Chapter 8

Beverages and Related Products

Muhammad Atif Randhawa, Moazzam Rafiq Khan, Masood

Sadiq Butt and Naveed Ahmad*

Abstract
Beverage market is divided into many categories with country wise variation. The
first category includes non-alcoholic entities such as coffee, tea, soft drinks,
nectars, carbonated drinks and juices. In some specific countries, these are used on
special festivals whereas, in some territories alcoholic beverages are preferred.
Beverages play their role as energy booster in our diet as they have high content of
sugar whereas, juices extracted from fruits and vegetables also provide vitamins,
minerals and other phytonutrients essential for the functioning of human body. All
beverages have some basic ingredients like sweeteners, acidulant, colors, flavors,
preservatives and water being the main ingredient, while fruit and dairy based
beverages contain juice, pulp or dairy ingredients. Processing of beverages include
various unit operations such as raw material handling, selection, syrup room
operation, pasteurization, deaeration and homogenization followed by packaging.
Packaging is mainly concerned with final presentation as well as promotion of
beverages and also prevents beverages from spoilage. In this chapter effort is made
to discuss the various processes carried out in preparation of beverages.
Keywords: Beverages, Classification, Processing, Ingredients, Production,
Spoilage, Safety
8.

*
Muhammaf Atif Randhawa˧, Moazzam Rafiq Khan, Masood Sadiq Butt and Naveed Ahmad
National Institute of Food Science and Technology, University of Agriculture, Faisalabad, Pakistan.
˧
Corresponding author’s e-mail: atifrandhawa@yahoo.com

Managing editors: Iqrar Ahmad Khan and Muhammad Farooq

Editors: Tahir Zahoor and Masood Sadiq Butt
University of Agriculture, Faisalabad, Pakistan.
218 M.A. Randhawa, M.R. Khan, M.S. Butt and N. Ahmad

8.1. Introduction of Beverage

Water is one of the basic needs to sustain life by quenching thirst and it also fulfills
the needs of other body processes and functions. Beverages are meant to
accomplish these desires with additional flavor, nutritional and functional
requirements. Fruit juices were the first known beverages fermented to increase
shelf life resulting in wines. Later on many other types were evolved which will be
discussed later in this chapter. Pakistan enjoying temperate and tropical climates
holds the potential of huge productions of fruits and other horticultural produce,
both for the purpose of local consumption and export. This country is ideal for
commercial cultivation of several fruits like mango, orange, apple, guava, apricot,
grapes, peach, plums, pears, pomegranate and many others.
After harvesting the fruits begin to soften if proper subsequent handling and
processing is not performed, so in ancient times extracted juice declined
aesthetically due to uncontrolled fermentation. The shelf life of juice based
beverages depends upon extraction conditions, processing and packaging. In the
recent era people want ease in food consumption, so consumer friendly and ready
to serve foods are increasing by leaps and bounds. The trend is increasing to
convert perishable commodities like fruits and vegetables into beverages
worldwide. Mostly grapes, orange, pineapples, tomato, mango and their blends are
tailored into juices and occupy major place in national and international market.

8.2. Types of Beverages

Some categories of beverage provide nutrients along with energy and positive
mood feelings, while others just fulfill our taste desire and some are health related.
As the beverages are rich source of readily available energy therefore people
regularly consuming sweetened beverages must judge the portion size that up to
how much content they should consume. The over consumption of beverages can
result into obesity and related health problems. Some people are weight conscious
and need calorie free beverage so they should use beverages like water, coffee, tea
and particularly the diet drinks (Ashurst 2005). According to Codex Alimentarius
“juice extracted from healthy, ripe fruits which is not fermented but fermentable
should be obtained by mechanical means and must be preserved by mechanical
means”. The juice may be clear or opaque depending upon its concentration or
water added but objective must be to adjust the composition. Addition of sugars
and organic acids must be in accordance with rules and regulations”. Juice can be
puree or pulp if it can be poured slowly or more slowly respectively. Juices are
further processed into concentrates which can be reconstituted to required level of
total solids designated as °Brix. Water addition must be according to standards
formulated by national and international food regulatory authorities in order to
protect consumers from economic fraud (Shachman 2004). Important types of
beverages are given bellow.
8. Beverages and Related Products 219

8.2.1. Water and its Types

Like all living things human body also needs water for hydration and it plays
essential role by contributing in life processes. Water intakes are quite difficult to
estimate but eight glasses of water are generally considered as daily requirement of
a healthy individual. The National Research Council (NRC) suggest intake of 1 ml
of water for each K Cal in adult male diet depending upon weight of an individual
i.e. 70 Kg. Types of water which are mostly considered for drinking purposes
include well water, tap water, potable water, spring water, purified water, bottled
water and mineral water.

8.2.2. Alcoholic Beverages and their Types

Beer, wines, spirits, liqueurs and rice wines are considered as major types of
alcoholic beverages. Other sub-types also depend upon the quantity of alcohol,
basic ingredients, processing and aging. These beverages provide energy to our
body while some types of beers and wines also provide minerals (like potassium,
phosphorus), trace minerals and even vitamins. Beers are prepared by the
fermentation of cereal grains especially barley while wines can be prepared from
fruits (like grapes, plums, apricots, peaches etc.), jaggery, molasses etc. but grapes
are mostly used for production of wines. In Beer making, Wort is liquid mix that is
made by adding malted cereals and yeasts and contains 4-8% alcohol. By
distillation of fermenting juice, whisky is made, while Rum is obtained from
fermented molasses aged at least for 36 months followed by addition of caramel
color. Oak casks are used for fermenting fruit to produce brandy which attains its
color from oak casks. Alcohol, flavors and water are combined to produce gin after
distillation. Aging does not affect the gin so casks are not used. Most of liquors
used for making gin or brandy contain 20-65% alcohol and they are consumed in
small amounts (Hornsey 2003).

8.2.3. Fruit based Beverages and their Types

8.2.3.1. 100% Juice
Juice obtained from whole food units and available in the forms like fresh-
squeezed, home squeezed, pulp free fortified and contains phytonutrients. This
juice contains no added water and without any additives like acidulants, colorants
or preservatives (Ringblom 2007). These are also free form carbohydrate based
sweeteners.
8.2.3.2. Fruit Drinks
Drinks contain juice but less than 100% and these are usually sweetened by
carbohydrate based sweeteners. Typically, the fruit drink should not contain less
than 12% fruit juice. However, it depends on country regulation which varies
among different parts of the world. The labeling guidelines must include percentage
of juice in drink (Hui and Evranuz 2012).
220 M.A. Randhawa, M.R. Khan, M.S. Butt and N. Ahmad

8.2.3.3. Fruit Nectars

These are sweetened fruit containing beverages which are prepared by addition of
30% fruit juice or pulp. These types of drinks are gaining popularity all over the
world among masses due to their rich taste, mouth feel and nutritional contents.
8.2.3.4. Soft Drinks
These drinks include non-alcoholic beverages that contain sweeteners, flavoring
and other ingredients. Drink can be calorie free or calorie rich depending upon the
type of sweetener. Soft drinks can be mild, low or high calorie, caffeine free or
caffeinated and carbonated (Ashurst 1999).

8.2.4. Sports Beverages

In order to support optimal activity and vigor of players specially formulated
beverages used are called sports beverages and they provide energy to boost body
performance as well rehydrate and restore the electrolyte balance of body after
strenuous performance (Soccol et al. 2013).

8.2.5. Energy Drinks

The energy drinks are also becoming popular in various parts of the world and most
of the energy drinks provide same type of the formulations. Most of the energy
drinks provide numerous nutrients to body like Vitamin-B complex, carbohydrates
and amino acids as well as herbal extracts, taurine and caffeine. Taurine (an amino
acid) is supposed to improve athlete performance and also regulate mineral balance
in the body and thereby enhances body ability to exercise.

8.2.6. Tea and its Types

Green, black and oolong are three major types of teas, although obtained from same
plant but difference occurs due to enzymatic reaction known as fermentation.
However herbal teas are also found in wide range and often considered as green tea
due to lack of knowledge. Now-a-days prepared tea and instant tea is also available
in some markets. Black tea is fully oxidized and frequently used in western cultures
while milk tea is popular in Pakistan and India (Wolf et al. 2008).

