Non-Alcoholic

Beverages
TSP II
A. Non-Carbonated Beverages
COFFEE
 Its indigenous to Ethiopia and was discovered in the early 15th
century. The tree where coffee is obtained from belongs to the plant
family Rubiaceae
 Types of Coffee
 Arabica coffee- cultivated from a plant called Caffea arabica
 Robusta coffee-cultivated from the plant Caffea canephora
About coffee

 The coffee plant is perennial and evergreen

 If left wild, the coffee tree can grow to a 10m height but it is normally
pruned to 3 meters to facilitate harvesting
 Robusta coffee must be cross-pollinated whereas Arabica coffee is
self-pollinating.
 The flower ovary of the plant usually develops into a drupe that is
initially green and later ripens into a bright red colour
 The two seeds are enclosed within the berry.
Comparisons between arabica and Robusta
coffee
ARABICA ROBUSTA

Grows in highlands, requires plenty of Lowlands, warm and humid climate

rainfall, requires colder temperatures
Prone to most diseases and pests Resistant to both

Requires plenty of attention during growth Less attention

Large, lighter beans produced Smaller, heavier beans produced

Low caffeine content High caffeine content, hence better

Higher acidity Less acidic, (suitable for instant coffee)

CONT..

COFFEE PESTS
 Nematodes –attack roots
 Coffee berry borer-berries
 Fruit flies-development of an undesirable onion flavour
 Coffee diseases
 coffee rust
 Coffee berry diseases
Processing Methods

 There are two major coffee processing methods

1. Dry processing
 It is used for Robusta and overripe and under ripe Arabica coffee(mbuni)
 The beans are sun-dried
 Dry beans are mulled whole
2. Wet processing
 It is done for red, ripe Arabica coffee
 Controlled harvesting ensures that over and under ripe beans are
excluded
 High quality products are processed/obtained
PROCESSING METHODS

 Bean reception
 Pulping stage
 Grading/classification
 Fermentation
 Final wash
 Drying
 Roasting
 Grinding
 Liquoring/tasting
1. Bean reception

 Harvested beans are transported quickly to the processing factory to:

 Avoid overheating
 Prevent bean discoloration
 Beans are preliminarily classified and sorted to remove leaves and
twigs
 The beans are further sorted to only remain with the red ripe ones
 Sorted beans/coffee are loaded into a receiving tank filled with water
 The tank is equipped with a weir-that allows separation of the floating
beans and a siphon that transports the heavier berries to the pulper
2. Pulping stage

 It aims at removing the outer skin of the berries

 It is done under running water, where the berries are subjected to
squeezing, compressing and tearing
 The parchment and mucilage are left intact
 The mucilage acts as a lubricant hence prevents bean damage
 The water is used for cleaning and also as a means of transporting
the beans
 Unpulped cherries pass through a narrow adjustment and are
repulped
3. Grading or classification

 Classification is carried out based on the weight and size of the beans
 Pulped beans pass through a series of vibrating sieves and are
classified into three grades
 Each grade is channeled separately
4. Fermentation
 Fermentation aims at removing the mucilage
 It is done in concrete tanks (painted tanks could contaminate the coffee.)
 It is an enzymatic process in which proteolytic enzymes break down the mucilage
 The mucilage contains pectin and sugar, and hence acts as a nutrient for microbial
growth(is therefore unwanted). It also attracts dust.
 Fermentation may occur under natural conditions although the optimum temperature
is 35 degrees Celsius and a Ph of 5-6.
 Enzymes used may be naturally present or externally added
 Fermentation takes about 48 hours, though the fermentation rate depends on the
enzyme concentration
 At the end, the parchment should become gritty and rough
 NB: sugars ferment to produce propionic acid which causes “onion” flavor, due to
prolonged fermentation
 Prolonged fermentation also gives rise to stinkers
5. Final wash

