatment to obtain better results.
3. Water treatment:
According to the RO Water Treatment Practice, a qualified RO water was prepared.
4. Sugar:
Dissolve in hot water, add appropriate amount of activated carbon and keep it at 85°C for 30 minutes. After frame filter and filter bag fine filtration, the 0.45m filter membrane confirmed that no activated carbon leaked into the single syrup, filtered, cooled, and entered the sugar storage tank.
5. Thaw extract:
Verify the microbial test report of the extract, and control the thawing time, not excessive. Otherwise, if the temperature rises too much, the bacteria will multiply more. The best use period is ice-water mixing.
6 accessories added:
Pay attention to the fragrance embedding work.
7. Provisioning constant volume: (CCP2)
(1) Feed sequence: single syrup - thawed barley extract (ice water mixture) - accessories;
(2) Add 50ppm Ninsin (bacteriostatic nisin) and quickly bring to volume. The research data shows that in the hot filling of low-acid beverages, adding an appropriate amount of Ninsin can play a good role in ensuring the product's bio-safety;
(3) It is better to keep the temperature of the ingredients and keep it <20°C;
(4) Each pot of ingredients is filled as far as possible within 1 hour to 1.5 hours.
8. Stirring:
Stir well, after testing qualified, filling as soon as possible.
9. UHT: (CCP3)
Sterilization formula: temperature 138±2°C, time 45 seconds. This is the key control point. Sterilization temperature ≥ 89 °C. At least one beverage center temperature is detected every hour. When stopping for a short time, you should pay attention to whether the temperature decreases.
The filling room should be 10,000 clean spaces. The number of dust particles should be measured before each production. Only when the standards are met can production be started.
After filling, the bottle thread should be flushed with hot water ≥80°C to avoid remaining beverage at the bottle mouth.
12. Capping:
Make sure the capping torque is between 10 in. pounds and 18 in. pounds. The capping machine should be properly adjusted to minimize the occurrence of defective caps.
13. Invert the bottle:
The bottle-returning time is ≥30 seconds, and the temperature of the beverage center after pouring is ≥85°C.
14. Coat/high cover inspection:
The coding format is handled according to GB7718-2004 "General Rules for Labelling of Prepackaged Food" and customer requirements. Sorghum and defective products should be removed.
15. Cold bottle cooler:
The first hot water shower: temperature 72 °C, time 3 minutes, (or other equivalent sterilization), gradually cooling in the latter stage, cold bottle machine export product temperature < 38 °C. After the cooling water contains 1ppm ~ 3ppm of chlorine.
16. Light inspection:
The visual inspection personnel checked one by one in the light background and removed defective products such as high-viscous lids, deformation, insufficient capacity, and poor coding.
17. Sleeve labeling, inspection, packing, and coding:
In accordance with the production requirements, set up the label, inspect the inspection personnel to visually inspect, pick out the product with bad label, and pack and spray the code.
18. Check-in for storage:
After the boxing and coding are completed, the product is stored in storage for 7 days until the microbiological inspection is completed and a product inspection report is issued.
The finished product warehouse should be cool and dry, avoid direct sunlight, preferably at room temperature < 30 °C.
19. Finished goods delivery:
After the qualified results of microbiological examination are released, they will be released. If there is a problem with the microbiological examination results, it cannot be released and the whole inspection should be reworked to eliminate defective products. Ensure that the factory product is qualified.

IV. Monitoring of key control points

Five, hot filling barley tea beverage reference formula (see magazine charts)

Sixth, product inspection standards (see chart in the magazine)

VII. Results and Discussion 1. The key to the production of barley tea beverages is to reduce the bacterial content of the materials as much as possible through each process, and reduce the pollution that may be caused by each link. Adding 50ppm of bacteriostatic agent Ninsin during the formulation process can increase the bactericidal strength at UHT, which can play a very good role in the biosafety of the product.
2. Through reasonable process design, good GMP and process control, coupled with the addition of appropriate antibacterial agent Ninsin, hot filling lines can produce low-acid beverages. Since the end of 2005, our company has mass-produced several batches of barley tea beverages and it is very popular among consumers.

10. Wash bottle, wash cover:
The bottles and lids are sterilized with chlorine water. Chlorine and water two: first: 20 ppm to 25ppm, second: 1ppm to 3ppm. Disinfection time >10 seconds. Make sure the number of colonies after the rinse is <1/ bottle (cap).
11. Filling: (CCP4)
In the case of good heat resistance of the bottle, control the filling temperature ≥ 92 °C, to ensure that the beverage center temperature ≥ 89 °C. At least one beverage center temperature is detected every hour. When stopping for a short time, you should pay attention to whether the temperature decreases.
The filling room should be 10,000 clean spaces. The number of dust particles should be measured before each production. Only when the standards are met can production be started.
After filling, the bottle thread should be flushed with hot water ≥80°C to avoid remaining beverage at the bottle mouth.
12. Capping:
Make sure the capping torque is between 10 in. pounds and 18 in. pounds. The capping machine should be properly adjusted to minimize the occurrence of defective caps.
13. Invert the bottle:
The bottle-returning time is ≥30 seconds, and the temperature of the beverage center after pouring is ≥85°C.
14. Coat/high cover inspection:
The coding format is handled according to GB7718-2004 "General Rules for Labelling of Prepackaged Food" and customer requirements. Sorghum and defective products should be removed.
15. Cold bottle cooler:
The first hot water shower: temperature 72 °C, time 3 minutes, (or other equivalent sterilization), gradually cooling in the latter stage, cold bottle machine export product temperature < 38 °C. After the cooling water contains 1ppm ~ 3ppm of chlorine.
16. Light inspection:
The visual inspection personnel checked one by one in the light background and removed defective products such as high-viscous lids, deformation, insufficient capacity, and poor coding.
17. Sleeve labeling, inspection, packing, and coding:
In accordance with the production requirements, set up the label, inspect the inspection personnel to visually inspect, pick out the product with bad label, and pack and spray the code.
18. Check-in for storage:
After the boxing and coding are completed, the product is stored in storage for 7 days until the microbiological inspection is completed and a product inspection report is issued.
The finished product warehouse should be cool and dry, avoid direct sunlight, preferably at room temperature < 30 °C.
19. Finished goods delivery:
After the qualified results of microbiological examination are released, they will be released. If there is a problem with the microbiological examination results, it cannot be released and the whole inspection should be reworked to eliminate defective products. Ensure that the factory product is qualified.

IV. Monitoring of key control points

Five, hot filling barley tea beverage reference formula

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