8.2.7. Coffee and its Categories

Coffee is more popular in USA and Europe than that of Pakistan and Asia.
Blending and roasting are very important processing steps to determine the flavor
and type of coffee. Caffeine is the main stimulant in coffee coupled with flavor and
aroma. One cup of coffee provides 75-150 mg of caffeine making it richest source
among other foods, while decaffeinated coffee only provides 3 mg/cup caffeine.
Coffee beans do not provide any significant amount of energy but other ingredients
like cream, milk and sugar are responsible for that (Potter and Hotchkiss 1995;
Steen and Ashurst 2008).
8. Beverages and Related Products 221

8.2.8. Dairy-based Beverages

Drinkables which not only contain milk as ingredient but also depend on milk for
its remarkable characteristics are known as dairy-based beverages. Various types of
milk products like condensed, evaporated, sweetened, skimmed, whole milk etc.
can be used alone or in combination with other ingredients or microbial cultures
can be used for this purpose. These products are nutritious and health promoting
which contains numerous compounds likes vitamins, minerals and calcium etc. A
cup of milk contains 280 mg of calcium which contributes to 1/3rd of calcium daily
requirement and it is also a source of vitamin D. The labeling guidelines must
include percentage of juice in drink (Hui and Evranuz, 2012). Fat content of milk is
main factor that tells about the energy content of milk while skim milk is fat free
and has less amount of energy (Marsh et al. 2014).
8.2.8.1. White Milk
Milk is defined as complete lacteal fluid obtained by full milking process of
mammalian animals. Milk (mainly cow’s milk) is considered as complete diet due
to its minerals and vitamins. This product dominates in total milk-based beverages
with huge consumption worldwide. Largely, different processing techniques like
pasteurization and UHT are coupled with suitable packaging material (polyethylene
bags and tetra-pack respectively) to ensure the product safety and shelf life.
8.2.8.2. Fermented Milk
Milk processing includes the addition of suitable microbial cultures mainly Lactic
Acid Bacteria (LAB) to produce numerous products like kefir or yoghurt. These
products have unique health promoting properties due to availability of probiotics,
prebiotics and essential nutrients.
8.2.8.3. Drinking Yogurt
This fermented milk product is prepared by somewhat similar processing of
fermented milk and homogenization is used for production of drinking yoghurt
with the addition of stabilizers, emulsifiers and sweeteners to maintain its texture.
Texture of yoghurt is broken by homogenization and cooled before packaging but
due to dry matter and homogenization its body is liquid and viscosity becomes low.
In order to protect from settling the stabilizers are added (Masson et al. 2011).
8.2.8.4. Flavored Milk
Milk is flavored to enhance aesthetic preference and also provides our body with
numerous ingredients like minerals and vitamins. Flavors like strawberry,
chocolate, banana, vanilla etc. are added to make the products more delicious and
attractive. Flavored milk is relished by all age groups like children as well as old
age people. This is a good choice for milk consumption to intrigue the children to
drink the milk to meet their dietary needs. Flavored milk is produced by adjusting
solid not fat (SNF) and fat followed by pasteurization then homogenization occurs
and flavor addition is carried out at the last step before primary packaging (Masson
et al. 2011).
222 M.A. Randhawa, M.R. Khan, M.S. Butt and N. Ahmad

8.2.9. Soy-based Beverages

This milk is produced from soybeans by water extraction and necessary processing
for product safety. It is rich in protein and minerals like calcium and iron etc. This
product is also available in flavored forms to meet the nutritional needs of Asian
countries where milk availability is not large enough to meet population needs.
This milk has soy proteins which are somewhat similar to that of cow’s milk for
amino acid availability but less saturated fat and devoid of lactose (Santos et al.
2014).

8.2.10. Syrups and Squashes

Syrups and squashes are examples of the products preserved by high sugar
concentrations but still preservatives are used for additional product safety. Syrups
can be prepared by fruits, dry fruits or herbs while squashes are by fruits only.
These are popular beverages in regions like sub-continent where summer is very
hot and more water is needed to quench thrust and support life. These beverages are
diluted before consumption typically in the ratio of 1:5 for syrups and 1:4 for
squashes.

8.3. Beverage Ingredients

8.3.1. Water
Water is the main constituent of all beverages which may account for 90% of the
product and also acts as a carrier for remaining beverage ingredients. Therefore, its
quality must meet stringent requirements regarding taste, appearance, and other
important physico-chemical characteristics, typically required for beverage
manufacturing. Depending upon the location of beverage plant, the water may be
contaminated with a number of impurities or contaminants that may adversely
affect the beverage flavor and may also cause serious health hazards. The water
should meet following quality characteristics and must be free from objectionable
taste or odor, high levels of mineral salts, and off course the organic matter. The
water should also be colorless and transparent, free from microbes, and dissolved
gases. The water impurities can be divided into following broad categories like
suspended particles, organic matter, high alkalinity and nitrates (Steen and Ashurst,
2008). In order to achieve the desired degree of purity in the water, it is necessary
to design a robust water treatment process which can address all issues related with
water contaminants. Although it is not possible to explain the water treatment
process in detail in this chapter, however, effort has been made to create an
overview of the water treatment process. A schematic sketch of a typical flow chart
of traditional water treatment process is shown in Fig. 8.1.
The simplest form of water treatment is to pass water through sand filter in order to
remove any particulate material followed by activated carbon filtration unit to
remove possible odour, smell, taints and organic matter, if any. Thereafter
polishing filter of 2µm be used to remove cryptosporidium. For hard waters, it is
necessary to install a coagulation plant or ion exchange or ultrafiltration. Ion
8. Beverages and Related Products 223

exchange can also remove the nitrates which may be present in water due to
excessive usage of nitrogenous fertilizers. As for as microbiological risk is
concerned, the water is usually chlorinated up to 8ppm chlorine level and held for
at least 2 hours. Ozonation is also becoming popular as an alternative tool for
chlorination particularly for the treatment of drinking waters, spring waters and
bottled waters. This step is followed by activated carbon filtration to remove
residual chlorine from water and the water is then passed through UV lamps
capable of delivering 50,000 microwatt-seconds per square centimeter to achieve
complete disinfection (Lund et al. 2000).

Fig. 8.1 A schematic flow diagram of water traetment process Source: (Lund et al.
2000)

In soft drinks preparation, it is sometimes mandatory to subject raw water to

membrane filtration to achieve desired water quality. In membrane filtration
pressure is applied to create a differential for movement of materials through semi-
permeable membrane from which the smaller molecules permeate and larger sizes
are rejected by the membrane depending on the pore sizes. Ultrafiltration, nano-
filtration and reverse osmosis systems operate in different particle size ranges.
Microfiltration operates at higher particle range followed by ultrafiltration, nano-
filtration and reverse osmosis. Typically, reverse osmosis, nano-filtration,
ultrafiltration and microfiltration operate in the range of 0–1nm, 0.6–5nm, 1–
200nm and above 100nm, respectively. The higher pressures are required for
separation of molecules from the smaller pore sizes (UNEP 2008).
Reverse osmosis obtains its name from the process of osmosis, in which the water
of low dissolved solids diffuses through a semi-permeable membrane into another
solution of higher solute content. A special case of osmosis is when instead of the
low solute solution, the pure water is permeated through membrane. The pure water
as "the low solution diffuses" through membrane into the high solute solution
(Fig. 8.2). The use of reverse osmosis is well-established for desalination of
224 M.A. Randhawa, M.R. Khan, M.S. Butt and N. Ahmad

drinking water and the production of deionized water for process use (Dvorak
2014).
Water Salt solution
Semi-permiable
membrane

Water

High pressure

Water Salt solution

Pure
Water Semi-permiable
level membrane
increased

Fig. 8.2 Reverse Osmosis Mechanism

Source: (Dvorak 2014)