 It improves the colour and quality of the coffee

 NB: overipe cherries or those that have been delayed during
processing acquire a brown parchment
6. Drying
 The cherries contain about 55% moisture. Drying aims at reducing it to 10% for
storage.
 Sun-drying(solar-drying) is used with continuous racking and turning of the coffee to
allow even drying
 Drying occurs in a number of stages:
 (i) Skin-drying stage: moisture is reduced to 45%. Surface microbes that cause rotting
are reduced.
 (ii) White stage: Moisture is reduced to 30 %. This stage results in the development of
fatty acids, significant in the quality of the bean.
(iii) Soft black stage: Sunlight is necessary at this stage to form the colour of the bean .
Moisture content is reduced to about 20 %
(iv)The black stage: Drying can be done at a faster rate at this stage. Moisture
content is reduced to 11%
(v) Conditioning stage : Moisture content is reduced to 10%
7. Roasting(export coffee is not
roasted)
 It is done at 180 degrees-200 degrees Celsius (medium roast)
 Roasting time varies, depending on the roasting equipment used
 Roasted coffee is cooled immediately to reduce flavor losses
 Objectives of roasting
 1. Roasting induces desirable chemical reactions that lead to flavor
development, e.g. the breakdown of carbohydrates to simple sugars
 It causes the release of oils onto the surface, making it shiny. The
more the oil the better the quality, because they retain the flavours
 Disadvantage: Excessive roasting causes the extracts to become
bitter. It also leads to the loss of flavor compounds
Objectives of roasting cont..

 2. Causes the colour to change from grey to green, to chocolate

brown, which is the final colour of the beverage
 3. Roasting increases the level of extractables, hence improving the
body of the coffee.
 4. Beans become brittle and easier to mill
8. Grinding

 Before being used as a beverage, coffee is ground(size-reduced)

9. Liquoring/Tasting

 Ground coffee is dissolved in hot water and tasted for aroma, flavor,
and body.
 The information obtained is used for blending purposes and for
payment in auctions
Composition of coffee
 Minerals- They contribute to the colour of the raw beans . Excess potassium causes a
brown colour which is undesirable.
 Caffeine- caffeine is a stimulant present in coffee. Robusta coffee has a caffeine
content of 2.2%, Arabica coffee- 1.2%
 Amino acids and proteins- proteins mainly contribute to the flavor of the coffee,
mainly sulphides.
 Carbohydrates-most are water-soluble hence contribute to the thickness of the liquor.
Carbohydrates also contribute to the acidity and flavor of the coffee.
 Lipids- mostly contribute to the aroma in coffee
 NB:
 Flavour in coffee is mainly contributed by aldehydes, ketones and sulphides. Oils help
retain and distribute flavor. They also reduce foaming.
 Taste is determined by soluble non-volatile components e.g. carbohydrates, minerals,
oils, caffeine, and some acids. These components also contribute to the body of the
brew and the thickness of the liquor
THE MILLING PROCESS FOR
EXPORT COFFEE BEANS
 In Kenya, this process is done at the new KPCU(Kenya Planters Cooperative
Union)
 After drying, the coffee beans meant for export are subjected to processes
that aid in the removal of the parchment, and sometimes the silver skin too.
 1. Cleaning: It is aimed at removing contaminants like sisal, soil etc.
Aspirators, and winnowing magnetic separators are used.
 2. Hulling: The beans are then subjected to functional forces between
rollers to remove the parchment.
 The silver skins may or may not be removed.
 If not removed, hulled beans must be passed through a polisher(series of
brushes), to remove the silver skins.
 The hulls and silver skins are then removed by the use of a blower.
Cont..
 [Link] grading : Sieves of varying sizes are used, through which
beans are passed and graded depending on the sieve size.
 4. Sorting: Beans are passed through an electronic sorter that
removes –deformed Beans, discoloured beans, beans attacked by
insects, and beans that contain foreign matter inside.
 5. Storage: Sorted beans at a moisture content of 10% are packed
and stored at a Relative humidity of 60%
 If not properly stored, mould activity is accelerated.
NB: Packed coffee is then handed to the coffee board for auction
INSTANT COFFEE PROCESSING
 Instant coffee is made from Robusta varieties
 PROCESSING
 Beans

