Complete Technology Handbook on Alcoholic and Non-Alcoholic Beverages (Fruit Juices, Smoothies, Sugar- cane Juice, Mocktails, Wine, Rum and Liquor Bottling) with Detailed Manufacturing Process and Formulations with Project Profiles

In a world brimming with myriad tastes and sensations, the art of crafting beverages has transcended mere refreshment; it has become an intricate symphony of flavors, a celebration of tradition, and a canvas for innovation. Within the pages of this compendium, "Complete Technology Handbook on Alcoholic and Non-Alcoholic Beverages (Fruit Juices, Smoothies, Sugar- cane Juice, Mocktails, Wine, Rum and Liquor Bottling) with Detailed Manufacturing Process and Formulations with Project Profiles," we invite you on an extraordinary journey—a journey through the captivating universe of beverages.

Beverages have woven themselves into the tapestry of human existence, entwined with culture, history, and celebration. From the velvety depths of wines and the timeless allure of whiskey to the effervescent charm of carbonated concoctions and the healthful embrace of fruit juices and smoothies, this handbook embarks on a quest to uncover the essence of these liquid treasures.

As we embark on this voyage, let us consider the heart of any beverage: the artistry of its creation. Behind every sip of that refreshing mocktail, every swirl of aged wine, and every exhilarating burst of carbonation lies a meticulous process—a blend of science and craftsmanship. This book serves as your guide to demystifying these processes, unlocking the secrets of formulation, and offering a glimpse into the industries that bring these beverages to life.

In these pages, you will explore the alchemy of flavorings and emulsions, understanding the magic that transforms raw ingredients into the captivating essences that tantalize our taste buds. The chapters on grape juice and citrus fruit processing reveal the meticulous care and attention required to harness the vibrant flavors of nature's bounty.

We also dive into the intriguing world of smoothies and mocktails, where fruits, herbs, and spices meld into concoctions that are as invigorating as they are wholesome. Our exploration extends to the globe's tropical corners, from the lushness of guava to the tang of passion fruit, offering a taste of paradise in each sip.

For those with an affinity for spirits, the chapters on whisky and rum take you on a journey through the history and craftsmanship behind these complex libations. Learn about the distinct distillation processes, the nuances of aging, and the chemistry that gives each bottle its unique character.

• Beer aficionados will find their thirst for knowledge quenched as we traverse the malting process, uncover the secrets of hops, and explore the diverse world of beer types, from pale ales to stouts.
  
• Vodka enthusiasts can delve into the intricacies of the vodka-making process, from raw materials to distillation, and even explore the realm of flavored and natural distilled fruit vodkas.
  
• Wine lovers will relish the insights into grape selection, fermentation, and the fine art of aging. And for those seeking to embark on their own brewing adventures, the world of microbrewery technology awaits, with equipment insights and industry know-how.
  

As we continue, we venture into the domain of country liquor bottling and the economics of blending and bottling plants, offering a comprehensive view of the industry landscape.

This book is not just a compendium of knowledge; it is an invitation to embark on your own beverage odyssey. Whether you are a seasoned industry expert, an aspiring entrepreneur, or simply an enthusiastic connoisseur, our aim is to quench your thirst for understanding the intricacies of beverage creation.

The world of beverages is a realm of sensory delight, tradition, innovation, and boundless possibilities. It is our hope that this handbook, rich with insights, formulations, and project profiles, will inspire your own journey into the fascinating world of beverages. May it be a source of both knowledge and inspiration, inviting you to raise your glass to the endless possibilities that this world has to offer.

This Book contains chapters on Introduction and Uses and Applications, Carbonated Beverages, Flavourings and Emulsions Technology, Technology of Grape Juice Processing, Citrus Fruit Processing Technology, Using of Citrus Pulp (Residue of Peel, Pulp and Seeds of Oranges, Grapefruit and other Citrus Fruits) By-products in Farm Animals Feeding, Apple Juice Technology, Flow chart of apple juice concentrate production, Smoothies Manufacturing Technology, Mocktails Manufacturing Technology, Various Tropical Fruit Juices , Whisky Manufacturing, Beer Production, Vodka Manufacturing, Rum Manufacturing, Table Wines Production, Microbrewery Technology, Country Liquor Bottling Technology, Technology of Sugarcane Juice Processing, Preservation and Aseptic Packaging, Plant Economics of Blending and Bottling Plant of Liquor from Ena , Plant Economics of Country Liquor Bottling Plant, Plant Economics of Craft Beer, Plant Economics of Drinking Mineral Water and Fruit Juice , Plant Economics of Extra Neutral Alcohol with Maize as Raw Material, Plant Economics of Fruit Juice and Smoothies, Plant Economics of Fruit Juice of Mango, Orange, Sweet Lime, Lime, Pineapple Plant (1200 ltr. Per Hour Capacity) in Tin Cans, Plant Economics of Liquor Bottling Plant (IMFL Bottling Unit), Plant Economics of Makgeolli Beer Plant, Plant Economics of Sugarcane Juice in Tetrapack, Plant Economics of Wine (Carbonated Wine) and Bottling Line of IMFL.

