Orange Juice Concentrate Production Process

Stage 1: Thorough Washing and Sorting

Following quality approval, the fruit enters a multi-stage washing line:

Immersion: The oranges are initially immersed in water tanks to thoroughly remove dust and initial debris.

Mechanical Washing: The oranges then pass through rotating brushes while being simultaneously washed with clean, high-pressure water sprays.

Final Inspection: At the final stage, the fruit passes along a visual inspection conveyor. The quality control team carefully identifies and removes damaged, pest-affected, or rotten fruit.

Stage 2: Oil Extraction

At this stage, the selected oranges enter the peeler, which is equipped with stainless-steel grooved rollers. By creating controlled abrasions on the surface of the peel without damaging the inner fruit tissue, the system facilitates the release of natural citrus oils.

At the same time, water nozzles spray the fruit surface at controlled pressure, allowing the resulting water-oil emulsion to be collected. This citrus oil, containing the natural aroma and characteristic compounds of orange, is subsequently separated and purified for use as a valuable by-product in the food, pharmaceutical, and cosmetics industries.

Stage 3: Juice Extraction and Primary Filtration

After oil extraction, the oranges enter the main juice extraction section. At this stage, the juice is separated from solid fruit tissues, including peel and seeds.

The extracted juice is immediately transferred to the primary filtration unit, where coarse pulp particles, peel residues, and seeds are carefully removed to prepare the juice for subsequent processing and purification.

Stage 4: Centrifugation, Pasteurization and Concentration

At this stage, the raw juice passes through disc centrifuges to reduce suspended pulp content to below 7%. Immediately afterward, rapid flash pasteurization is carried out at 87–95°C to inactivate naturally occurring enzymes while preserving the product’s flavor quality.

The clarified juice is then transferred to the evaporator. This is a critical stage in preserving product quality, with a residence time of only 5–7 minutes inside the evaporator. The process is carried out under vacuum conditions, ranging from atmospheric pressure to full vacuum, allowing the product to reach a concentration of 61 ± 1°Brix at lower processing temperatures while minimizing the loss of volatile aromatic compounds.

Stage 5: Aroma Recovery

During evaporation, volatile aromatic compounds are separated from the juice along with water vapor. We use an advanced two-phase aroma recovery system designed to capture and separate both water-phase aromatics and oil-phase aromatics.

Essential oils and aromatic compounds obtained from high-quality citrus fruit grown in the provinces of Gilan and Mazandaran are reintroduced into the product at this stage, helping preserve the fruit’s natural, fresh aroma and flavor in the final concentrate.

Stage 6: Packaging, Freezing and Cold Chain

Following production, the final concentrate is filled into aseptic bags and rapidly frozen to −18°C to preserve maximum quality.

To ensure product quality, safety, and traceability, each drum is assigned a unique serial number linked to the complete production records and quality control analyses of its corresponding batch. This enables full traceability throughout the supply chain.

Packaging Specifications and Storage Conditions

To preserve the quality and safety of the concentrate throughout its shelf life, our packaging and storage processes comply with stringent food industry standards:

  • Primary Packaging: The concentrate is filled into 260 kg aseptic bags made from food-grade polyethylene, providing a sterile and isolated environment for the product.
  • Secondary Packaging: The aseptic bags are placed inside steel drums with an internal epoxy coating, providing the necessary protection against environmental factors and the pressures associated with transportation.
  • Storage Conditions: The product must be stored at −18°C (±2°C) in a dry, cool environment, away from direct sunlight.

Shelf Life: When the recommended storage conditions are fully maintained and the integrity of the primary packaging is preserved, the product has a shelf life of up to 36 months from the date of production.

Benefits of Orange Juice Concentrate

Orange juice concentrate is a rich source of essential nutrients, including vitamin C, potassium, and natural antioxidants. These compounds contribute to its distinctive refreshing taste and offer a range of nutritional benefits.

In addition to its nutritional properties, orange juice concentrate is a versatile ingredient with a wide range of industrial applications. Concentration reduces the water content of the juice, helping inhibit microbial growth and extending its storage stability compared with fresh juice.

Beyond its distinctive aroma and flavor and its industrial versatility, orange juice concentrate contains valuable nutrients and bioactive compounds that can contribute to overall health:

Powerful Immune Support: Its high vitamin C content supports the normal function of the immune system and helps the body maintain its natural defenses.

Cardiovascular Health and Antioxidant Properties: Antioxidants in orange juice concentrate help neutralize free radicals and reduce oxidative stress, supporting cardiovascular health and normal circulatory function.

Healthy and Radiant Skin: Beneficial compounds such as vitamin C and beta-carotene, a precursor of vitamin A, contribute to skin health, support collagen production, and help protect cells against damage caused by ultraviolet (UV) radiation.

Blood Pressure Regulation: Essential minerals such as potassium, together with other beneficial compounds, support electrolyte balance and contribute to the maintenance of normal blood pressure.