Soft Drink and Fruit Juice Problems Solved

Front Matter......Page 1
References and Further Reading......Page 0
Preface......Page 3
Table of Contents......Page 5
1.1.1 How Do I Obtain the Main Brief for a New or Modified Product?......Page 19
1.1.3 How Much Technical Input Should There Be in Deciding the Brief?......Page 20
1.1.5 What Timescale Should Be Allowed for the Development of a Product?......Page 21
1.1.6 What Microbiological Tests Should Be Carried Out on a Developmental Product?......Page 22
1.2.2 How Detailed Should the Product Brief Be? How Much Technical and Marketing Information Should Be Provided?......Page 23
1.2.4 Are There Any Special Regulations for Drinks for Babies?......Page 24
1.3.1 Should the Initial Product Concept be Developed without Reference to Cost?......Page 25
1.3.3 How Much Influence Should the Company Accounting Function Have on Product Development?......Page 26
1.3.5 Will New Capital Plant Be Needed?......Page 27
1.4.3 What Influence Does Packaging Have on Production and its Costs?......Page 28
1.4.4 Can I Design My Own Packaging?......Page 29
1.5.3 When Should I Consider Outsourcing the Initial Manufacture of a New Product? Is Contract Packing a Viable Option?......Page 30
1.5.5 Do Some Ingredients Require Special Handling Facilities?......Page 31
1.6.1 Can Shelf-Life Be Predicted?......Page 32
1.6.3 What Facilities Do I Need to Conduct Shelf-Life Tests?......Page 33
1.6.4 How Does Shelf-Life Impact on the Business Plan?......Page 34
1.7.1 How Can Likely Consumer Reactions to New Products Be Best Assessed?......Page 35
1.7.4 How Can I Predict Likely Sales Volumes?......Page 36
2.1.1 How Much Does Water Quality Affect Soft Drinks?......Page 38
2.1.2 Should Water Treatment Be Installed in a Soft Drink or Fruit Juice Processing Plant?......Page 39
2.1.5 Can I Use Natural Mineral Water or Spring Water to Make a Soft Drink or Reconstituted Fruit Juice, and Can I Bring These Waters in by Tanker?......Page 40
2.2.1 What Types of Fruit Components are Readily Available and What are the Differences between Juices, Comminutes, Fruit Purées and Fruit Extracts?......Page 41
2.2.3 How Do I Calculate the Fruit Content of a Product When Using a Concentrated Fruit Preparation?......Page 42
2.2.4 What Factors Do I Need to Consider in the Specification for Fruit Ingredients?......Page 43
2.2.6 Are All Exotic Fruits Permitted in Beverages and How Can I Establish Which are Allowed?......Page 44
2.2.7 Can a Product Be Labelled 'Sugar Free' if Only Fruit Components are Added?......Page 45
2.2.8 How Can I Be Sure of the Authenticity of Fruit Materials?......Page 46
2.3.1 What Carbohydrate Sweeteners are Available for Use in Soft Drinks?......Page 47
2.3.2 How Do other Sweeteners Compare with Sucrose?......Page 48
2.3.4 How Do Different Sweeteners Affect Production and Process Control?......Page 49
2.3.6 Are Special Technical or Process Requirements Needed to Enable the Handling of Bulk Carbohydrates in Dry or Syrup Form?......Page 50
2.4.1 How Do I Select the Right Intense Sweetener for My Product?......Page 51
2.4.3 What Kind of Stability Can I Expect from Intense Sweeteners?......Page 53
2.4.5 Are There Any Natural Intense Sweeteners?......Page 54
2.4.7 Why Has the Use of Cyclamate Declined?......Page 55
2.5.1 What Types of Flavourings are Available and Why are They Used?......Page 56
2.5.3 What Kind of Shelf-Life Do Flavourings Have?......Page 57
2.5.4 How Do Flavourings Affect Product Stability?......Page 58
2.5.5 How Much Interaction Can I Expect between Flavourings and other Ingredients?......Page 59
2.5.7 How Do Specific Ingredients That Add Flavour, Such as Quinine and Caffeine, Have to be Labelled?......Page 60
2.6.1 What Factors are to be Considered in Selecting Natural or Artificial Colourings?......Page 61
2.6.3 Are There Any Ingredients That Will Give Colour to a Product but Do Not Require a Label Declaration as Such?......Page 63
2.6.4 What are the Main Factors That Affect the Stability of Colour in a Product?......Page 64