So, without further ado, let us embark on this exhilarating expedition into the realm of beverages, where every sip is a revelation and every bottle a testament to the artistry of creation. Cheers to your journey!

Chapter 1

Introduction and Uses & Applications

Functional Drinks

Fermented Beverages

Zero-Alcohol Beer

Non-Alcoholic Wines

Digital Age Boosts Non-Alcoholic Beverages Sales

Alcoholic beverage

Potable Alcohol (Alcoholic Beverage)

Types of alcoholic beverages

Fermented Beverages

Distilled Spirits

Compounded Beverages

Shifting Benefits and Risks

The Bottom Line: Balancing Risks and Benefits

Alcoholic Beverages Market

Legal Licenses Required

Food License

Trade License/ Eating House License

Fire Department NOC

Shops and Establishment Registration

Pollution clearance

Tax registrations Income

Infrastructure Licenses

Chapter 2 

Carbonated Beverages

Introduction

Carbonation

Health Effects of Soft Carbonated Beverages

Obesity

Dental Health

Bone Health

Ingredients Used in Preparation of Carbonated Beverage

Sweetener

Carbon dioxide

Acids

Flavouring and colouring ingredients

Emulsifiers, stabilizers and clouding agents

Foaming agents

Manufacturing Process of Carbonated Beverages

Syrup preparation

Carbonation and filling

Carbonated Water

Uses of Carbon Dioxide

Measurement of Carbonation

Carbonation determination

Carbonators

Chapter 3 

Flavourings and Emulsions Technology

Emulsion technology

Emulsion classification

Production methods

Emulsion stability

Flavourings

Nonalcoholic flavouring extracts

True fruit flavours

Imitation, artificial extracts, essences and flavours

Legislation

Flavour development

The composition of the microbial population

Starter cultures

Application of Flavourings and Emulsions

Flavor extraction and Measurement methods

Extraction of flavors:

Beverage Emulsions and Their Formulation

Solid Phase Extraction (SPE)

Solid phase micro extraction (SPME)

Steam Distillation

Super critical fluid extraction

Microwave aided extraction

Flavor analysis

Sensory Analysis

Volatile analysis

Some terms in flavor

Beverage Emulsions

Formulation of Beverage Emulsions

Effect of Oil Type on Beverage Emulsion Formation and Stability

Effect of Emulsifier and Stabilizer Type on Beverage Emulsion Formation and Stability

Thermal Treatment

pH

Presence of Minerals

Chapter 4 

Technology of Grape Juice Processing

Grape cultivars

The chemistry of grape juice

Carbohydrates

Acids

Mineral content

Phenolics

Volatiles

Modern grape juice processing

Harvesting/ripening

Process technology of Making Grape Juice

Select raw materials

Grape cleaning

Desteming and crushing

Heating for color distilling

Pressing and filtrating

Juice blending

Classification

Canning and sealing

Sterilization and cooling

Stemmer/crusher operation

Hot-break process

De-juicing/pressing operation

Coarse filtration

Bulk storage and tartrate precipitation

Enzyme clarification

Polish (fine) filtration

Hot fill

Process alternatives

Cold-pressing

Aseptic process

Concentration

Sulfur dioxide preservative

Chapter 5 

Citrus Fruit Processing Technology

Oranges

Large-scale operations

Focus on concentrate

Separation, concentration and pasteurization of oranges

Aroma and oil recovery

Lemons

Versatile revenue maximization

The oils side

Hermetic separation

Orange Juice Production Steps

Fruit Reception

Truck Unloading

Prewashing, Destemming And Pregrading

Sampling

Fruit Storage

Surge Bin

Final Fruit Washing

Final Grading

Juice Extraction

Fruit Sizing

Extractor Types

The Squeezer-type Extractor

Modifications For Premium Pulp Premium Juice “Low-oil” Extractor

The Reamer-type Extractor

The Oil Extraction System

Downstream of the juice extractors

Clarification

Screw-type Finishers

NFC Production

Oil Reduction

Adjusting the extractor

Vacuum flashing of preheated juice

Centrifugal separation of the oil phase from the clarified juice

Deoiling with Centrifuges

Primary Pasteurization

Deaeration

Long-term Frozen Storage

Aseptic Storage In Tanks

Aseptic Storage In Bag-in-box Bulk Containers

NFC Reprocessing

Concentrate Production

Tubular Evaporator Systems

Other Tubular Evaporation Systems

Plate and Cassette Evaporator Systems

Homogenization

Essence Recovery

Automatic Fruit Processing Plant -Pulp, Juice, Jam

Product Details:

Single tube heat exchangers

Multi tube heat exchangers

Concentric tube heat exchangers

Scraped surface heat exchangers/Automatic Juice Pasteurizer

Cabinet-type Orange Peel Dehydrator

Industrial Orange Peel Dehydrator

Chapter 6 

Using of Citrus Pulp (Residue of Peel, Pulp and Seeds of Oranges, Grape- fruit and other Citrus Fruits) By-products in Farm Animals Feeding

Using citrus by-products in farm animals feeding

Energy value and digestibility

Chapter 7 

Apple Juice Technology

Apple juice production process

Apple sorting

Apple cleaning

Apple crushing and juice extracting

Pasteurization

Homogenization for cloudy juice

Clarification for clear juice

Apple juice Blending

Apple juice filing and sealing

Sterilization and cooling

The end products of Apple Processing Line

Ultrafiltration system for clear apple juice

Flow chart of apple juice concentrate production

Complete line for production of juice concentrates

Apple juice enzyme treatment system

Value added products from apple pomace

Ethanol and high crude protein

Pectin esterase by using

Microbial colours

Citric acid

Clarification of Juice

Chapter 8 

Smoothies Manufacturing Technology

Preparation and Preservation Of Smoothies

Formulations

Coconut Raspberry Smoothie

Pieapple Cucumber Smoothie

Instructions

Peach Mango Smoothie

Spinach Smoothie

Pineapple Citrus Smoothie

Banana Peanut Butter Smoothie

Blueberry Smoothie

Green Pineapple Coconut Smoothie

Chapter 9 

Mocktails Manufacturing Technology

Equipments Required for Making Mocktails:

Ingredients Required

Golden Rules For Making Mocktails

Service of Mocktails

Mocktail Formulations

Virgin Mint Lemonade

Pomegranate Spritzer

Virgin Sangria

Virgin Mary

Apple Fizz

Mojito

Cindrella

Quick Fruit Punch

Classic Shirley Temple

Virgin Colada

Lemon Lavender

French 75

Rose Lemon Spritzer

Sparkling Cranberry Lime

Sunburst

Grapefruit Spritzer

Vanilla Lemonade

Orange Julius

Hot Not Toddy

Thanksgiving Punch

Sweet Sunrise

Coconut Martini

Sweet Adeline

Mango Julius

Butterbeer

Blue Lagoon Margarita

Crockpot Hot Apple Cider (Wassail)