 Blending

 Roasting

 Grinding

 Extraction

 Drying

 Aromatization

 Packaging
Instant coffee processing cont..
1. Blending: Varying varieties of beans are mixed to obtain products of desired quality
2. Roasting: It aids in rich flavor development and colour development
3. Grinding: It helps reduce the size of the grains in between fine and coarse grains.
4. Extraction: Powdered or ground coffee is dissolved in water(the most common) or in
some other solvents.
5. Drying: The solution obtained above is either freeze-dried or spray-dried.
 Freeze drying: The solution is first pre-concentrated then freeze-dried.
 The principle of freeze drying is that fluid coffee will be frozen at -40 degrees Celsius.
The ice that remains will be ground to grains. The frozen coffee grinds are then passed
to the freeze drying chambers. The chambers are airless(vacuum). The fluid withdraws
from the grains by a concentrated heat supply. Before the grinds melt, the ice changes
into steam. Also here, the fine powdered coffee remains.
 Advantage: It yields products that are of a good texture, and that are porous(which is
a good coffee instant characteristic).
 Disadvantage: It is very expensive
Cont..
 Spray drying: The solution obtained is first pre-concentrated, then
dried into a powder. The powder obtained is then instantised.
 The principle behind spray drying is that a hot stream of air is used to
evaporate the fluid. The coffee is pulverizing under high pressure in a
tube where streams of hot air pass through. The water from the coffee
evaporates and brown coffee powder remains that will be collected at
the end of the process.
 Advantages:
 Is a relatively simple and short process
 Is cheaper than freeze-drying
 Disadvantages:
 The high temperatures used cause a loss in some volatiles which
have/need to be added.
 The high temperatures affect the aroma, colour and taste of the
product
Cont..
 6. Aromatization: Volatile aromas that might have been recovered
from earlier steps in the manufacturing process are sprayed on the
dry coffee particles. This step may be done during the packaging
operation.
 7. Packaging: Instant coffee particles are hygroscopic, that is
they absorb moisture from the air. Consequently, they must
be packaged under low humidity conditions in a moisture-
proof container to keep the product dry until purchased and
opened by the consumer. Also, to prevent loss of aroma and
flavor, the product is packaged in a low-oxygen atmosphere.
TEA PROCESSING

 Tea comes from a terminal bud of the plant Camellia sinensis

 Tea originated from China
 It is grown in Kenya by both small scale and large scale farmers
CHEMICAL COMPOSITION OF TEA
 1.)Minerals: the most predominant mineral in tea is potassium, 4-5%
 2.)Polyphenols: They are very important components of tea. They
undergo chemical reactions to yield colour and flavor in tea.
 3.) Proteins and amino acids
 4.) Vitamin B2
 5.) Aromatic compounds: they contribute to flavor in tea
 6.) Pigments: Chlorophyll is a basic component of tea but is degraded
during processing. Anthocyanin is also a pigment present in tea.
 7.) Carbohydrates: are found in small quantities in tea
 8. )Pectin
 9.) flavonoids
 10) caffeine
 11)enzymes like:
 Polyphenol oxidase
 Peroxidase
Factors affecting leaf/shoot
composition
1. Genetics: Various genotypes have varying compositions.
 Examples of the major genotypes include Camellia sinensis and
Camellia assamica
 2. Environment:
 Is inclusive of cultural practices, altitude, climate and harvesting)
 a.) Cultural practices- Involves mainly what happens to the in the farm
e.g. pruning, fertilizer application and shading of the bushes.
 b.) Altitude: Tea from higher altitude areas(e.g. Muran’ga and Kericho)
is more superior in quality compared to that from lower altitude areas.
 c) Climate: Rainfall, temperatures and day length
o The best climatic conditions are those which favor the slow growth of
tea bushes, which yield the best quality.
o The disadvantage of this slow growth is that it affects yield, hence its
not economically viable.
o Solution: The best climate is that which is in between, not too slow nor
too rapid.
o d) Harvesting:
Cont..

