- https://www.sciencedirect.com/topics/agricultural-and-biological-sciences/carbonated-beverage#:~:text=The process of carbonation involves,liquid level in the container.
Bring a bottle of carbonated drinks on a sweltering summer day to quickly relieve the heat.
So what is the production process of carbonated beverages? Why do carbonated beverages feel cool? Let’s take a look together~
Twice filling method
Once filling method
The primary filling method and the secondary filling method are the main distinctions between them:
- To use the secondary filling method, fill the container with syrup first, add aerated water and seal it shut. Finally, mix well.
- One-time filling technique: Water and syrup are combined before being sealed for durability.
Step 01 Preparation of sugar liquid
Sugar dissolves in two different ways, either occasionally or continuously. Cold-dissolving and Thermomelting are two types of intermittent dissolution (steam heating and hot water).
- Dissolve cold drink mix in water to create a syrup for immediate consumption.
Use a container equipped with a stirrer to correctly register the sugar and water, stir at room temperature, and filter and remove impurities after they have completely dissolve.
Generally 45- 65°Bx (must be 65°Bx to be stored for 1 day). Cold-melting production requires strict hygiene controls but can save fuel. Using the correct amount of water is important, so you do not overload the drink mix and make it too sweet. Too much water will make the drink less flavorful.
You must use sterile canning jars to store the syrup and process them according to canning procedures. Home canning is not recommended for this product because of the risk of botulism poisoning. When canning, add 1/4 teaspoon of citric acid or 1 tablespoon of lemon juice per quart (946 ml) of syrup.
This will help preserve the flavour and colour of the syrup during storage. Store in a cool, dark place and use within 6 months. Make sure to label and date the storage tanks so you know when to use them.
- Hot melt is perfect for those high-purity requirements beverages or drinks that need to be stored for longer periods.
Hot dissolving can kill bacteria in sugar, separate impurities in coagulated sugar, dissolve quickly, and can produce a large amount of sugar liquid in a short period. Hot dissolving is widely used in the food industry because of its many benefits. For example, hot dissolving can help improve a beverage’s taste by separating out impurities in the sugar.
Additionally, hot dissolving can help extend a beverage’s shelf life by killing bacteria that may cause spoilage. Finally, hot dissolving is also very efficient, as it can produce a large amount of sugar liquid in a short period. Consequently, hot dissolving is an important method for ensuring the quality and safety of many food products.
The equipment needed for this is a standard stainless steel double-layered pot that can dissolve sugar, a stirrer, and a pipeline to discharge the product at the bottom of the pot.
Step 02 Mixing syrup with ingredients.
To ensure your food is cooked evenly, follow this stirring sequence:
- Raw syrup: To properly dispense medication, you must first measure its concentration and required volume.
- Preservative: After weighing, dissolve the contents in warm water.
- Sweetener: add after dissolving in warm water.
- Sour agent: 50%
- Emulsifier and stabilizer
Finally, add water to the specified volume
The mixing process is as follows.
- First, the solid raw materials, such as sugar and flavouring, are weighed and sent to the mixing tank. Then, add water to make a syrup with a 60-70% concentration.
- Next, add citric acid or potassium citrate and sodium citrate according to the recipe And then heat to dissolve. Finally, cool to room temperature and filter. After the coordination is completed, the concentration of the syrup can be measured.
At the same time, a small amount of syrup is added to carbonated water, and the colour and lustre are observed, the taste is evaluated, and it is checked whether it conforms to the standard sample. Mixing in a stainless steel container with a stirrer and a capacity scale, The stirring method is mostly inclined or waist type, which can prevent impurities such as dust and oil from falling into the syrup due to vibration.
To ensure product quality, Flavors need to be periodically replaced. It should be noted that when filters clog, They should be cleaned in time so as not to affect production.
- Lastly, it is worth mentioning that during storage, Be sure to pay attention to sealed storage To prevent evaporation of volatile components in flavouring, influencing product quality. Carbonated beverage syrup usually has a shelf life of 6 months.
After 6 months, it should be re-inspected before use. If it does not meet the requirements, it should be discarded. Therefore, regular replacement of flavouring is necessary to produce high-quality products.
Step 03 Carbonation
Carbonation is the process by which water absorbs carbon dioxide to form carbonic acid.
The function of carbon dioxide
- Carbon dioxide has a cooling effect on the body. When released from the body, it takes the heat from inside the body, thus providing a cooling sensation.
- Carbon dioxide also inhibits the growth of microorganisms and thus helps prolong soda’s shelf life.
- Carbon dioxide also enhances the fragrance of soda.
- Finally, carbon dioxide provides a comfortable brake taste when combined with the other gas components in soda water. This is what gives soda its unique flavour.
Carbonation systems needed
At the heart of every carbonation system is a gas pressure regulating station. This station regulates the amount of carbon dioxide pumped into the water cooler.
The water cooler then mixes the carbon dioxide with the water, and the soda water mixer further regulates the mixture.
Finally, the carbonated filler machine bottle the beverage. All of these machines work together to create the perfect can of soda.
STEP 04 Beverage filling
- Twice carbonated beverage filling method working principle
The working principle of a carbonated beverage filling machine is simple and easy to invest in, making it ideal for small to medium-sized beverage factories that want to maintain product hygiene.
However, since the syrup is not carbonated, the gas content decreases after mixing it with carbonated water.
This method is still widely used because its equipment is less complex and easier to operate than other methods.
