Special Series : Part 1 Raw Material Pretreatment

Special Series

Part 1 Raw Material Pretreatment

IDEA’s turnkey apple and cherry processing plant equipment transforms fresh fruits through flotation washing,crushing, enzymatic treatment, juicing, ultra-filtration, concentration, and sterilization to achieve flavor-preserving and efficiency-enhanced juice extraction. The entire production process realizes full automation including automatic control and fault protection along with automatic cleaning functions. This integrated flow covers from raw materials to finished product in a turnkey project that combines advanced European and American processes with Mainland China’s investment characteristics to form a unique and excellent solution for apple and cherry processing lines. Furthermore, we provide customized turnkey project designs based on each client’s investment status and production realities delivering attentive service experiences.

Traditional processes frequently involve extensive manual participation, high energy consumption and significant material loss. Our new-generation equipment achieves intelligence high efficiency and low consumption at this stage. This series divides into three phases titled Raw Material Pretreatment, Separation Purification＆Concentration and Filling with other auxiliary engineering progressively introducing our full-chain processing plant equipment.

I. Technology-Empowered Raw Material Pretreatment Full Analysis of Our Equipment Highlights

Current juicing equipment mostly operates as standalone units with low automation especially during fruit pretreatment exhibiting problems like low impurity removal rates high energy consumption and difficult cleaning. Our key equipment including the Bar Screen Washer Paddle Flotation Washer and Crusher adopts industry-leading intelligent recognition low-temperature preservation and modular integration processes effectively solving traditional pain points to truly realize the goals of more thorough cleaning more intelligent processing and more efficient pulping.

1. Multi-Stage Washing System Cleaner and Water-Efficient
Our self-developed multi-stage spray plus bubble integrated washer employs a four-stage cleaning logic comprising primary coarse washing using high-pressure water and bubble agitation secondary spray filtration removing floating residues and impurities spray sterilization section with integrable ozone or sodium hypochlorite modules and fresh water rinsing section with recyclable water. The impurity removal rate exceeds 98 percent reaching industry-leading levels. Beyond this our key equipment can be configured with automatic water quality detection and recycling modules reducing water consumption during production by 30 percent compared to industry standards.

2. AI Intelligent Sorting System
Equipped with the latest AI visual recognition algorithms this system automatically eliminates various defective fruits including rotten fruit cracked fruit and insect-damaged fruit. Its recognition accuracy surpasses 95 percent ensuring your juice product quality. Our equipment possesses powerful single-channel processing capacity achieving 20 tons per hour. Simultaneously clients may adjust processing volume and specifications according to their needs ranging from 600 tons per day to 15000 tons per day to accommodate different application scenarios.

3. Crushing and Preheating Integrated Device and High-efficiency Flavor Preservation
Crushing serves as the key step transforming fruit flesh from solid to pulp state. Traditional crushing methods cause oxidation due to frictional heat generation. Our equipment employs a variable-frequency disc crusher that dynamically adjusts crushing size between 1-2 centimeters during early stage and 2-3 centimeters during late stage based on apple ripeness. Smaller particle size enhances juice yield for underripe fruit while larger particles prevent pectin membrane blockage for ripe fruit.
? Low-speed spiral crushing blades minimize thermal damage
? Integrated with automatic preheating chamber enabling direct temperature-controlled processing post-crushing to prevent pectin sedimentation
Key parameter highlights include
? Operating temperature control maintains 55 to 65 degrees Celsius preventing substantial vitamin loss
? Vitamin C retention rate exceeds 90 percent
? System incorporates automatic slag discharge and CIP cleaning pipelines reducing daily cleaning time by 40 percent

II. Modular Integrated Design

The complete raw material pretreatment system adopts modular stainless steel frame structures allowing rapid combination upgrades and maintenance according to client capacity requirements.
? Single-line processing capacity ranges between 20 and 40 tons per hour
? Standard layout occupies less than 4500 square meters featuring compact footprint and high unit efficiency
? Pre-assembled equipment enables rapid on-site commissioning with deployment completed within just 7 to 10 days demonstrating strong adaptability

III. Next Issue Preview

Part 2 Purification and Concentration coming soon

We will explore the most invisible aspect of juice processing how to retain fruit aromas effectively and how to achieve energy conservation during concentration. IDEA’s membrane separation plus vacuum concentration system will unveil the solutions.