 d) Harvesting:
o Plucking standard- Refers to the size of the harvested shoot. The
recommended size is two leaves and a bud. The yield may be
increased by increasing the number of leaves picked, but this lowers
the quality of tea.
o Damaging of leaves should be avoided
o Harvested tea should not be bulked
o The tea should be processed immediately(minimal tea delay)
o Tea is usually harvested and put into baskets and is carried at the
back of special trucks
TYPES OF TEA
 Types of tea manufactured are classified depending on the length of
fermentation on the leaf.
 Green tea: It is usually blanched to inactivate enzymes, no fermentation is
done
 Oolong tea: Partial fermentation takes place to some extent, but does not
go to completion.
 Black tea: Fermentation is allowed to completion( is most common tea in
Kenya)
 Yellow tea: Also called blue tea.
 it occupies an intermediate position between green and black tea and is
closer to green tea. The yellow infusion is brighter than green tea. It has a
milder taste and aroma than green tea and is extremely popular in India.
 Its produced from the 2nd and 3rd leaves and tender shoots of the plant.
 Its processing steps include: withering, roasting and rolling and finally
firing
 White tea; It is fermented tea peculiar to china.
 Its made from large and medium leaves with profuse hair, sprouting buds
are used for processing
MANUFACTURING OF BLACK TEA
 A) WITHERING
• This is the partial drying process, where air is used at 38 degrees Celsius
to dry the leaves (moisture content is reduced from about 80% to 60-68%.)
• Functions of withering
• It prepares the leaf for the nest stage
• It makes the leaf tissues flaccid, hence permeable to juices.
• It encourages both physical and chemical changes in the leaf.
• Advantages of withering
• It encourages biochemical reactions e.g. increase in enzymatic activities
that facilitate fermentation
• Encourages oxidative reactions
• Components associated with quality in tea increase during withering
• Withering increases essential oils which aid in aroma development
Cont..
 Characteristics of Unwithered tea
o Unwithered tea has a stripped cortex resulting in a lot of fibre in the
final product
o It hampers oxygen supply
o Can be water-logged in the next stage
 The Degree of wither can be expressed in the following ways:
1.) weight of the withered leaf × 100
weight of the fresh leaf
o The weight of the withered leaf is expressed as a percentage of the
weight of the fresh leaf.
o disadvantage: the method can be misleading because the moisture
content of the fresh leaf can vary
Cont..
 2. weight of dry tea × 100

Weight of withered tea

 Weight of dry tea expressed as % of the withered tea
 Advantage: it is reliable because the moisture content of dry tea is
some-what a constant
Withering systems
 1. Natural withering
 It is not used in Kenya. Withering is accomplished by air in natural
circulation.
 Tea leaves are placed on the floor with a wire mesh netting, covered
with a hessian cloth
 Disadvantages:
 No control of speed, temperature or relative humidity
 The rate of wither depends on natural conditions and the drying time
Cont..
 2. Controlled withering: can be done by the use of the following methods:
 A. Tunnel withering
o The leaves are spread on trays and the trays are put onto mobile trolleys
o These trolleys are wheeled into the tunnel and the tea leaves are subjected to a
warm air blast at 38 degrees Celsius.
o B. Trough withering (done in Kenya)
o The trough has an air conduit(passage) at the bottom.
o Air is drawn into the conduit by the use of a fan and is blown over a heater
o Air attains a temperature of about 38 degrees Celsius and it is blown through the
bed of leaves
o Drying takes 18-21 hours
o The air direction/flow can be reversed.
o Advantages:
 Air parameters can be controlled(temp, R.H, Speed)
 There is effective withering, whose rate depends on air parameters and time
 Uniform drying of product is achieved
Cont..
 C. Continuous withering
o Tea leaves are placed on perforated trays
o The trays are placed on a moving, perforated belt
o Warm air flows upwards through the perforations(belt and tray), and
the leaf bed
o The belt speed is variable and determines the withering time.
Factors affecting leaf withering
 1. Extent of leaf damage: Damages cause premature chemical changes to take place,
causing changes in the leaf appearance and liquor quality
 2. Type of leaf received:
 The standard is two leaves and a bud
 Coarse plucking(more than two leaves and a bud) leads to slow withering
 The size of the leaf affects the physical withering process, while the chemical composition
of these leaves affects the chemical withering process
o 3. Moisture content of the leaf surface:
 Is determined by the time of harvesting
 Degree of water is determined by time and surface moisture
 Surface moisture encourages bacterial growth
o 4. Thickness of the spread:
 Determines the air flow rate through the bed
 The thicker the spread, the lower the flow rate
 A thicker spread therefore lowers/reduces the degree of withering and increases the
withering time
 Uneven spreading due to sagging troughs also causes uneven withering
Cont..
 5. Drying air parameters: It determines the drying capacity of air(e.g.
temp, Relative humidity, speed)
 6. Duration of withering
 Influences the quality of the final product
 Short/over-withering results in low quality tea
 Recommended withering time is 18-20 hours
 B. ROLLING
 Is a process that brings together the enzyme and substrate
 Macerating the leaf tissues breaks down the cell walls and cell
membranes to extract the substrate(contained in the cells) and mixes it
with the enzymes( found on the outside of the cell).
 Rolling also mixes in oxygen that facilitates fermentation
 Methods of rolling/cutting
 1. Pressure rollers(orthodox)
 Is a batch method
 Consists of a vertical calendar whose lower ends rest on a table
 It contains a rod with protrusions(cutters)
 The cylinder is closed by a cap that determines the pressure(the screw
adjusts pressure)
 As the rod rotates, the protrusions cut the leaf and twist it
 Cut leaf pieces are then recycled.
2. Legg cutter
 Tea leaves are compressed into a form cake
 The cake is cut into small stripes
 3. Lawrie tea processor
 Has a barrel with a shaft carrying a series of knives and beaters
 The shaft rotates at a high speed
 Tea leaves are blown into a barrel/ machine where they are cut by the use
of knives
 Cut leaves are then discharged by the means of a centrifugal fan
 4. Rotar vane( used in Kenya)
 Both the batters and the vane are cutters
 The vane works in a series with CTC machines
 5. CTC Machines
 Are horizontally mounted stainless steel rollers.
 They rotate in opposite directions at different speeds
 Each roller is corrugated and the gaps between the teeth vary, becoming
progressively smaller. The corrugations(teeth)cut the leaves.
 C. FERMENTATION
 Is an enzymatic reaction. It refers to the oxidative chemical reaction
mediated by enzymes and the substrates are polyphenols
 Polyphenols are preset in the vacuoles while the enzymes are in the
cytoplasm.
 Rolling aids the mixing of enzymes plus substrate
 Fermentation takes place in the presence of oxygen
 Polyphenols (Gallocatechin) + Oxygen O-
Quinone
 + ( Catechins) polyphenol oxidase
 catechol oxidase
 O- diphenol oxidase