Apple Cinnamon Mule

White Christmas Dream Cocktail

Basil and Mint Lemonade

Frost Bite Mocktail

Mulling Spices for Apple Cider

Virgin Piña Colada

Sweet Adeline

Chapter 10 

Various Tropical Fruit Juices

Nutritional Value

General steps in juice processing

Fruit Juice Processing

Significance of Few Important Steps in Fruit Juice Production

Straining/Filtration/Clarification

Disintegration

Hot break process

Mash enzyme treatment

Fruit juice extraction process

Deaeration

Kiwifruit

Varieties in India

Nutritional content

Kiwi Ready-To-Serve Beverage

Flow Chart

Ingredients used for preparation of kiwi RTS beverages

Kiwi juice/Pulp

Machines Used

Guava

FSSAI specification

Ingredients

Flow Chart

Flow-sheet for processing of RTS beverages

Guava Nectar

Mango

Preparation of Mango RTS

Materials and Methods

Process Flow Chart

Machines

Ppassion fruit juice

How to Make Passion Fruit Juice

Passion Fruit Juice Beverage Processing

Passion Fruit Juice Proces- sing Technological Flowchart

Key Machine Introduction for Passion Fruit Juice Processing Plant

Passion fruit and guava peeling and crushing machine

Passion fruit and guava mash preheating and pulping machine

Passion fruit and guava puree/juice filling machine

Pineapple

Pineapple sorting process 

Pineapple washing

Pineapple Peeling and Extracting

The second pressing

Pineapple juice filtration

Pineapple juice degassing

Pineapple juice sterilization

Pineapple juice cooling

Pineapple juice filling

Juice filling machine combines 3 functions of washing, filling and sealing

Acerola

Flow chart for the production of 6 categories of pasteurized pineapple juice

Processing of the non- sweetened acerola tropical fruit juice by hot fill method

Banana

Applications of Banana Juice

Description of Banana Juice Processing Line

Clear Banana Juice Technical Parameter

Technological Flowchart of Clear Banana Juice Processing Line

Clarification of Banana Juice

Preparation of Whey-Based Banana Beverage

Preparation of whey

Flowchart for preparation of whey

Preparation of banana juice

Process flow diagram for preparation of banana juice

Preparation of whey beverage

Flow chart for the preparation of a whey-based banana beverage

Lulo fruits

Nutritional Value

Applications

Flow chart the sample preparation and treatments

Papaya

Papaya Processing Line End Products and Package

Papaya Processing Line Technological Flowchart

Key Machine Of Papaya Processing Line

Papaya Bin Tipper

Papaya washing and sorting machine

Papaya peeling and deseeding machine

Papaya pulp preheater

Papaya pulper and finisher

Papaya puree evaporator

Papaya puree sterilizer

The Future

Juice Market Trend Analysis

The Packaged fruit juice

non-alcoholic malt beverages market

Chapter 11 

Whisky Manufacturing

Introduction

History of whisky production

Outline of whisky production processes

Individual operations

Raw materials

Malted cereals

Unmalted cereals

Mashing and cooking

Mashing

Cooking followed by malt mashing

Fermentation

Distillation

Pot still distillation

Continuous distillation

Maturation and aging

Blending and coloring

Effluent disposal and spent grains recovery

Organoleptically important components of whisky

Concentrations of organo- leptically important compounds

Chemical nature of organo- leptically-important compounds

Contribution of compounds to organoleptic properties

Origin of organoleptically- important compounds 

Chapter 12

Beer Production

The malting process

Outline of the Brewing Process

Effective cleaning and sorting of the grain

Brewing: beer production process

Hops and hopping

Fermentation

Warm fermentation

Cool fermentation

Spontaneous fermentation

Brewing yeasts

Maturation and Carbonation

Filtration

Continuous bottling

Byproducts/Waste

Process stages in beer production

Beer Defects

Light struck

Diacetyl

Oxidation

Acetaldehyde

Acetic acid

Gushing

Microbiological spoilage

Common Off-flavours and how you can fix them

Alcoholic

Metallic

Diacetyl

Estery

Oxidized

Off-flavour: Yeasty

Vegetal

Grassy

Solvent

Tannic

Off-flavour: Musty

Aceteldehyde

Sulfur

Phenolic

Sour/Acidic

Skunky

The State of the Industry

Beer Industry Segmentation

Packaging Insights:

Production Insights:

Alcoholic Content Insights

Flavor Insights:

Competitive Landscape

Different Types Of Beers

Palr Ales

India Pale Ales

Pilsners

Stouts

Porters

Brown Ales

Types of Brown Ales

Wheat Beers

Types of Wheat Beers

Sour ales

Types of Sour Ales

Chapter 13 

Vodka Manufacturing

History and the Manufacturing Process of Vodka

Process of Making Vodka

Ingredients

Vegetables or Grains

Yeast

Malt Meal

Water

Flavorings

The formula and composition of vodka

Raw Materials

Vegetables or grains

Water

Malt meal

Yeast

Flavorings

The Manufacturing Process

Mash preparation

Sterilization and inoculation

Fermentation

Distillation and rectification 

Water added

Bottling

Quality Control

Distillation

Plain vodka Process

Flavored and colored vodka Process

Natural Distilled Fruit Vodka or Liqueur

Distilling Infusions

Making Vodkas by Mixing Method

Sweet Vodkas

Use of Extracts and Essential Oils

Preparation of the Mash

Inoculation and Sterilization

Fermentation Process

Distillation and Modification 326 Adding Water

Bottling

Chapter 14 

Rum Manufacturing

Harvesting

Sugar extraction

Fermentation

Light or heavy rum

Distillation of rum

Pot (alembic) still rum production

Column still rum production

Rum terroir

Ageing rum

Charcoal filtration of rum

Rum blending

Bottling rum

Types of Rum

Carbonyl Compounds

Esters

Phenols

Alcohols

Aldehydes

Ketones

Lactones

Thiols

Miscellaneous compounds

Chapter 15 

Table Wines Production

Grape as raw material for wine

Science and technology of wine making

Production of must

Alcoholic fermentation

Fermentation

Post-fermentation treatment

Malolactic fermentation

Clarification

Fining

Filtration

Centrifugation

From wine to bottle

White wine technology

Special wines

Rosé wines

Passiti wines

Sparkling Wines

Beaujolais wines

Wine tasting

Basic steps of the winemaking process

Machinery & Equipment for Wineries

Chapter 16 

Microbrewery Technology

Microbrewery Description

The chemical composition of beer

Brewing process

Packaging

Things to Consider before Starting a Micro-brewery

Required Microbrewery Machinery & Equipment

Commercial brewing equipment

Small, medium, and large brewery solutions

Mid-Size Craft & Regional Brewers

Large Scale Automated Production & Packaging Brewers

Micro/Pub Brewery

Hypro Brewing System

Stainless Steel Tanks for Breweries

Chapter 17 

Country Liquor Bottling Technology

Liquor Bottling & RTD Plant

Manufacturing process of IMFL bottling plant

Process Description

IMFL Bottling Plant

Packaging 

Packing Standards

Packaging Requirement

Production of brandy

Components of Brandy

Ethyl Alcohol

Production of rum

Pretreatment of Raw Material

Fermentation

Fermentation Temperature

pH Value

Fermentation Time

Yeast

Distillation

Continuous Distillation

Maturing

Manufacturing process of whisky

Pressing

Fermentation

Alcoholic Fermentation

Acidic Fermentation:

Bottling

Vodka

Treatment Methods

Chapter 18 

Technology of Sugar cane Juice Processing, Preservation and Aseptic Packaging

Processing and preservation of sugarcane juice

Sugar : Processing Steps

Sugarcane Juice Processing Plant Description

Sugarcane Juice Processing Plant

Sugarcane Juice Processing Plant Main Machine Introduction

Sugarcane Juice Processing Plant Technological Flowchart

Aseptic Packaging

Schematic diagram of aseptic processing and packaging system

Chapter 19 

Plant Economics of Blending and Bottling Plant of Liquor from Ena

Plant Economics

Land & Building

Plant & Machinery

Fixed Capital

Working Capital Requirement/ Month

Total Capital Investment

Turn Over/Annum

Chapter 20 

Plant Economics of Country Liquor Bottling Plant

Plant Economics

Land & Building

Plant & Machinery

Fixed Capital

Working Capital Requirement/ Month

Total Capital Investment

Turn Over/Annum

Chapter 21 

Plant Economics of Craft Beer

Plant Economics

Land & Building

Plant & Machinery

Working Capital Requirement/Month

Total Capital Investment

Turn Over/Annum

Chapter 22 

Plant Economics of Drinking Mineral Water and Fruit Juice

Plant Economics

Land & Building

Plant & Machinery

Fixed Capital

Working Capital Requirement/ Month

Total Capital Investment

Turn Over/Annum

Chapter 23 

Plant Economics of Extra Neutral Alcohol with Maize as Raw Material

Plant Economics

Land & Building

Plant & Machinery

Fixed Capital

Working Capital Requirement/Month

Total Capital

Investment

Turn Over/Annum

Chapter 24 

Plant Economics of Fruit Juice and Smoothies

Plant Economics

Land & Building

Plant & Machinery

Fixed Capital

Working Capital Requirement/Month

Total Capital Investment

Turn Over/Annum

Chapter 25 

Plant Economics of Fruit Juice of Mango, Orange, Sweet Lime, Lime, Pineapple Plant (1200 ltr. Per Hour Capacity) in Tin Cans

Plant Economics

Land & Building

Plant & Machinery

Fixed Capital

Working Capital Requirement/Month

Total Capital Investment

Turn Over/Annum

Chapter 26 

Plant Economics of Liquor Bottling Plant (IMFL Bottling Unit)

Plant Economics

Land & Building

Plant & Machinery

Fixed Capital

Working Capital Requirement/ Month

Total Capital Investment

Turn Over/Annum

Chapter 27

Plant Economics of Makgeolli Beer Plant

Plant Economics

Land & Building

Plant & Machinery

Fixed Capital

Working Capital Requirement/Month

Total Capital Investment

Turn Over/Annum

Chapter 28 

Plant Economics of Sugarcane Juice in Tetrapack

Plant Economics

Land & Building

Plant & Machinery

Fixed Capital

Working Capital Requirement/ Month

Total Capital Investment

Turn Over/Annum

Chapter 29 

Plant Economics of Wine (Carbonated Wine) and Bottling Line of IMFL

Plant Economics

Land & Building

Plant & Machinery

Fixed Capital

Working Capital Requirement/Month

Total Capital Investment

Turn Over/Annum