Sugar Syrup Preparation For Carbonated Soft Drinks

SUGAR AND SUGAR SYRUP PREPARATION

WHAT IS SUGAR?

SUGAR OR SUCROSE IS A CARBOHYDRATE THAT OCCURS NATURALLY IS VERY FRUITS AND VEGETABLE IN THE PLANT KINGDOM

SUGAR IS A CLASS OF EDIBLE CRYSTALINE CARBOHYDRATES, MAINLY SUCROSE, LACTOSE GLUCOSE AND FRUCTOSE ARE PRESENCE. THEY ARE MONOSACCHARIDE, DISACCHARIDE AND POLYSACCHARIDE CARBOHYDRATE, CHARACTERISED BY A SWEET FLAVOR. SUCROSE AND OTHER SUGARS ARE PRESENT IN NATURAL AND REFINED FORMS IN MANY FOODS. THE COMMON CHEMICAL FORMULA OF SUGAR IS CnH₂nOn(n=3 to 17).

SUCROSE IN ITS REFINED FORM AND SUGAR NORMALLY REFERS TO SUCROSE, WHICH PRIMARILY COMES FROM SUGAR CANE & SUGAR BEET. SUCROSE IS A DISACCHARIDE.

Types OF SUGAR?

THERE ARE MANY DIFFERENT TYPES OF SUGAR.

1.WHITE SUGAR

2.GRANULATED SUGAR

3.RAW SUGAR

4.BROWN GUGAR

5.BARBADOS SUGAR 

6.LIQUID SUGAR

7.TORNADO SUGAR

8.INVERT SUGAR 

IN SUCROSE MOLECULAR FRUCTOSE AND GLUCOSE BOTH ARE PRESENCE.

SUCROSE FORMED BY DICOMPOSE OF FRUCTOSE AND GLUCOSE TO REMOVE ONE MOLECULE WATER BY THE REACTION,

C₆H₁₂O₆+ C₆H₁₂O₆  = C₁₂H₂₂O₁₁+H₂O

SOURCE OF SUGAR

THE MAIN SOURCE OF SUGAR ARE SUGAR CAN AND SUGAR BEET. MANY OTHER FRUITS ARE ALSO SOURCE OF SUGAR, SUCH AS FRUCTOSE AND GLUCOSE ARE FRUIT SUGAR. CORN SYRUP ARE HIGHLY FRUCTOSE SUGAR. GLUCOSE AND FRUCTOSE CAN ALSO PRODUCE SYNTHESIS WAY.

RAW SUGAR TEST

ICUMSA=INTERNATIONAL COMMISSION FOR UNIFOR METHODS OF SUGAR ANALYSIS.IS AN INTERNATIONAL UNIT FOR EXPRESSING THE PURITY OF THE SUGAR IN SOLUTION. IS DIRECTLY RELATED TO THE COLOR OF SUGAR. MORE THEN THIRTY COUNTRIES STABLISHED A GLOBAL BODY. SUCH AS EU, USA BRAZIL ETC.

Here, %Brix=Simple Syrup Brix.

Density=Simple Syrup Density

Log T=Transmitant

BY THIS EQUATION WE CAN TEST SUGAR COLOR IN ICUMSA UNIT. 

Standard ICUMSA VALU.

For Brazilian Sugar ICMUSA=45 Max

For EU Sugar ICMUSA=42 Max

PURITY TEST

PURITY TEST:

WEIGHT ACCURATE 14 G SUGAR AND MAKE 100 G SOLUTION BY WATER, IT CALLED 14% BRIX SOLUTION AND TEST BRIX%.

CALCULATE PURITY BY THE,

ASH CONTENT:

WEIGHT ACCURATE 28G SUGAR AND MAKE 100 G SOLUTION BY WATER,IT CALLED 28% BRIX SOLUTION. AND TEST CONDUCTIVITY. CALCULATE ASH BY THE,

NUTRITION VALUE OF SUGAR

SUGAR SYRUP PREPARATION

INTRODUCTION

SUGAR IS A MOST IMPORTANT INGREDIENT OF SWEETENS FOOD PRODUCT. FOR ALL KINDS OF SWEETENS FOOD PRODUCTS  SUGAR INCREASED IT SWEETNESS BEHAVIOR. IT IS BROADLY USED IN FOOD AND BEVERAGE INDUSTRIES, PHARMACEUTICAL INDUSTRIES, FOOD PROCESSING AREA ETC.

NOW WE DISCUSS SYRUP PREPARATION FROM REFINED SUGAR     GENERALLY FROM SUCROSE.

Process Description

PROCESS CARRY OUT BY FLOWING WAYS

•  •    HOT WATER COLLECTION
• •   SUGAR DUMPING & DISSOLVING
• •   CARBON DOSSING & REACTION
• •   FILTRATION
• •   COOLING
• •   RESERVE & DISTRIBUTION 

HOT WATER COLLECTION

FIRST TREATED WATER COLLECT IN DISSOLVING TANK BASED ON SUGAR QUANTITY.