 Theaflavins bis-
flavonols


 Thearubigins
Changes during the fermentation
process

 1. Loss of the green colour to acquire a coppery-red shade

 2. Loss of the grassy odour to acquire a pleasant aroma of fermented
tea
 3. Loss of the bitter taste of unoxidated tannins to produce a pleasant
, tender and astringent taste
 Nb: Theaflavins influence flavor. Therefore, the higher their content,
the better the tea quality
 Thearubigins are colour compounds
Effects of variables during fermentation
 1. Oxygen supply: adequate amounts are needed. If less, fermentation will
not reach the desired extent.
 2. Temperature: done at 32.2 degrees to obtain maximum theoflavin
content.
 High temperatures decrease/lower the oxygen solubility making it less
available.
 3. Time- Is determined by the colour change of the leaf.
 Fermentation is stopped when the colour is deep copper-brown or red.
 Green Yellow Brownish yellow Light brown
 Deep copper brown/red
 Time normally ranges between 45minutes-3 hours, but largely depends on
fermentation temperature
 4. Extent/degree of wither: an excessive increase in the degree of withering
causes a decrease in theaflavin content
 5. Ph: At 4.5-4.8 pH, there is an increase in theaflavin content, therefore better
quality
 6. UV Radiations: Exposure to this light causes an increase in the theaflavin
content hence improved flavor, increased fermentation rate and improved
colour
 7. Size of leaf : The smaller the leaf the faster the reaction rate, due to a
more rapid oxygen diffusion
Other fermentation reactions..

 Pectin methyl esterase produces methanol which is lost(volatilized)