For effective reverse osmosis, the raw water should have low turbidity otherwise
membrane can be damaged and it will result in membrane fouling or damage. As a
rule of thumb raw water is always passed from sand filter and coagulation process
before subjecting to semi permeable membrane in conventional filtration process.
In traditional filtration systems, all the solvent (water) passes through the mesh,
where as in reverse osmosis system two products are obtained i.e. permeate and
retentate. The retentate is often called as concentrate, because it is that part of
solution which does not flow through the membrane. Under the force exerted by
pump, it flows through another outlet given in the system and also carries the
material rejected by the semi-permeable membrane. In this way the material
rejected by membrane is concentrated and also known as concentrate. In order to
facilitate the process, retentate is usually maintained in a range of 10-15% of the
water being treated. This ratio also depends on the type of impurities preset in the
water (Steen and Ashurst 2008).
8. Beverages and Related Products 225

8.3.2. Sweeteners for Beverages

Sweetness in a beverage is contributed by sugar or by artificial sweetener. Sugar is
soluble carbohydrate sweetening matter which contains carbon, hydrogen, and
oxygen. Sugar is one product that is 99.9% pure. It has no vitamins, no minerals, no
undesirable impurities, just pure sweet sucrose and carbohydrate energy.
Granulated sugars vary due to crystal size and method of processing. Large crystals
indicate the purity of sugar, larger the crystals the purer the sugar. Glucose, fructose
and lactose have 0.7, 1.2 to 1.7, 0.4 times sweetness level by taking sucrose as base
having sweetness equivalent to 1 (Ringblom 2007).
Principal sugar and syrup used in manufacturing of soft drinks are sucrose, dextrose
(D-glucose) and liquid sugar. Other sugars, such as fructose (Laevulose), lactose,
maltose are rarely used in beverage manufacture. The major food value of
carbonated beverages is obtained from the sugar ingredients, since most carbonated
beverages contain about 10% of sugar, the total amount of calories contributed by
an 8 Ounce (226.80 mL) bottle is less than 100 calories (Wolf et al. 2008)
Besides sugar being a sweetener also function as: helping in producing a balanced
flavor soft drink by balancing the acid and other taste-producing components,
furnishes body to the beverage and carry the flavor.
While selecting the sweeteners, the requirements to be considered may include the
relative sweetness of various sugars, degree of solubility and crystallization,
specific gravity of syrups, water content in dry sugars, hygroscopicity, specific
flavor, molecular weight, osmotic pressure and tendency towards browning.
8.3.2.1. Sucrose
Sucrose is a disaccharide which is commercially obtained from sugarcane and
sugar beet. Sugar is the principal sugar used in the carbonated beverage industry.
Excessive impurities present in sugar is the cause of foaming at the filler, resulting
in short filled bottles, beverage ingredients spilled on the bottle surface and
reduction in the speed of operation; sediment in the beverage; off taste or masking
of beverage flavor; off odor or yeast or bacterial spoilage. In fruit juices, which are
all more or less acidic, sucrose undergoes inversion depending on the pH of the
juice, the time and the storage temperature. Therefore, sucrose must contain no
more than 0.015% ash and free from any objectionable taste or odor. Originally
present acidic properties of sucrose are enhanced at high temperatures. Traces of
salts such as NaCl, MgSO4, CaCl2, and KHPO4 tend to increase inversion. Alkaline
salts such as NaHCO3, Na and K carbonates minimize inversion. While nitrogen
compounds (Ammonium salts, Amino Acids and Amides) increase both inversion
and color through Millard or browning reaction (Yam and Lee 2012).
8.3.2.2. Liquid Sugar
The commercial sources of a sweet beverage depend to a great extent on
uniformity, texture and distinctive taste and this depends greatly on the sweetening
agent. The presence of certain non-sugar solids in trace amount can completely
mask certain beverage flavors. For this reason the beverage industry demand a truly
neutral sweetener, this is available in most perfect form as highly standardized
226 M.A. Randhawa, M.R. Khan, M.S. Butt and N. Ahmad

liquid sugar. The bottler’s constant emphasis on higher standards of quality is

reflected in the continuing advanced refining techniques utilized by producing
sugars for beverages. Sucrose syrup, invert liquid sugar and corn syrup are
available which exceed the acceptable industry standards for dry sugars. These
liquids are refined to an extremely low ash and organic non-ash content, and
adjusted to a specific pH, since these may be detrimental to flavor. Ash contents as
low as 0.1% have shown to render synthetic flavor distinguishable after a few
weeks shelf life. Slight variation in sugar will alter not only the flavor, but color,
consistency and stability of beverage. Liquid sugar is equal to the quality of
bottler’s grade dry sugar (Marsh et al. 2014).
Liquid sugar is sugar dissolved in water. The three types are (a) Sucrose: which is
made from cane or beets (b) Invert syrup: made by inverting sucrose syrup and (c)
Corn syrup: made from corn starch. Soft drinks taste the same weather made from
dry sucrose, liquid sugar or from invert type liquid sugar. The liquid sugar in the
market may be classified as follows:
1) A liquid sucrose solution filtered through char with the result that all the
taste and odor are removed by additional purification with the aid of
vegetable carbon, after which the solution is concentrated to 60oBrix and
is water-white. Analysis shows solids 68%, 0.2% invert sugar, 0.05% ash,
pH 6.5, water-white and showing no turbidity (Soccol et al. 2013).
2) A liquid sucrose solution also containing about 67% of sucrose, but
leaving more ash than the first category and having a slight coloration.
3) A partially invert liquid sugar that contains about equal quantities of
sucrose and invert sugar. This type of sugar is more suitable for beverage
manufacturers because of two reasons:
a) It contains less water and manufacturer does not pay more on the
transportation charges.
b) Since solid contents are very high, there are less chances of yeast
contamination. A typical analysis of 50% invert sugar is 76% solids,
0.05% ash.
4) A partially inverted liquid sugar, containing about an equal quantities of
sucrose and inverted sugar but more ash and color than the highest grade
liquid invert sugar.
8.3.2.3. Invert Sugar
Invert sugar is a mixture of 50% dextrose and 50% fructose. When sucrose is acted
upon by acids or certain other agents, such as enzymes, it combines with water and
is broken down in to equal parts of two simple sugars, dextrose and laevulose
(Wolf et al. 2008).

8.3.3. Preservatives
Antimicrobials are the chemicals added intentionally to control the growth of
microorganisms. All fruits and vegetables have natural micro-flora (yeast, mold and
bacteria) on their surface which can ultimately spoil the beverages and also can
8. Beverages and Related Products 227

result in cross contamination etc. Therefore, preservative or antimicrobial agents

are added to enhance shelf life and storage stability of the beverages. Yeast is the
most important in case of fruits and vegetables because it is naturally present on
fruits and vegetables and it can cause spoilage of fruit based beverages. Another
thing that makes beverages susceptible is their high water activity which favors the
growth of microbes. Furthermore, ready to serve beverages/drinks/juices usually
contain optimum sugar level required for the proliferation of microbes, thus making
them susceptible to spoilage. Therefore, beverages are preserved by preservatives
as well as by adopting the GMP throughout the beverage processing (Lund et al.
2000).
8.3.3.1. Sorbic Acid
Sorbic acid is a natural component of unripe berries, where it occurs along with
malic acid. It is a white crystalline powder with melting point of 133°C and having
chemical formula CH3CH=CH2–CH2=CHCOOH. It is available commercially as
sodium, potassium and calcium sorbate. However, potassium sorbate is more
commonly used in beverages as well as for other food preservation purposes. The
solubility of potassium sorbate is not very good (0.16% m/v at 20°C). In contrast to
benzoic acid, sorbic acid is effective even at high pH values (6.0-6.5).. Sorbic acid
is effective against yeasts (Candida, Saccharomyces, Streptococcus, Trichoderma),
mold and a few bacteria. In USA, the sorbic acid has given GRAS status and its
permissible usage level in different foods is 0.05 - 0.3%. In EU countries its
permitted levels range between 0.015 - 0.2%. However, in soft drinks it is usually
used at 0.03% level. Sorbic acid is considered as safe preservative as human body
can metabolized it just like fatty acids, therefore WHO has set the ADI for sorbates
at 25mg/kg body weight (Hui and Evranuz 2012).
8.3.3.2. Benzoic Acid
Benzoic acid is also naturally occurring organic acid in fruits and vegetables and
particularly in cranberries, where its concentration can go up to 0.08%. In its pure
form benzoic acid is a white crystalline powder with melting point of 122°C and
having chemical formula C6H5COOH. It is commercially available as sodium,
potassium and calcium salt of benzoic acid. However, sodium benzoate is preferred
form due to its fairly good water solubility (0.35% m/v at 20°C) than other two
forms and it is more commonly used in beverages as well as for other food
preservation purposes. The complete dispersion of benzoate in the batch is
recommended before addition of acid due to its possible localized precipitation in
the medium. In contrast to sorbic acid, benzoic acid is only effective at low pH
values (4.0-4.5), with increasing pH values its activity decreases very significantly.
The optimum activity is noticed at pH 3.0.
Benzoic acid is effective against molds, followed by yeasts and least effective
against bacteria. Therefore, its synergistic effect with sulphur dioxide or sorbate
gives good results. Its permissible level in carbonated and fruit based beverages
range between 0.03-0.05%, whereas much higher levels (0.10%) are allowed in
concentrated fruit based products like syrup, jam and jellies.
228 M.A. Randhawa, M.R. Khan, M.S. Butt and N. Ahmad