EQUATION FOR REQUIRED WATER AGAINST TARGET BRIX%,

THEN TREATED WATER CIRCULATE INTO A PLATE HEAT EXCHANGER UPTO WATER TEMP RISED 80˚C.(80 ˚C TO 85˚C TEMP BEST FOR SUGAR DISSOLVING)

FIG: WATER & SYRUP CIRCULATION SYSTEM THROUGH HEAT EXCHANGER

DUMPING AND DISSOLVING

TARGET AMOUNT OF SUGAR DUMPED INTO THE DUMPING HOPPER, AT SAME TIME FROM DISSOLVING TANK HOT WATER PASS THROUGH THE HEAT EXCHANGER TO HOPPER LINE TO DISSOLVING TANK IN A CIRCULATING WAY.SUCH A WAY PROCESS GOING ON UPTO WHOLE SUGAR DUMPING AND DISSOLVING.

FOR 12000KG SUGAR DUMPING TIME 2.5 TO 3.0 HOURS.

DUMPING AND CIRCULATING SYSTEM

CARBON DOSSING AND REACTION

• •   DISSOLVED SUGAR PASS THROUGH A PIPELINE WHERE 0.1% CARBON DOSSING BASED ON SUGAR 
• QUANTITY, DEPEND ON SYRUP FLOW RATE.
• •   IN REACTION TANK CARBON REACT WITH SUGAR SYRUP,  ADSORPED COLOR, AND ODOUR.
• •    FOR THIS PROCESS ABOUT 50 TO 60 MINS NEED.

[CARBON INITIALLY DISSOLVED IN CARBON TANK]

CARBON DOSSING SYSTEM

ACTIVATED CARBON

• ACTIVATED CARBON IS A FORM OF CARBON, ALSO CALLED ACTIVATED CHARCOAL, ACTIVATED CHAR OR CARBO ACTIVATUS. IT PROCEED TO MAKE IT EXTREMELY POROUS AND THUS TO HAVE A VERY LARGE SURFACE AREA FOR AVAILABLEADSORPTION OR CHEMICAL REACTIONS.
• 
  
•  DUE TO HIGH DEGREE OR MICROPOROSITY IT HAS HIGH ADSORPTION CAPACITY.1 GRAM OF ACTIVATED CARBON HAS A SURFACE AREA EXCESS OF 500M² WITH1500M² BEING READILY ACHIEVABLE.
• IT SURFACE AREA IS DETERMINED BY ADSORPTION OF NITROGEN GAS.

 ACTIVATED CARBON BINDS MATERIALS BY VANDERWALL FORCE. 

FILTRATION

BED PREPARATION:

IN FILTER PRESS 48 NOS OF FILTER PLATE.INFEED TANK 11KG FILTER AID DISSOLVED AND CIRCULATE INTO THE FILTER PLATE[HERE AS FILTER AID WE USED HYFLO & STANDARD (BRAND NAME)5.5 KG&5.5 KG, WHICH ARE CELLULOSE FILTER AID 1 TO 10 µm DIAMETER] AND PREPARED FILTER BED.BED THICKNESS 3-5 mm.ABOUT 50 MIN TAKE TO PREPARE A FILTER BED.

  

AFTER BED PREPARATION SYRUP CIRCULLETE  THROUGH THE FILTER BED (ABOUT 15 MINS) AND CHECK CLARITY OF SYRUP AND PASS SYRUP THROUGH THE FILTER PRESS. DURING TRANSFER TIME 4 KG FILTER AID (HYFLO2KG & STANDARD2KG)DISSOLVED IN FEED TANK FOR BODY DOSSING TO IMPROVE BED EFFICIENCY.

 CLARITY TEST:

50ML SYRUP DISSOLVE INTO 100 ML WATER AND PASS THROUGH .45µm FILTER PAPER BY VACUUM FILTRATION METER AND VISUBELY CHECK THE FILTER PAPER.

FIG: VACUUM FILTRATION METER

POLISHER

AFTER FILTER PRESS SYRUP PASS THROUGH THE 20µm POLISHER TO REMOVE ANY PARTICLE GATER THER 20µm.

COOLING

AFTER POLISHER SYRUP PASS THROUGH A HEAT EXCHANGER TO REDUCE TEMP BELLOW 20°C. BECAUSE of THIS TEMP  CONTROL  MICROORGANISM GROWTH.

RESERVE & DISTRIBUTION

THEN     SYRUP RESERVE IN A RESERVE TANK AT BELLOW 20°C TEMP. HERE SYRUP CAN STRAY 72 HRS WITHOUT ANY PROBLEM. FROM THIS TANK SYRUP DISTRIBUTE  IN SEVERAL PLANT.

SYRUP PREPARATION SYSTEM IS A MODERN, AUTOMATION AND HIGH CAPACITY OF SYRUP PREPARATION PROCESS. BY THIS PROCESS DAILY 96000 KG SUGAR SYRUP CAN BE PROCESS. IN OUR PROCESS WE NORMALLY PREPARATION ABOVE 60% BRIX SYRUP.BECAUSE BY THIS BRIX SYRUP ACT AS SELF PRESERVATIVE AND SUITABLE         FOR OUR USED.