during storage
 Chlorophyllase breaks down chlorophyll, hence the loss of the green
colour
 Cycosidase breaks down glycosides to release some volatile
substrates
Fermentation Methods
 1. Floor fermentation:
 Cut leaves are spread on a concrete floor to a depth of 1-2 cm. The floor absorbs the heat generated
 Disadvantages
 Large floor area is required.
 Danger of bacterial build-up may occur if the floor is not smooth
 [Link] fermentation
 The cut leaf(dhool) is spread on trays stuck on frames in a fermenting room.
 There is natural circulation of air
 3. Tub (used in Kenya) fermentation
 Leaves are placed on perforated wire meshes . An air conduit supplies oxygen
 These tubs are mobile. Air supplies oxygen and also provides a cooling medium for temperature
control. The air supplied has to be humid to prevent the drying of the leaf
 4. Continuous fermentation
 The dhool is spread on moving perforated belts or trays
 A continuous air flow is maintained through the perforated trays/belts and bed of tea leaves
 At times, the leaves from the top belt drop on the lower belt or tray(providing a turning effect)
Disadvantages;
It is expensive( moving parts)
and difficult to clean/maintain
 D. DRYING/FIRING OF TEA
 Involves exposing the tea leaves to high temperatures without
burning. Temperatures used are averagely between 100-105 degrees
Celsius.
 Lower temperatures can be used in order to retain the volatile
components of the tea. Drying time is very critical
 i. fast drying- causes case hardening
 ii. Slow drying- long exposures to high temperatures cause the
development of an unpleasant taste(stewed tea)
 Drying functions:
 i. stops fermentation: when maximum quantities of desirable
components are produced, enzymes are then inactivated. This
happens at a temperature of 100 degrees Celsius and an moisture
content of 20%
 ii. Fixes the colour of the tea
 iii. Aids in preservation: reducing the moisture content of the tea
prevents microbial proliferation.
Drying methods/ equipment
 1. Endless chain drier
 Consists of perforated moving belts, stuck one on top of the other.
 Air is heated in a heater using wood or oil or gas as fuel and is blown by the use of a fan through the leaf bed on
the belts
 Air temperatures can be as high as 200 degrees Celsius
 Countercurrent tea and air movements are encouraged for better drying
2. Fluidised bed drier
 Particles of tea are fluidized in the air on a perforated bed
 Hot air(150 degrees Celsius) at high velocity fluidizes the tea
Disadvantages of fluidised bed drier
 Stewing may occur in the early stages before fluidizing takes place
 There is no precise control over the drying time
 High air velocities may cause the loss of volatile substances
Advantages of both methods
 Reduced/low maintenance costs due to fewer moving parts
 Yields clear tea of less fiber
 Achieves even firing of tea particles
 E. SORTING
 Dry tea is passed through electrostatic rollers to remove fibres and stalks
 It is then sorted in terms of size on electric vibrating screens (sieves) and
graded as follows:
 Orange pekoe (OP)
 Pekoe fannings (PF)
 Broken orange pekoe( BOP)
 Fannings
 Dust(D)
 The tea obtained is then assessed for
 Briskness
 Brightness
 Strength
 Body
 Colour
 Flavour
 Aroma
 acidity
INSTANT TEA
 Soluble materials are extracted from the tea leaf, the water is then
evaporated to yield instant tea. This done after fermentation.
 PROCEDURE
 i. Extraction: The soluble substances are extracted with hot water at 80-90
degrees Celsius . A dilute solution of about 5% tea is obtained
 ii. Decreaming: The extract is separated from the leaf by centrifugation or
filtration. The resulting extract is cooled and a milky precipitate or cream
forms.
 This material is removed to form a product that is soluble in cold water.
 Iii. Concentration: The solution is then concentrated by
o Vacuum concentration, or
o Freeze concentration
 Concentration is done in two stages: first up to 40% solids, then followed by
the actual drying
 Nb: if concentration is done in an evaporator, most volatile components
would be lost. To avoid this, the aromas are first stripped then added back
later after concentration
Iv. Aroma stripping:
 Is done by the use of nitrogen, carbon dioxide or steam
 The gas/steam is passed through the solution and carries with it the
volatiles
 The stripped tea solution is then concentrated by any of the above
methods
 The aroma is added back to the final concentrate
V. Drying
 The concentrated solution is then dried by spray drying or freeze
drying to get instant tea powder.
 Helpful properties of tea:
1. Helps in digestion
[Link] a good medicine against mental fatigue
3. reduces blood pressure
4. it has antimicrobial properties
5. long term intake of tea catechins help in weight loss
Carbonated Beverages
 Carbonated drinks are beverages that contain dissolved carbon
 dioxide.
 CO2 + H2O H2CO3
 (carbon (water) (carbonic acid)
 Dioxide)
 Carbonated beverages are generally prepared by mixing flavored syrup with
carbonated water, both chilled.
 Carbonated beverages in the form of naturally occurring carbonated mineral
water have been known to exist since long.
 Presence of carbon dioxide in aerated water and carbonated drinks enhance
both palatability as well as appearance of these products.
 The origin of carbonated water is traced back to the work of Joseph Priestly
who produced first man-made carbonated water in 1767.
 Carbonated drinks are invariably consumed without dilution and include
crushes, lemonades, cola drinks and mixed drinks.
 Carbonated beverages are quite popular across the globe with an impressive
dominance in world beverage market.
Ingredients
 1. Water
 It is the main ingredient of carbonated beverage that comprises more than
90% of the total volume.
 The water which is used in preparation of carbonated beverages must of