The sorbates are excreted in urine of humans through Hipuric acid pathway.
Human body can detoxify benzoic acid in the liver, which can metabolize up to
90% of the ingested benzoates; therefore 5mg/kg body weight is the recommended
ADI for benzoate (Shachman 2004).
8.3.3.3. Sulphur Dioxide
Romans used sulfur for preservation of wines in storage barrels. The ease with
which it can be produced and its germicidal effects on bacteria, molds and yeasts
makes it a versatile antimicrobial food additive. Its distinct mode of action of
creating anaerobic conditions (suffocation) in the medium/solution makes it perfect
antimicrobial agent. Now-a-days various sulfur dioxide liberating chemicals are
available in the market of which potassium and sodium metabisulphite are most
commonly used. As with most of the antimicrobials the effectiveness of sulfur
dioxide is greatly increased in acidic conditions and its optimum pH is less than
4.0. This makes sulfur dioxide ideal preservative for most of the beverages
formulations. However, the drawback of sulfur dioxide is its reactivity with organic
components making trihalomethanes and other related compounds and convert
sulfur dioxide to bound form. Free sulfur dioxide must be available in the medium
to perform its action. Another disadvantage of sulfur dioxide may be its allergic
reactions to some groups of population e.g. asthma. Sulfur dioxide can be used up
to 1000 ppm level in concentrated citrus juices; however, its use is becoming
limited in EU legislation up to 20 ppm in fruit juices. The recommended ADI for
sulfur dioxide is 0.7 mg/kg body weight (Shachman 2004).

8.3.4. Acidulants
Acidulants are usually third major component in the beverage formulations. In
addition to thirst quenching properties the acidulants also provide a number of
important functions in the beverages such as reducing the pH and ultimately
preserving the beverages, enhance flavor, and also increase storage stability of the
beverages by preventing discoloration and rancidity. The most commonly used
acidulants in the food industry are citric acid, lactic acid, acetic acid, phosphoric
acid, etc. In beverage, citric acid and phosphoric acid are used in large quantities in
contrast to lactic and acetic acid being used in other food products in substantial
quantities. Malic acid is also becoming popular in fruit flavored carbonated drinks,
and in low calorie cider and apple drinks. It is also used to mask the off-taste of few
sugar alternatives. Fumaric acid is being used in some parts of the world in herbal
based drinks and instant fruit powder drinks (Wolf et al. 2008).
8.3.4.1. Citric Acid
Citric acid is a white crystalline solid, available as granular powder or the
anhydrous form. However, the anhydrous form is more commonly used by soft
drink formulators. Citric acid is natural constituent of the citrus family and unripe
lemons contain up to 8% of citric acid. It has fruity character and therefore
preferred ingredient for fruit flavored beverages. It is also the major organic acid in
currants and cranberries. Traditionally, citric acid was commercially produced from
8. Beverages and Related Products 229

limes and lemons and now-a-days it is being produced by controlled enzymatic

break down of mono and disaccharides (Wolf et al. 2008).
8.3.4.2. Phosphoric Acid
Phosphoric acid in its pure form is color less crystalline solid and used in syrupy
liquid form in beverage formulations. Phosphoric acid is the only inorganic acid
widely used in cola flavored carbonated soft drinks. Because, its typical astringent
acidity complements the dry, balsamic character of cola based drinks. The
phosphoric acid has drier and sharper flavor than citric or tartaric acid and
responsible for giving flat sourness as compared to fruitiness of citric acid.
Phosphoric acid is commercially available in various concentrations such as 75, 80
and even 90% strength. Phosphoric acid is corrosive to most construction materials
therefore food grade stain less steel utensils are recommended (Ashurst 2005).

8.3.5. Colors
Unquestionably, colors are vital constituents of foods. It is probably one of the first
characteristics perceived by the senses and is indispensible to the modern day
consumer as a means for the rapid identification and ultimate acceptance of food.
Almost all foods from raw agricultural commodities to finished products have an
associated color acceptance to the consumer on the basis of social, geographic,
ethics and historical backgrounds. From a modern manufacturing viewpoint, color
additives are also indispensible. Recent initiative in the food color field has been
taken up by the EEC (European Economic Community) and the FDA (food and
drug administration of USA). The initiative was taken in the early 1950s jointly by
the Food and Agricultural organization (FAO) and the World Heritage Centre
(WHC) of the United Nations. The Codex Alimentarius Commission and the joint
expert committee on food additives have evolved a thorough procedure for
checking the safety of any additives which may be present in food. The major
factors included are evaluation and establishment of a clear specification, the
undertaking of biological studies such as acute toxicity, short and long term feeding
studies, metabolic studies and effects to identify mutagenic potential and hyper-
sensitivity reactions (Tennant 2008).
8.3.5.1. Stability Properties of Colors
The stability of synthetic food colors toward the conditions prevailing in food
processing depends upon a number of factors including action of light, effect of
food processing temperature, action of alkalis and acids, action of food
preservatives, action of ascorbic acid and action of reducing and oxidizing agents.

8.3.6. Flavors
In the modern age, the most skilled flavors manufacturing processes are based upon
scientific knowledge and technical control, because of the high quality assurance to
the consumer and absolute uniformity. Since a considerable amount of knowledge,
skill and experience is necessary in the extraction, compounding and blending of
such essences, this has now grown into a specialized industry. Flavoring materials
used in making soft drinks are primarily alcoholic extracts, emulsion, alcoholic
230 M.A. Randhawa, M.R. Khan, M.S. Butt and N. Ahmad

solutions or fruit juices. Sometime essential oils or aromatic chemicals dissolved in

a solvent are referred to as extracts. Alcoholic extracts are made by percolating
finely ground dry materials with alcoholic solution or by washing immiscible flavor
oils that have been secured by pressure or distillation with a water-alcohol mixture
and then allowing the oil to separate (Dasgupta 2015).
Vanilla extract is the flavoring extract prepared from vanilla with or without sugar,
dextrose or glycerin. Peppermint extract is the flavoring extract prepared from oil
of peppermint, or from peppermint. Other examples of alcoholic extracts are lemon
and lime flavors. Emulsions are prepared by emulsifying the essential oils with
gum acacia, mixing with a heavy sugar or glycerin syrup and then running the
mixture through homogenizer e.g. orange flavor. Simple spice extract are made up
of solutions of volatile oils in dilute alcohol. Some of the more common spice
extracts are allspice, anise, cardamom, cinnamon, clove, coriander, fennel, ginger,
mace, nutmeg, orange flavor and rose. The criteria to be observed for beverage
flavors should be solubility, acid resistance and non-contaminating.