2.6.6 Why are the Media So Critical of Colourings?......Page 65
2.7.1 What Factors Should Be Considered in Deciding Whether to Use Any Preservative?......Page 66
2.7.2 How Can the Right Preservatives Be Selected for a Product?......Page 67
2.7.3 Does the Use of a Preservative in a Product Mean That it Does Not Need to be Pasteurised?......Page 68
2.7.5 Does Dimethyl Dicarbonate (DMDC) (Trade Name Velcorin) Have to be Declared as a Preservative?......Page 69
2.7.6 Why Will Some Local Authorities Not Purchase Products Containing Benzoic Acid?......Page 70
2.8.1 What are Nutraceutical Ingredients; How Can I Use Them and How Should They Be Labelled?......Page 71
2.9.1 What Miscellaneous Additives Can I Use in a Product and What Functions Do They Perform?......Page 74
2.9.3 Is There an Industry Standard for Carbon Dioxide?......Page 75
2.9.5 How are Additives in Ingredients Declared?......Page 76
2.9.6 Can I Use Antifoam?......Page 77
3.1.1 How Much Responsibility for Ingredient Quality Can Be Transferred to the Supplier?......Page 78
3.1.3 Are Compound Ingredients Best Outsourced or Mixed Locally?......Page 79
3.1.5 How Do I Avoid Product 'Drift'?......Page 80
3.1.7 Do Some Ingredients Demand Special Production Plant?......Page 81
3.1.8 What Do I Need to Specify on a Supplier Contract?......Page 82
3.2.1 What Type of Mixing Plant is Ideal for Soft Drinks?......Page 83
3.2.3 If Undissolved Materials Remain in the Syrup Mix, What Action Should Be Taken?......Page 84
3.2.6 What is the Most Likely Cause of White Flecks on the Surface of My Syrup during Manufacture?......Page 85
3.2.8 Should I Dissolve Ingredients prior to Addition?......Page 86
3.2.10 How Much Automation Should Be Installed?......Page 87
3.3.1 When is Pasteurisation Necessary?......Page 88
3.3.2 What Pasteurisation Conditions are Needed and How Can These Be Calculated?......Page 89
3.3.3 When is it Desirable to Homogenise a Product?......Page 90
3.3.5 Are Changes to the Taste or Appearance of a Product Likely as a Result of Pasteurisation?......Page 91
3.4.1 Do Different Filler Types Affect Product Quality?......Page 92
3.4.3 What is a Typical Cleaning Regime for a Filler?......Page 93
3.4.4 At What Temperature Should Products Be Filled?......Page 94
3.4.6 What is the Average Fill System (E-Mark)?......Page 95
3.4.7 How Should I Deal with Broken Bottles in the Filler?......Page 96
3.4.9 What Hygiene Requirements Apply to Manufacturers of Soft Drinks and Fruit Juices?......Page 97
3.5.1 How Does Secondary Packaging Affect Product Quality?......Page 98
3.6.1 What are the Ideal Conditions for Product Storage?......Page 99
3.6.3 When Do Products Need to be Quarantined?......Page 100
4.1.2 What are the Key Parameters That I Should Evaluate to Assess Ingredient Quality?......Page 101
4.1.5 How Do I Ensure Consistent Product Quality and Avoid Drift?......Page 102
4.1.7 How Do I Deal with Variations in Natural Ingredients, Particularly Fruit Juices from Different Sources?......Page 103
4.2.2 What are the Most Likely Effects of Ingredient Interactions?......Page 104
4.2.5 What are the ICBA Guidelines on Benzene Formation and Where are They Available?......Page 105
4.3.2 How Meaningful are Specifications for Natural Ingredients That May Be Standardised to Only One or Two Parameters (e.g. Concentrated Juices)?......Page 106
4.3.4 Is it Possible to Specify Flavour Character?......Page 107
4.4.1 A Process Worker Has Added Too Much of One Ingredient; How is This Best Dealt with?......Page 108
4.4.3 A Batch of Product has been Made Up but Not Bottled Off. It is Then Noticed That a Preservative (or other Ingredient) Has Not Been Added. Can the Missing Ingredient Simply Be Added to the Bulk Product?......Page 109
4.4.5 What Actions Generally Need to be Taken during a Stop in Production, Particularly with Respect to Products in the Pasteuriser?......Page 110
4.4.7 How Much Record Keeping is Required and for How Long Should Records Be Kept?......Page 111