very high potable standards.
 Therefore, water pre-treatment is necessary to ensure the high standards of
finished beverage such as removal of microscopic and colloidal particles by
coagulation, filtration, softening and pH adjustment in the areas where
water is of poor quality.
 Disinfection and chlorination remains the preferred method for the
destruction of microorganisms.
 High level of nitrates in the water could be considered as possible risk for
infants. It may also cause corrosion of tin plate and perforations of lacquer
lining of cans.
 De-aeration of water is also required to facilitate subsequent carbonation
and filling operations to minimize foaming problems.
Cont..
 Water used in carbonated beverage must possess following
properties:
 Low alkalinity, to check neutralization of acids otherwise it would
affect flavours and may decrease preservation effect of acids.
 Low iron and manganese, to prevent reaction with flavouring and
coloring compounds
 No residual chlorine- as it affects flavour adversely and cause
oxidation
 Very low turbidity and colour, to impart attractive appearance to the
drink.
 Organic matters and inorganic solids must be very low, as it provides
nuclei for CO2, resulting in beverage boiling and gushing at the time
of filling or opening of bottles.
Ingredients cont.
2. Sweetener
 Sweetener serves three basic functions in carbonated beverages; impart sweetness, provide
body and calorie.
 Sweetener used primarily in carbonated beverages is crystal sugar which must be of very high
purity. It is used in the form of sugar syrup and final concentration of sugar varies between 8
to 14 percent in finished beverage.
 However, other sweeteners like glucose syrups, invert syrup, High fructose corn syrup (HFCS)
etc. may also be used.
 Low calorie carbonated drinks invariably contain high intensity sweeteners or artificial
sweeteners such as saccharin, aspartame, acesulfame-k and/or sucralose.
3. Carbon dioxide
 Carbonated beverages contain carbon dioxide which sparkles the beverage and imparts
fizziness,
 CO2 gas is inert, non-toxic, almost tasteless, easy to produce and impregnate in the liquid as
compared to other gases.
 It is also available at relatively lower cost in liquefied form.
 It is soluble in liquids where its solubility increases when the temperature of liquid is
decreased and it can exist as gas, liquid or solid.
 CO2 produces carbonic acid when dissolved in water which in combination with other
ingredients produces acidic and characteristic biting taste of carbonated water and beverages.
 CO2 may be obtained from carbonates, limestone, burning of organic compounds and
industrial fermentation processes. CO2 obtained by any process is purified to ensure that it is
free from impurities and fit for human consumption.
 Purification of CO2 is done by scrubbing with water to remove sulphurous compounds and
passing through activated charcoal or carbon tower to remove odorous compounds. Many
beverage manufacturers produce their own CO2 on site by using packaged system.
Ingredients cont..
.4 Acids
 Application of acids enhances the flavour and it also contributes towards the preservation
of the beverage.
 Wide varieties of acids are available for carbonated beverage manufacture, but citric,
malic; fumaric, tartaric and phosphoric acid are most commonly used. Phosphoric acid is
mainly used in cola type of beverages.
5. Foaming agents
 Presence of foam in headspace is considered desirable in certain carbonated soft drinks,
such as ginger beer and colas.
 The most effective foaming agents are saponins which are extracted either from the bark
of Quillaia or Yucca trees. The permitted level is up 200 ppm (in European Union) and 95
ppm in USA.
Ingredients cont.
6. Flavouring and colouring ingredients
 The flavouring component of the sugar syrup has the major influence on the flavour of the
final product, used at very minor amounts i.e. 0.01 to 0.02 %.
 The nature of flavouring usually is determined by the type of the product. Fruit flavours are
most commonly used, except in colas, which are flavoured by extract of cola root together
with about 10% caffeine and a mixture of essences.
 Fruit flavour may be added in the form of juice, as comminuted (in the case of citrus fruit)
or as an essence. Juice is normally used as a concentrate, citrus fruits; especially oranges
are most widely applied.
 Essences may be prepared from artificial or natural sources. Artificial flavouring is not
preferred because of doubtful safety. Natural citrus essences are composed largely of
essential oils from the peel of the fruit. Hydrocarbons mostly limonene, constitute more
than 90% of the oil, but contribute little or nothing, to flavour, acting primarily as a carrier.
 Important colouring agents for carbonated beverages synthetic colours particularly certified
coal tar colours. Caramel obtained from heated or burnt sugar is non synthetic colour and
are widely used in cola beverages. Permitted food dyes are generally preferred over natural
fruit colours because of their greater colouring power and stability. Even when natural fruit
extracts or juices are used their colours are generally supplemental with synthetic colours.
Ingredients cont..
 7. Emulsifiers, stabilizers and clouding agents
 Emulsions may be used to impart cloudiness and/or as flavouring
agent as flavoured emulsions.
 The clouding agent must contribute to opacity without affecting
colour, taste or odour.
 A soy protein based clouding agent has been found effective for use.
 Stabilizers are used both to stabilize emulsions and also maintain the
fruit components in dispersion. Besides they also improve mouthfeel
and viscosity of the beverages. Most commonly used ones include
guar gum, gum Arabic, pectin, CMC and alginates.
Processing of carbonated beverages
1. Syrup preparation