8.3.7. Carbon Dioxide and Carbonation

The main constituents of a carbonated soft drink are flavored syrup, water and
carbon dioxide. Carbon dioxide is the smallest constituent by weight but usually the
largest by volume. It provides the characteristic sparkle to all carbonated soft drinks
and also prolong the shelf life of the product. The popularity of carbonated drinks is
due to the unique taste, zest and sparkle imparted by CO2.When dissolved in water,
CO2 produces carbonic acid and the solution is chemically active because of its
acidic properties. Its pH value is in the range of 3.7 to 3.2. In beverages
manufacture, CO2 not only provide the distinctive taste of carbonated drinks, but
also inhibit the growth of harmful bacteria. The CO2 action is just an additional
safety factor and cannot be any excuse for relaxing strict sanitary conditions (Yam
and Lee 2012).
8.3.7.1. Properties of Carbon Dioxide
Carbon dioxide is a color less, noncombustible, slightly acid gas with slightly
pungent odor. It is heavier than air and has a specific gravity, compared to air of
1.529. In common with other gases, carbon dioxide is more soluble in water at
lower temperature than at higher temperature. One liter of CO2 at 0°C and at a
pressure of 760 mmHg weight 1.977 g. it can be poured from one vessel to another
as water can. It exists in three states: Solids (dry ice), liquid and gas. Temperature
and pressure conditions determine the existing conditions (Yam and Lee 2012).
8.3.7.2. Use of CO2 in Soft Drinks
The storage of fruit juices under compressed CO2 is a practiced method of
preservation. To ensure that the juice keep fresh, CO2 concentration of 1.5% are
necessary, this corresponding to a gauge pressure of some 7 Bar at 15°C. The
microorganism, especially the yeast is not killed by the CO2 even under the
influence of pressure. Their growth is merely inhibited and they remain perfectly
capable of certain enzymatic reaction. For instance, yeast retains some ability to
produce alcohol. CO2 has only a limited action against lactic acid fermentation, so
8. Beverages and Related Products 231

the risk of lactic acid fermentation exists even if the juices are stored under
compressed CO2. Experience has long shown that drinks containing CO2 have
better resistance to microbial spoilage than do still drinks. The micro-organism
contents of such drinks decline with increasing storage time and rising CO2
concentration (Ashurst 1999).
The volume of CO2 at the finished beverage point is a most important factor, for it
is the quantity of CO2 dissolved in the beverage that gives it its sparkle and governs
the length of time, along with the other factors, such as temperature, that the
beverage will continue to effervescence. Henry’s law states that at given
temperature, the volume of the gas dissolved is proportional to the pressure of CO2
on water. At atmospheric pressure the amount of CO2 dissolved by water will be
dependent on the temperature. Solubility of CO2 is higher at lower temperatures
than at higher temperatures. At 60°F beverage will absorb one volume of CO2,
represented as zero on CO2 volume gauges. When the pressure is increased to about
15 pounds, that is, the pressure of one additional atmosphere, the water will absorb
two volumes of gas and for each additional 15 pounds an additional volume of gas
will be absorbed by water. The commercial bottlers usually use liquid CO2 kept in
heavy steel tanks. The tanks are connected to equipment known as carbonator by
means of metal connecting tubes. The carbonator is a device by means of which a
larger surface of water can be exposed to CO2 gas under pressure. The carbonator
of larger surface and pressure enables the cooled water to absorb the gas quickly.
The degree of effervescence is probably the most important property of carbonated
soft drink. The quantity of dissolved CO2 gives the beverage its characteristic
sparkle which complements the flavor of the drink. For any particular recipe there
is a certain degree of carbonation required in that drink as too low a carbonation in
Gingerale and other mixes. Since carbonation is so vital, it is imperative to be able
to measure the degree of carbonation in order to ensure consistency of product
(Hornsey 2003). The maximum volume of CO2 which will dissolve in a liquid and
the time in which that condition is attained depend upon the combination of
different factors such as surface area of contact between gas and liquid, time of
contact, absolute pressure of the gas-liquid mixture, temperature of the liquid,
receptivity of the liquid to CO2 and purity of CO2..
8.3.7.3. Testing of Gas Volume (Carbonation) of Finished Beverage
• From Stock: Clamp the bottle in the frame of the tester and pierce the
crown but do not shake the bottle. Sniff off the top gas quickly until the
gauge reading drops to zero. Make certain to close the valve when needle
touches zero. Shake the bottle vigorously until the gauge gives a reading
that additional shaking does not change. Record the pressure and also note
the temperature, then obtain the volume of gas from the table.
• Beverage from the Bottling Line: A beverage taken from the production
line usually has little or no carbon dioxide pressure in the head space.
Consequently, the determination of gas volume of beverages taken from
the production line should be allowed to remain quite for at least 5 minutes
prior to testing or the following procedure should be employed. Clamp the
bottle in the frame of the gas volume tester. Puncture the crown and shake
232 M.A. Randhawa, M.R. Khan, M.S. Butt and N. Ahmad

until maximum pressure is reached. Allow the bottle to remain quite 30

seconds in either an upright position or on its side. Sniff the head pressure
quickly to zero and then close the sniff valve. Shake the bottle again until
maximum pressure is reached. Record this pressure and also note the
temperature to obtain the gas volume with table (Ashurst 1999).

8.4. Processing Steps of Beverages

Fruits if fresh play important role in formulation of beverage but to maintain the
quality various techniques are need. Thus, preservation methods are adopted that
has direct effect on juice quality. Processing and production of fruit beverage on
commercial scale was practically unknown till about 1930, but since then it has
gradually become an important industry. In tropical countries like Pakistan, fruit
based beverage provide delicious drink in hot summer. Due to their nutritive value
these are becoming more popular than other type (Steen and Ashurst 2008).

8.4.1. Fruit Cleaning, Washing and Grading

Fruits are inspected, sorted and graded on physical or chemical properties. An
inspector takes sample and after acceptance fruit is shunted on conveyor belt and
processed to remove the dirt, dust and debris by roller brushers. Graders remove
low standards fruits and separation occurs depending upon size and noteworthy
parameters.
Proper size is important for the extraction process.
• Fresh fruits are cleaned, washed, graded and sorted. Sometimes brushes
and agitation systems are used.
• Mangoes are passed from destonner and then crushed
• Conveyor belt sorts and grades the produce
After grading extraction process is performedSome fruits are pulped while some
are pitted as in guava but in case of citrus fruits juice is extracted to make
concentrate (Hornsey 2003).

8.4.2. Syrup Room Operations

All juices are sweetened by adding sugar, except those of apple and grapes. Sugar
also act as preservative for color and flavor and prolong the keeping quality. Sugar
can be directly added to fruit juices or as syrup made by dissolving it in hot water,
clarifying by adding small quantity of citric acid or few drops of lime juice. It is
also recommended to use sugar filters before adding the syrup into final product
(Varnam and Sutherland 1994).

8.4.3. Filtration and Clarification

Fruit juices always contain varying amount of suspended matter consisting of
broken fruit tissues, seeds, skin, gums, pectin substances and protein in colloidal
8. Beverages and Related Products 233

suspension. Seeds and pieces of pulp and skin which adversely affect the quality of
juice are removed by straining through a thick cloth or sieve. Removal of all
suspended matter improves the appearance but often results in disappearance of
pulpy character and flavor. In case of grape juice, apple juice and lime juice cordial
a brilliant clear appearance is preferred. Complete removal of all suspended
material from juice as in lime cordial is known as clarification which is closely
related to quality, appearance and flavor of juice. Settling, filtration, freezing and
high temperature are methods used for clarification along with use of some
chemicals and enzymes (Ringblom 2007).

8.4.4. Pasteurization
Fruits are perishable so need strict control on quality. Pasteurization is used as basic
technique and its two types are used i.e high temperature short time (HTST) where
heating is done for short time and low temperature long time (LTLT). Heat
exchangers are devices used for heating of liquid products and their types are
tubular heat exchanger (THE) and plate heat exchanger (PHE). Numerous factors
like plant layout and type of product to be processed determine the type of heat
exchanger. Mostly juices are double pasteurized. This enhances the keeping quality
of product as various damaging enzymes are inactivated. Clarification increases the
life of juice and flash pasteurization removes the negative flavors. Various
techniques are used for heating juices. In tubular heat exchangers juice is passed
through pipe being heated by hot water or steam outside the tube. Temperature of
about 80°C is attained in few seconds (Steele, 2000). The primary pasteurization is
performed after evaporation and done at 95-98°C for 10 to 30 seconds. The major
objective here is to kill microorganisms as well as enzymes. The second
pasteurization is done before filling and objective is to kill recontamination and
temperature is 95°C for 15 seconds (Varnam and Sutherland 1994).