4.4.8 What Regular Checks Should Be Carried Out on a Tunnel Pasteuriser?......Page 112
4.4.9 What are the Main Risks of Contamination and How Can I Check for These?......Page 113
4.5.2 A Product Displays a 'Ring' at its Upper Surface; What is This Likely to be and How Can it Be Resolved?......Page 114
4.5.4 (a) A Concentrated Soft Drink That is Normally Cloudy Separates into a Clear Upper Layer and a Dense Lower Layer of Pulp; What is the Likely Cause and How Can it Be Resolved?......Page 115
4.5.5 Fruit Pulp Forms a Plug or Mat on Top of the Product; What Causes This and How Should it Be Dealt with?......Page 116
4.6.1 What Factors Affect Flavour Deterioration?......Page 117
4.6.2 How is the Flavour Profile of a Product Best Assessed?......Page 118
4.6.4 Apart from the Obvious Source (i.e. the Flavouring), Which Ingredients are Most Likely to Cause Flavour Problems?......Page 119
4.6.5 Where Can I Get Help in Determining the Likely Origin of an Unusual Flavour Taint?......Page 120
4.6.7 How Can Packaging Influence Flavour Deterioration?......Page 121
4.7.1 What Problems are Most Likely to Arise When Plastic Packaging of Any Kind is Used?......Page 122
4.7.3 What Special Problems, other than Physical Contamination, are Possible if Glass Packaging is Used?......Page 123
4.7.6 How Much Attention Should I Pay to the Specification of Packaging Material?......Page 124
4.7.7 What are the Major Packaging Problems?......Page 125
4.7.9 What is the Best Plastic in Which to Pack Still Drinks?......Page 126
4.8.2 What are the Organisms That I Need to be Particularly Aware of?......Page 127
4.8.3 Can Soft Drinks Become Contaminated with Pathogenic Organisms?......Page 128
4.8.5 How Do I Find the Likely Source of Microbial Contamination in a Product?......Page 129
4.8.7 How Can I Best Ensure That the Water I Use Does Not Become a Source of Contamination?......Page 130
4.8.11 I Know That Most Product Spoilage Results from Yeast and/or Mould Contamination; What Bacterial Infections Might Affect Soft Drinks?......Page 131
4.9.3 What Does the Term 'Shelf-Life' of a Product Actually Mean?......Page 132
4.9.5 Why Do Products Need a Long Shelf-Life and How Can This Be Maximised?......Page 133
4.9.6 How Does Packaging Affect Shelf-Life?......Page 134
5.1.1 What UK Legislation Applies to Bottled Waters?......Page 135
5.1.2 What are the Differences between Natural Mineral Water, Spring Water and Table Water?......Page 136
5.1.3 How Should Different Waters Be Labelled?......Page 137
5.1.5 What Testing Regime Do I Need to Put in Place?......Page 138
5.1.7 What other Ingredients Can I Add to Bottled Waters?......Page 139
5.2.2 How Does My Borehole Need to be Protected?......Page 140
5.2.4 How Can I Establish Whether the Water from My Borehole is of Consistent Quality?......Page 141
5.2.6 Can Extraction from a Borehole Be Intermittent?......Page 142
5.3.1 What Treatments Can I Apply to Different Water Sources?......Page 143
5.3.4 Do I Need to Take Any Special Precautions in a Water Bottling Plant?......Page 144
5.4.2 What are the Most Likely Sources of Taints in Bottled Waters?......Page 145
5.4.4 Does the Carbon Dioxide Added to Bottled Waters Need to be of Special Quality?......Page 146
5.4.5 What Shelf-Life Can Be Expected from Bottled Waters?......Page 147
5.5.1 Do Bottled Waters Require Any Special Storage Conditions?......Page 148
6.1.1 What Factors Should Be Taken into Account When the Selection of Packaging is under Consideration for a New Product?......Page 150
6.1.2 How Do I Evaluate the Likely Performance of Different Types of Plastic Packaging? What Factors Should I Consider?......Page 151
6.1.3 What Do I Need to Look Out for When Selecting the Closure?......Page 152
6.1.4 Where Can I Go for More Help with Packaging Problems?......Page 153
6.1.6 What Special Problems are Likely to be Associated with the Use of Returnable Glass Bottles?......Page 154
6.1.8 What Problems Can I Expect from the Use of Cartons?......Page 155