Carbonated beverage filling machines work by first sterilizing the bottles to be filled.
Next, syrup and carbonated water are mixed in specific proportions before being pumped into the bottles.
Finally, the bottles are sealed and cooled before packaging and shipping.
- One-time carbonated beverage filling method working principle
The one-time carbonated beverage filling method is an advanced filling technology that uses a bottling or beverage filling machine to fill the beverage into bottles or cans. This type of filler is also called a monobloc carbonated filler.
Compared with the traditional two-step method, this method has the advantages of an accurate ratio of syrup and water, easy-to-control filling capacity, stable product gas content, and is suitable for large-scale beverage factories.
Its disadvantage is not suitable for carbonated drinks with pulp, and the equipment is complicated. In addition, this method requires rigid containers and capping requirements. Therefore, it is only suitable for large-scale production of beverages in regular factories.
- Combined carbonated beverage filling method working principle
The combined carbonated beverage filling method is a bottling process suitable for carbonated beverages with pulp. This system comprises machines installed according to the general one-time filling method. When filling carbonated pulp beverages, a bypass is installed on the blending machine so syrup can be pumped into another pipeline without mixing with water. The syrup is sent to the blender and mixed with carbonated water using a pump and control system. Finally, the beverage is filled.
This method uses machines to combine and fill the carbonated beverage instead of manual labour. As a result, it is more efficient and quicker than traditional methods. Additionally, because a bypass is installed on the blending machine, this ensures that the syrup and water do not mix together until they reach the blender. This system is also controlled by a pump and control system to ensure accuracy and precision.
Filling system needed
- Twice filling machine
A twice-filling system is a set of machines used in bottling beverages. The system includes a grouting machine, a water filling machine and a capping machine. The grouting machine is used to fill the bottles with the beverage. The water filling machine is used to fill the bottles with water. The capping machine is used to seal the bottles. The system is used to bottle carbonated beverages. You can operate the system in either manually or automatically. The system is designed for use with PET bottles. The system can be used to fill bottles of any size.
- One-time beverage filling machine
Adding syrup to a carbonated beverage filling system is crucial in ensuring that the final product is of the highest quality. The proportioner is placed before the mixer to ensure the correct syrup ratio to carbonated water is used. This is vital, as too much or too little syrup can adversely affect the drink’s taste.
The filling system consists of a filling machine and a capping machine, both driven by a power mechanism. Once the syrup has been added, the drink is bottled and sealed, ready for consumption.
Common problems and solutions of carbonated filling machine
1. There are solid impurities
This is because the heavily contaminated old bottle was not washed and had fallen into impurities during the blending process.
To fix this problem, you must pay attention to hygiene during production and use the bottle after cleaning and inspection.
One of the main problems that can occur with a carbonated beverage filling machine is precipitation.
This can be caused by product contaminants, poor quality, or improper handling of raw materials.
To solve this problem, you must to stabilize the purchase channels of raw and auxiliary materials and reduce the quality difference caused by manufacturers and origins. With these measures, you can help to ensure that your carbonated beverage filling machine runs smoothly and without issues.
3. Abnormal changes in flavour, musty, rancid, and peculiar smell
Carbonated beverage filling machines are susceptible to problems with abnormal changes in flavour, mustiness, rancidity, and peculiar smells.
These problems are often caused by poor quality raw and auxiliary materials or improper handling. For example, high impurity content in carbon dioxide can cause off-flavours, while oxygen from the air can make substances oxidized and taste bad.
Other common causes of flavour problems include an imbalance in the ratio of sweet and sour ingredients or staleness caused by the improper deployment of ingredients. Carbon dioxide pressure that is too high or too low can also reduce flavour balance.
To avoid these problems, choosing the appropriate formula and a good process during production is necessary. This includes the reasonable sugar-acid ratio, the correct deployment sequence, and the selection of the appropriate processing technology for various raw and auxiliary materials.
You can ensure that your carbonated beverages taste great every time by taking these precautions.
4. Discoloration (including browning and fading)
The discoloration is a common problem with carbonated beverage filling machines. There are two main types of discoloration: enzymatic browning and non-enzymatic browning.
Enzymatic browning is caused by polyphenol oxidase in the product’s raw materials; non-enzymatic browning is caused by the Maillard reaction.
Fading is another common issue, which can be caused by light exposure, high temperatures, or redox reactions of substances.
To prevent discoloration, finished products should be managed carefully to avoid light exposure and overexposure. The storage period should be as short as possible, and storage temperature should be kept as high as possible.
5. Exploded bottle or lack of gas
Several factors can contribute to it, including poor carbonation effect, high storage temperature and high carbon dioxide content, increasing gas volume, or poor bottle quality and low-pressure resistance.
To avoid this problem, selecting production machinery and equipment with good performance, especially carbonation equipment and filling system, and strengthening the inspection of bottle quality is important. By taking these measures, you can ensure that your carbonated beverages are properly filled and do not explode or lack gas.
In conclusion, the production of carbonated beverages is a highly technical process that requires attention to detail and precise control. By following the proper steps and taking appropriate precautions, you can ensure that your carbonated beverages taste great every time.
For 25 years, iBottling has been producing high-quality carbonated beverage filling machines, fillers, and other bottling equipment. Our goal is to provide you with the best possible products so that your bottles are filled quickly and efficiently while ensuring safety throughout the process. Browse our selection of carbonated beverage filling machines today and contact us for more information!