8.4.5. Deaeration
This is performed immediately after the pasteurization and involves removal of air
from the product by mechanical means or by using vacuum. These gasses are
usually oxygen, air or produced in product by microbes. Deaeration deteriorates
quality as it causes oxidation of vitamins like vitamin C and cause discolorations as
well as off flavor. Fruit juices contain some air, most of which is present on the
surface of juice and some is dissolved in it. Most of the air is removed by
subjecting the fresh juice to a high vacuum. This process is called as deaeration and
the equipment used for this purpose is called as deaerator.
Gas especially oxygen cause damage to product and affect the consistency of the
product. Presence of oxygen causes threats to juices, nectars by enhancing aerobic
microbe’s activity. During processing gases can cause incomplete processing and
damage the gaskets, pipes and pressure gauges. During packaging gases pose
problems in bottling and form foams. Carbon dioxide can combine with water to
form acid that corrodes the cans. Sulphur dioxide is also threat to drinks so
deaeration must be done to residual air up to 7ppb.
234 M.A. Randhawa, M.R. Khan, M.S. Butt and N. Ahmad

A deaerator can be two types like tray and spray type. Tray type has vertical dome
shape and deaeration chamber is at its top. While in spray type the deaerator is
attached inside (Yam and Lee 2012).
8.4.5.1. Importance of Deaeration
• Oxygen affects the browning and oxidation of juice contents like vitamin
C
• Oxygen may affect flavor of fruit based beverage
• Deaeration by vacuum causes loss of dissolved gases but flavor can be
preserved by using recovery integrated cycle
• Deaeration can ensure safety of process/equipment

8.4.6. Homogenization
Homogenization provides uniform and stable product by maintaining their
composition. This reduces particle size of product under pressure, temperature and
shear forces. Product is passed through a valve at high pressure which causes
homogenization. Juices having variable size of particle are forced through valve to
achieve homogenization from 0.4-1 micron. Raw product enters at high pressure
and leaves at low pressure. Homogenizer is a machine used for homogenization
purpose, it takes large particle size product enters and exits as small particles.
Standard term homogenization is applied to avoid separation (Masson et al. 2011).
Homogenization means doing one or more of the following; stirring, disrupting,
blending, emulsifying, mixing and dispersing etc.
8.4.6.1. Homogenizing Techniques
i. Single-Stage or Two-Stage Homogenization
Single stage assembly valve are used for processing of emulsion but 15-25% of
pressure is applied in second stage. Dispersions are formed by single-stage
assembly.
ii. Multiple-Pass Homogenization
Homogenization may be applied once again for further fineness of milk particles.
Installation of more than one homogenizer can be applied for this purpose. This
type of homogenization is preferred because it gives uniformity, viscosity,
consistency and shelf life to product (Masson et al. 2011).
The parameter to be optimized for maximum efficiency of this homogenizer
depends on different features including size and design of generator, speed of rotor,
initial sample size, product viscosity, processing time and flow rate as well as
vessel shape and rotor-stator positioning.
8.4.6.2. Homogenization Processes
Homogenization process includes agitation, blending, emulsifying, homogenizing,
hydrating, dissolving, deagglomeration and particle size reduction.
8. Beverages and Related Products 235

8.4.7. Filling
Most critical operation is juice filling which should be done when product is still
hot. Delicate packaging must be saved by packaging in sterile environment.
Sometimes approved agents can be applied before filling. Usually belt conveyor is
used to fill the produce immediately after pasteurization. It is also recommended to
use cold water spray just after filling.

8.4.8. Packaging and Storage of Beverages

Packaging of carbonated and non-carbonated beverage is a technical process. The
packaging requirements for all types of beverages are:
• Should be leak-proof to avoid contamination
• Must provide a barrier to external flavors
• Should be inexpensive and dispose off easily
• Have excellent aesthetic appearance
• Necessity ensure the product quality and safety can be ensured
• Protection is needed in all stages of handling
• Pack size, label tag and requirements must be fulfilled
• Packaging system must be properly functioning
8.4.8.1. Packaging Material for Fruit Based Beverages
i) Glass Containers
Glass bottles use is wide-spread but intensive care is needed during subsequent
procedures of processing. Mostly glass is preferred for high quality products. The
glass bottle packaging system must be light in weight, surface must be coated to
increase scratch resistance and use of wide mouth enclosures must be fitted with
easy-open-caps
ii) Metal Containers
Cans make with mild steel are 99.75% pure and are coated with tin with their ends
that are easy to open. These containers have either 2 or 3 pieces. Corrosion is
prevented by lacquering (Lund et al. 2000).
iii) Plastic Containers
There are organic substances in juice that can be spoiled by bacteria so hot
packaging is done for such products to have long shelf-life. Polyethylene
Terephthalate (PET) bottles are suitable for hot filling. During design and
production specific features are conferred to containers. Hot filling bottles are made
one and half time heavier than cold filling ones. Bottles have strengthening grooves
along their circumference. After the bottle is filled and cap is secured even then
product inside began to cool creating vacuum.
Flexible plastic packages are economical as compared to metal and glass containers
and these are gas permeable. Thus, selection is very important to have least
236 M.A. Randhawa, M.R. Khan, M.S. Butt and N. Ahmad

air/oxygen permeability. Flexible and polyester packs are used to fill products
without acidic corrosion. These pouches are either flat or stand-up. The product has
limited shelf-life in these packs.
iv) Aseptic Packages
Aseptic pack provide excellent barrier and saves the fruits/fruit based beverages.
Paper board and aluminum foil along with thermoplastic are used for aseptic packs.
Contents of beverages are saved due to multilayered foil as barrier against oxygen.
Plastic layer inside is used to seal the product. Stiffness is provided by outer layer
that is made up of paper thus novel graphics and labeling tags are possible on this
layer. Aseptic environment makes the product germ free. There is variety of
opening devices used to have handy access. Drinking straw is attached to pack for
ease in drink. Recently packs are made with pulling taps that are separated from
detachable pack. To enhance the brand image, conventional designed caps are
added that have excellent integrity. Bottles designs including specific shape are
being made to have easy access and effective space utility. These packs have shelf
stability at room temperature and have long shelf life while nutrient composition of
the fruit juice least affected by the barrier properties.
v) Bag-in-box System
This is a collapsible bag having outside a crate or pot to provide mechanical
strength. This system has two bags. Inner primary bag has a liquid and outer
secondary bag provides strength and support. Heat sealing is performed for sealing
purpose at corners. A spout attached to bag is very handy and can aid product
dispensing or filling. Capacity can be as little as 100 mL or as much as 1000 litres.
The objective of rigid container is to provide strength to bag while handling stages
and this bag can withstand storage conditions and transport is also very easy.
During post filling operation, each bag is stored in a box independently (Ashurst
1999).
8.4.8.2. Packaging Materials for Carbonated Beverages
Carbon dioxide is dissolved in water for carbonation purpose and beverages have
numerous ingredients like artificial sweeteners, antioxidants, coloring agents,
flavoring agents, foaming, and preservatives are then added. Rancidification can
occur in carbonated beverages resulting loss of flavor. Effectiveness of packaging
is main component that protect loss of gas. Using antioxidants and de-aeration of
mix can be helpful before carbonation. Carbonated beverage containing pack
should withstand pressure of carbon dioxide and not emit any off-flavors.
Previously all drinks were packed in glass bottles with cork. Recently, bottles are
returnable and they have protective paper or plastic to avoid breakage chance.
Crown cork used initially was replaced now with roll-on aluminum. Three piece
metal containers are used that are made up of metal for packaging of carbonated
beverages. Recent version is two piece aluminum can. Lacquers retain their
structure better than tin alone. Epoxy, vinyl and vinyl organosol coatings are best
lacquers mostly used for cans. Epoxy amine has a good flexibility, adhesion and
gives color to the can. PET bottles are among the plastic containers and most
preferred packaging material for used for soft drinks.20ppm is maximum
8. Beverages and Related Products 237

permissible limit of CO2 in citrus beverages while cola drinks have 40ppm. Elastic
deformation and creep resistance are some important factors. The PET bottles are
satisfactory for most of the carbonated soft drinks. Numerous design formation
techniques are available for PET bottles enhancing their strength and transparency.
These bottles are breakage resistant (Yam and Lee 2012).
The advantages of PET container are:
• Superior packaging to product ratio: PET container being 47.13% and
63.5% more energy efficiency than aluminum cans and glass bottles
respectively.
• Aluminium-cans and glass bottles generate 175.14% and 230.34% times
more atmospheric emissions compared to PET.
• Less solid waste by weight is given by PET bottles contributing 18% and
68% compared to aluminium containers and glass.
• To produce 1000 1-litre PET bottles, 100 kg of oil is required against
equivalent glass bottles require 230 kg.
• PET bottles are fuel saving due to their less weight.
• Resins used in PET bottles are special for carbonated drinks. PET bottles
retain the ability to have strong internal pressure. These bottles also have
expansion release strength. This is achieved by a resin having inherent
viscosity and less co-polymer levels (Ashurst 1999).