 Syrup is usually prepared by mixing 1 part (volume) syrup to 3-6

parts (volume) water in stainless steel tanks fitted with top driven
agitators.
 In sugar based products, the syrup typically consists of sugar syrup of
67 Brix strength, citric acid, flavouring, colourings, preservatives and
water.
 Sugar syrup is passed through a plate heat exchanger to decrease
the microbial load.
 Syrup is pre-prepared, tested and diverted to proportioner for mixing
with water and carbonation. Flow meters are most frequently used for
proportioning.
 The syrup is dosed through a mass flow meter and the water dosing
is done volumetrically by using a magnetic induction flow meter.
 2. Mixing:
 Mixing of water and syrup is fundamental to food processing operations, such as in the
preparation of ingredients, the addition of solids to liquids and the development of
structure.
 3. Injection of CO2 :
 Carbonation in soft drinks creates the bubbles that float to the top when the drink is
opened. These bubbles are carbon dioxide gas that is suspended in the liquid and are
released when the bubbles pop at the surface because these processes in which
injection of Carbon dioxide into the soft drink.
 4. Bottle filling & Capping:
 It is a Machines based-process used for filling of liquids or beverages into bottles. The
process involves bottle filling & fixing of the bottle cap seals at the top of the bottles.
Thick-walled, reusable, glass bottles were used for many years, but are being replaced
by thin-walled, non-reusable glass and increasingly, PET bottles.
 8. Refrigerated Storage: Beverages should be stored at a cool temperature (0 to 7
degrees celsius)
Carbonated Water
 The consumption of carbonated water has increased rapidly. As per
FSSA definitions, carbonated water is water conforming to the standards
prescribed for packaged drinking water under Food Safety and Standard
act, 2006 impregnated with carbon dioxide under pressure and may
contain any of the listed additives singly or in combination.
 Permitted additives include sweeteners (sugar, liquid glucose, dextrose
monohydrate, invert sugar, fructose, Honey) fruits & vegetables
extractive, permitted flavouring, colouring matter, preservatives,
emulsifying and stabilizing agents, acidulants (citric acid, fumaric acid
and sorbitol, tartaric acid, phosphoric acid, lactic acid, ascorbic acid,
malic acid), edible gums, salts of sodium, calcium and magnesium,
vitamins, caffeine not exceeding 145 ppm, ester gum not exceeding 100
ppm and quinine salts not exceeding 100 ppm.
 It may contain Sodium saccharin not exceeding 100 ppm or Acesulfame-
k 300 ppm or Aspartame not exceeding 700 ppm or sucralose not
exceeding 300 ppm.
Packaged Drinking Water (other than mineral water)

 It can be defined as water derived from the surface water or

underground water or sea water which is subjected to herein-under
specified treatments, namely decantation, filtration, combination of
filtration, aerations, filtration with membrane filter depth filter,
cartridge filter, activated carbon filtration, de-mineralization, re-
mineralization, reverse osmosis and packed after disinfecting the
water to a level that shall not lead any harmful contamination in the
drinking water by means of chemical agents or physical methods to
reduce the number of micro-organisms to level beyond scientifically
accepted level for foods safety or its susceptibility.
 The standards, packaging and labelling requirements have also been
specified under FSSA rules.