6.2.1 What are the Most Likely Defects Associated with Glass Bottles?......Page 156
6.2.3 What Inspection Regime Do I Need to Put in Place to Minimise the Risk of Any Defective Container Reaching the Consumer?......Page 157
6.2.5 What is the Best Way to Print 'Best before' or 'Best before End' (BBE) Dates on Containers?......Page 158
6.3.1 What are the Most Likely Problems That Can Arise during Packaging with Any of the Packaging Types in Regular Use?......Page 159
6.3.3 What Process Quality Checks Should Be in Place to Minimise the Consequential Problems of Packaging Defects?......Page 160
6.3.5 At What Temperature Should Containers Be after Filling?......Page 161
6.3.6 What are Appropriate Carbonation Levels for Different Products and Container Types?......Page 162
6.4.2 What Special Problems are Posed When Filled and Closed Packs are Subjected to Tunnel Pasteurisation?......Page 163
6.4.3 Are There Any Particular Problems That Can Arise after Secondary Packaging is Applied?......Page 164
6.4.5 What is Stress Corrosion of Cans and How May it Be Prevented?......Page 165
6.5.2 What Level of Handling Abuse Do I Need to Consider When Specifying Secondary Packaging?......Page 166
6.5.4 Are There Particular Storage Conditions for My Products That Need to be Avoided?......Page 167
6.6.1 How Much Do I Know about the Distribution Network That Handles My Products?......Page 168
6.6.3 Are There Places Where Products are Likely to be Distributed Out of Order?......Page 169
6.6.4 How Can Damage during Distribution Be Minimised?......Page 170
7.1.1 What System Should Be in Place for Handling Complaints?......Page 171
7.1.2 How Should Complaints Be Classified?......Page 172
7.1.4 What Procedures Should a Manufacturer Have in Place to Identify the Likely Cause of Complaints and Any Corrective Action Necessary to Prevent Their Recurrence?......Page 173
7.1.6 How Can Situations Likely to Result in a Product Recall Be Identified?......Page 174
7.2.1 How Effective Should a Traceability System Be?......Page 175
7.2.3 When is it Necessary to Obtain Expert Assistance in the Event of a Contamination Incident?......Page 176
7.2.4 Where Can Further Assistance Be Obtained to Deal with Complaints of a Serious Nature?......Page 177
7.2.6 When Do Product Problems Require That Enforcement Authorities Be Informed and When Should a Product Recall Be Instituted?......Page 178
7.2.7 What Should Be Regarded as a Complaint and What is a Typical Level of Consumer Complaints?......Page 179
8.2 What are the Major Sources of Waste from My Business?......Page 180
8.5 Am I Meeting My Obligations under the Packaging Waste Regulations?......Page 181
8.8 What is IPPC and Does it Relate to My Business?......Page 182
8.12 Are Coloured Plastics Recyclable?......Page 183
9.1 How Much Information Should Be Available in Product Formulations?......Page 185
9.3 How Can the Fruit or Juice Content of a Product Be Calculated for the Purpose of Declaring the QUID Value or for Confirmation of a Claim?......Page 186
9.4 How Important is it to be Able to Access Historical Formulas?......Page 187
9.6 Should the Local Trading Standards Department (or other Relevant Enforcement Authority) Be Involved in Approving Product Labels?......Page 188
9.7 How Can Nutritional Claims Be Sustained, and How Should Nutritional Data Be Obtained?......Page 189
9.9 Does Allergen Labelling Apply to Soft Drinks?......Page 190
9.10 What are the Main Statutory Requirements with Which a Beverages Manufacturer Must Comply in the United Kingdom?......Page 191
9.11 What Does a Manufacturer Need to be Aware of When Wishing to Make Nutritional Claims for a Product as Listed in EU Regulation 1924/2006?......Page 192
9.12 How is the Nutritional Value of a Product Calculated?......Page 193
9.13 Are There Any Special Health and Safety Issues That Relate to Soft Drinks Manufacture?......Page 194
References and Further Reading......Page 195
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