8.5. Beverage Spoilage

It refers to any undesirable change in appearance, color, taste or odor taking place
in a beverage and may be due to physical, chemical, biochemical and
microbiological factors. Certain physical change may be due to heat or sunlight.
Direct sunlight is detrimental to the flavor of almost all the beverages and
particularly those containing fruits juices. Chemical changes that cause spoilage of
beverages are due to oxidation, enzyme action, reaction of free metals or oil caused
off-taste. The growth of microorganisms in beverages may cause scums, clouds,
sediments, etc. These various factors often act together making it difficult to isolate
their specific effects.

8.5.1. Physical Spoilage/Light

The spoilage effects of light can be considered in two main categories (a)
undesirable changes which are characterized as terpene like, oily, sour, etc. and (b)
off-tastes and odours in beverage made with the fruit bases. Terpene like and oily
tastes are found principally in citrus flavored beverages. Light induced rancidity
occurs in products containing fixed oils, like vegetable oils including brominated
vegetable oils. Second category in spoilage is fading of colors. Not all colors used
in the beverages are light fast and even colors with good light fastness will fade
when subjected to strong sun light. To prevent spoilage from exposure to light, it is
necessary to take every precaution to keep carbonated soft drink out of direct sun
238 M.A. Randhawa, M.R. Khan, M.S. Butt and N. Ahmad

light even during transportation in trucks and especially orange flavored bottles
should be prevented from direct sun light exposure. The rotation of finished
beverage stock is essential to preserve fruit based beverages (Wan et al. 2015).

8.5.2. Temperature Change

Wide variation in temperature may cause undesirable changes in soft drinks. High
temperature may affect the flavor adversely by speeding up the chemical reactions.
It is well to recall that carbon dioxide is far less soluble in water at high
temperatures than at lower temperatures. This can tend to cause leeks in bottled.
Some bottles/cans may not withstand increase in pressure caused by increase in
ambient temperature. Freezing temperature may also have deleterious effects. Some
colors and flavors are much less soluble at very low temperature. These colors may
precipitate at lower temperatures and may not go back into solution/emulsions and
ultimately may not be able to give desired/same shade. Particular care must be
taken not to expose flavor emulsions to lower temperatures as freezing results in
breading of emulsions. There is a separation of sugar and water and beverages need
to be remixed (Marsh et al. 2011)

8.5.3. Appearance
Presence of ring in the neck of the bottles or precipitates of any types is the
evidence of spoilage. The presence of a ring shows that the emulsion of the
beverage has been broken down. It may also be a cause of inadequate
homogenization by the flavor manufacturers. The oil globules should be reduced to
less than 2 µm in size. Flocculent precipitates may be the result of poor water
treatment practices or poor filtration or due to microbiological activity,
precipitation of coloring matter or its metal lake. Care should be taken to see that
no brush bristles or other foreign material remains in the bottle after washing and
rinsing (Wolf et al. 2008)

8.5.4. Boiling and Gushing

The loss of carbonation at the filler or after the bottle has opened, is a problem in
the manufacture and sale of carbonated beverages. Such sudden or rapid loss of
carbonation is termed boiling when it occurs at the filler and gushing when it
occurs as the bottle cap is removed. Cooling the water and syrup prior to
carbonation prevents the boiling at the filler. This is due to the factors like presence
of discharge nuclei, excess air in the drink, unnecessary agitation and improper
storage (Hornsey 2003).

8.5.5. Chemical Spoilage

Chemical spoilage is a result of reactions of the beverage ingredients with oxygen
or from reactions among incompatible ingredients. Rancidity or oxidation of
terpenes or of fixed oils in beverages in induced by a physical cause, however,
which is caused by oxygen of the air present in the neck of the bottle or head space
of the can. Oxidation of terpenes and rancidity are not only the undesirable
8. Beverages and Related Products 239

oxidative changes but many flavor compounds which are sensitive to oxidative
changes if oxidized will spoil the beverage flavor. Such oxidative reactions are
catalyzed by light and are accelerated by heat and can be kept to minimum by
proper storage temperatures. Rinsing after washing of bottles should be adequately
administered to remove all the caustic and washing compounds. Otherwise such
chemicals will spoil the final beverage. Other chemical spoilage may be a cause of
low pH. Only proper amount of acid should be used. Different sweetening agents
and their substitutes may be cared for their effect of quality of beverage when
stored for long durations. Hardness in water used for soft drink manufacture is not
desirable. Thus if calcium concentration is too high and combined with tartaric acid
as acidulant then ultimately the precipitates of calcium tartrate may occur (Hui and
Evranuz 2012).

8.5.6. Biochemical Spoilage

Biochemical spoilage is caused by enzyme activity. The principal enzymes
affecting soft drinks are carbohydrases and lipases. The carbohydrases such as on
sucrose (invertase) and amylases catalysis the hydrolysis of carbohydrates and
lipases are responsible for hydrolysis of fats and esters. Enzymes may be present in
the natural products used in the manufacture of carbonated beverages, fruit juices,
fruit concentrates, etc. Such enzymes may cause undesirable changes in the raw
materials themselves or in the final beverage. Greater disadvantages may stem from
the presence of lipases in natural products. As these enzymes hydrolyze fats and
esters, therefore as a consequence of their fat splitting action they may cause
rancidity and off-odors in beverages containing salts, fixed oils, brominated fixed
oils. Since many of the most important flavoring components, whether natural or
synthetic, are esters, it can readily be seen that esterase enzymatic hydrolysis would
split such esters and reduce the flavor intensity or even cause off-flavor, off odor
and off taste (Ringblom 2007).

8.5.7. Microbiological Spoilage

Undoubtedly spoilage attributable to the activity of microorganisms is the most
serious problem of the beverage manufacture. As far as beverage manufacture is
concerned, the fungi are most important group of spoilage organisms. Individual
microorganisms form colonies, clouds, precipitates, sediments and scums which are
visible to the naked eye and are the direct signs of spoilage. It is generally accepted
that over 90% of the spoilage problems in the bottled soft drinks are caused by
yeasts. Yeast growth shows up as sediment, haze, flocculated clumps, off-tastes due
to metabolic end products, and possibly increased internal pressure of the package
from CO2 production.
Yeast can gain entry into the plant and ultimately into the finished product by
several routes.
• Stockpiles in the plant of returnable bottles and containers awaiting
washings.
• Inadequate washing of bottles and cans.
240 M.A. Randhawa, M.R. Khan, M.S. Butt and N. Ahmad

• Air borne contamination/dust or dirt picked up during manufacturing.

• Contaminated equipment such as tanks, pipelines, pumps, fillers and can
seamers.
• Insanitary operating conditions/plant operations.
• Contaminated sugars and syrup/raw material containers such as sugar
sacks.
• Contaminated flavors and coloring matters.
• Dusty crowns.
The potential for yeast contamination is greatly increased from the blending
operation at the proportioned to all points downstream. This process can occur
because the diluted syrup can now support the rapid growth of these
microorganisms. It is extremely important to keep the blending equipment
(proportioner, carbonator and filler) clean and hygienic using good sanitation
procedures and it must be performed on regular basis. Neglect will result in yeast
gaining on foothold in various product contact area such as valves and rubber
materials etc. For this purpose the modern systems are equipped with cleaning-in-
place (CIP system) capability that includes flooding, spraying and recirculation.
The bottle filling valves consist of many small working parts such as rubber seats,
tubes and springs. They are notorious for becoming breeding grounds for yeasts if
not properly sanitized (Lund et al. 2000) The following procedure referred to as
cold sanitizing for cleaning and sanitizing, is recommended at the end of each day.
• Drain the entire product from the equipment.
• Flush with clear water.
• Flush equipment with detergent solution.
• Flush this solution with water.
• Fill equipment with a chlorine solution of 50 ppm and hold for 30 minutes.
• Flush with clear water.

8.6. Conclusions
Beverages or drinks are type of liquids, which are especially prepared for humans
for a number of purposes especially as an instant source of energy, nutrients, and
minerals to quench the thirst and has become a part of the culture of human society.
Drinks are classified in a number of ways on the basis of ingredients used in them
such as alcohol, non-alcoholic drinks, soft drinks (carbonated drinks), fruit or
vegetable juices and hot drinks. The consumption of sugar-sweetened drinks has
been increased all over the world over the past 30 years. Wine, cocktail, beers,
spirits and liqueurs come under the category of alcoholic beverages while juices,
squashes and carbonated drinks, as well as tea, coffee, chocolate, milk and milk-
based drinks are collectively known as non-alcoholic beverages.
Water is one of the most important ingredients utilized in the formulation of
beverages because 90% of the volume of product is contributed by it, that’s why its
8. Beverages and Related Products 241

quality can’t be compromised. A number of water treatments processes have been

established to meet the desired requirements regarding taste, appearance and other
important physico-chemical characteristics of water, typically required for soft
drinks manufacturing. It must be free from any objectionable taste and odour due to
its superior solvent characteristics for remaining beverage ingredients. Water is
passed through a number of purification processes like chlorination, ultrafiltration,
nanofiltration, reverse osmosis, ozonation and many others.
Ozonation is one of the new drinking water treatment techniques as an alternative
tool for chlorination due to its excellent disinfection and oxidation qualities.
Usually ozone is used for pre-oxidation of the water impurities before the
application of sand or active carbon filter. Reverse osmosis is another new
technique for water purification which does not require thermal energy. In addition
to water purification this technique is now being used for concentrating food liquids
(such as fruit juices) than conventional heat-treatment processes. The second most
important ingredient is liquid sugar in beverage formulation along with other aiding
ingredients such as preservatives, color and flavor enhancers which make the drinks
more appealing for consumers by improving its aesthetic appearance.
Different processing steps are involved up to final product development among
them filtration, clarification, pasteurization and homogenization are most
important. One of the most critical step in the handling of final prepared product is
its packaging requirements. Packages material should be such that it can protect
from any type of contamination, should be leak-proof, can maintain product natural
flavor, not to be hygroscopic, have good aesthetic appearance and ensure the
product quality and safety.

References
Arabi, S.A., X. Chen, L. Shen and D.S. Lee (2012). Flavour-released food and
beverage packaging. In: Yam, K.L. and D.S. Lee (2012). Emerging Food
Packaging Technologies: Principles and Practice. Woodhead Publishing,
Sawston, Cambridge, UK. pp. 96-108.
Ashurst, P.R. (1999). Production and Packaging of Non-Carbonated Fruit Juices
and Fruit Beverages. Aspen Publishing, lnc. N.Y.
Ashurst, P.R. (2005). Chemistry and Technology of Soft Drink and Fruit Juices.
Wiley-Blackwell Publishing; 2nd Edition, West Sussex, UK.
Dasgupta, A. (2015). Alcoholic beverages: Antioxidant and other health benefits of
moderate consumption. In: Dasgupta, A. and K. Klein. Antioxidants in Food,
Vitamins and Supplements: Prevention and Treatment of Disease, Elsevier,
Suite 1900, San Diego, CA 9210. pp. 259-276.
Dvorak, B.I. (2014). Drinking water treatment: Reverse osmosis.
http://ectention.unl.edu/publications. Accessed on September 2014
Hornsey, I. S. (2003). A History of Beer and Brewing. The Royal Society of
Chemistry; Cambridge CB40WF, UK.
Hui, Y.H. and E.O. Evranuz. (2012). Handbook of Plant-Based Fermented Food
and Beverage Technology. CRC Press: 2nd Edition, Boca Raton, FL 33487,
US.
242 M.A. Randhawa, M.R. Khan, M.S. Butt and N. Ahmad

Larsen. J.C. (2008). Legal and illegal colours. Trends Food Sci. Technol. 19: 64-69.
Lund, B.M., T.C. Baird-Parker and G.W. Gould (2000). The Microbiological
Safety and Quality of Food. Aspen Publishing: 1st Edition, Orchard Ridge
Drive, Suite 200, Gaithersburg, Maryland 20878.
Marsh, A.J., C. Hill, R. P. Ross and P. D. Cotter (2014). Fermented beverages with
health-promoting potential: Past and future perspectives. Trends Food Sci.
Technol. 38: 113-124.
Masson, L.M.P., A. Rosenthal, V.M.A. Calado, R. Deliza and L. Tashima (2011).
Effect of ultra-high pressure homogenization on viscosity and shear stress of
fermented dairy beverage. Food Sci. Technol. 44: 495-501.
Pescuma, M., E. M. Hebert, F. Mozzi, G. F. Valdez (2010). Functional fermented
whey-based beverage using lactic acid bacteria. Int. J. Food Microbiol. 1416:
73-81.
Potter, N. N., J. H. Hotchkiss (19*95). Food Science. Chapman & Hall, New York.
Ringblom, M. U. (2007). Selecting the ideal packaging for fruit based beverages.
Article based on the Presentation during the International Fruit World 2007
(28-29 March 2007) in Cologne, Germany.
Santos, C.C.A.A., B.S. Libeck and R.F. Schwan (2014). Co-culture fermentation of
peanut-soy milk for the development of a novel functional beverage. Int. J.
Food Microbiol. 186: 32-41.
Shachman, M. (2004). The Soft Drinks Companion: A Technical Hand Book for
the Beverage Industry. CRC Press; 1st Edition, Boca Raton, FL 33487, US.
Soccol, C.R., A. Pandey and C. Larroche (2013). Fermentation Processes
Engineering in the Food Industry. CRC Press, Boca Raton, FL 33487, US.
Steen, D.V. and P.R. Ashurst (2008). Carbonated Soft Drinks: Formulation and
Manufacture. Blackwell Publishing, Garsington Road, Oxford, UK.
Tennant, D.R. (2008). Screening potential intakes of colour additives used in non-
alcoholic beverages. Food Chem. Toxicol. 46: 1985-1993.
UNDP (2003). Human Development Report 2003. Water for People, Water for
Life, The United Nations Development Programme.
UNEP (2008). Water Quality for Ecosystems and Human Health, United National
Environmental Programme, GEMS Water Programme, Ontario, Canada.
Varnam, A.H and J.P. Sutherland (1994). Beverages: Technology, Chemistry and
Microbiology. Aspen Publishing, Orchard Ridge Drive, Suite 200,
Gaithersburg, Maryland 20878.
Wan, X., A. T. Woods, K-H. Seoul, N. Butcher and C. Spence (2015). When the
shape of the glass influences the flavour associated with a coloured beverage:
Evidence from consumers in three countries. Food Quality Preference. 39: 109-
116.
Wolf, A., G. A. Bray and B. M. Popkin (2008). A short history of beverages and
how our body treats them. Obes. Rev. 9: 151-164.
Woodroof, J.G. and G.F. Philips (1981). Beverages: Carbonated and Non-
Carbonated. AVI Publishing Company, Inc. Westport.
Yam, K.L. and D.S. Lee (2012). Emerging Food Packaging Technologies:
Principles and Practice. Woodhead Publishing, Sawston, Cambridge, UK. pp.
1-9
8. Beverages and Related Products 243