PRACTICAL PROJECT:

PRODUCTION OF MANGO POWDER FROM MANGO

Table of Contents
I. DESIGN PROPOSAL..................................................................................................................3
a. Introduction of the project:................................................................................................3
b. Clear description of the proposed process:.......................................................................3
c. Flowchart representing the units, streams, the known and unknown variables:..............4
II.DESIGN....................................................................................................................................6
a. Full description of the selected unit operations including the operating conditions:.......6
b. Description of the selected equipment of each unit operation:........................................7
c. Identify all the utilities needed for the process:.................................................................7
d. Flowchart representing the units, the streams and identify all the unknown variables:..8
e. How many mangoes are needed?......................................................................................9
f. Perform a material balance for each unit and an overall material balance for the plant:
..............................................................................................................................................10
III. CONCLUSION.......................................................................................................................11
IV. REFERENCES........................................................................................................................11
I. DESIGN PROPOSAL
a. Introduction of the project:
Main objective of this manuscript is to design a process that starts with the collecting of
mangoes and ends with the packaging of 100 kg of mango juice powder. Relevant unit
operations should be proposed and those units must achieve the given production
specifications.

Specifications:

 Calculations are carried out for the packaging of 100 kg of mango juice powder.
 Mango has on average 80 percent water by weight, 20 percent pulp, and weighs
roughly 150 grams.
 60% of the mango pulp can be recovered.
 60% of the concentrated mango juice is water, with the rest being aroma
substances.
 Dehydrated mango juice includes only 2% wt. of moisture in the final phase, with the
rest being aroma substances.

b. Clear description of the proposed process:

Raw mangoes are conveyed to the washing vat for cleaning and sent to the sorting section
for to separate bad mangoes. The juice is refined after the peel and seeds have been
thoroughly removed.

Figure 1: Sketch of the proposed process

The juice is then concentrated using evaporators, and the concentrated pulp is subsequently
transformed into fruit powder by spray drying the concentrated pulp. Vapor stream out of
the evaporator can be transformed into a range of products such as puree, ketchup, paste,
and so on, depending on the needs.

c. Flowchart representing the units, streams, the known and unknown variables:
Following flowchart represents all the units, streams, known and unknown variables of the
proposed production process.

 Total mass of the fresh mango feed is unknown. Mango has 80% water by weight,
20% pulp by weight. Therefore, mass fractions of water and pulp in the fresh mango
feed are known.
 Cleaning of mangoes does not affect the total mass of mangoes and its mass
fractions. However, if there are bad mangoes, sorting process affects the total mass
of fresh mango feed. Total mass is reduced while removing the skin and seeds of
mangoes too. For our production process, let’s assume that there are no bad
mangoes in the feed and removal of skin/seed does not affect the total mass of fresh
mangoes. Thus, feed mass flow rate and mass fractions to the evaporator are same
as that of fresh mango feed.
 Vapor flow out from the evaporator contains both water and pulp. However, mass
flow rates of water and pulp in vapor flow are unknowns. Total mass of the
concentrated pulp is unknown while 60% of the concentrated mango juice is water,
with the rest being aroma substances. Thus, mass fractions of water and aroma
(pulp) in concentrated pulp are known.
 Concentrated pulp is then introduced to the spray drying unit and dehydrated.
Water is removed from the concentrated pulp and its value is unknown. Dehydrated
mango juice power includes 2% of water, with the rest being aroma substances.
Total mass of mango juice powder is 100kg.
Figure 2: All units, streams, known and unknown variables of the proposed production process
II.DESIGN
a. Full description of the selected unit operations including the operating
conditions:
There are two main unit operations involved in this process:

I. Evaporation:
 Evaporation is required to remove majority of water from the mango pulp and give
uniform consistency for the concentrated pulp. Evaporation should be carried out
around 80 – 90 oC.
II. Drying:
 Drying is used to remove the water content furthermore and produce mango juice
powder. Final moisture content of mango juice powder is 2 wt% and hence operating
temperature of the drying unit should be around 150oC.

Other than these two major unit operations, following operations are involved in the
proposed process.

Washing and sorting:

 Fresh mangoes are washed through two processes: immersion in a basin and
showering on an elevator. After washing, mangoes are sent to the sorting section
where mangoes are inspected by personnel. A brushing machine is used to remove
any unwanted matter and dirt that has adhered to the fruits during the final cleaning
process.

Pulp refining:

 This operation is used to refine the puree to the desired consistency while
minimizing air absorption and so oxidation. This permits both the yield and the
quality of the final product to be maximized.

Thermal treatment and Pasteurization:

 Thermal treatment is used to prevent chemical and microbial spoilage.

Pasteurization is used to kill harmful bacteria in the concentrated mango pulp.
b. Description of the selected equipment of each unit operation:
I. Evaporation:
 Evaporation is required to remove majority of water from the mango pulp and give
uniform consistency for the concentrated pulp. Evaporation should be carried out
around 80 – 90 oC. We can use a thin-film continuous evaporator to achieve this
objective. Thin-film evaporators offer many advantages including low operating
pressure, short duration and high evaporation rate,
II. Drying:
 Drying is used to remove the water content furthermore and produce mango juice
powder. Final moisture content of mango juice powder is 2 wt% and hence operating
temperature of the drying unit should be around 150 oC. We can use a spray dryer to
achieve this objective. Spray dryers offer many advantages including continuous
operation, constant product characteristics and suitability for heat-sensitive
products.

c. Identify all the utilities needed for the process:

 Evaporation: we need steam as a utility
 Drying: we need drying air as a utility
 Pasteurization: we need cooling water as a utility
d. Flowchart representing the units, the streams and identify all the unknown
variables:
In the project proposal, it was assumed that there are no bad mangoes in the feed and
removal of skin/seed does not affect the total mass of fresh mangoes. Following flowchart
represents the units, streams, known and unknown variables of the proposed production
process which involve calculations.

Figure 3: Units of the proposed process which involve calculations

e. How many mangoes are needed?
Spray drying unit:

Applying component mass balance for aroma substances:

( m3 × x aroma ,3 ) =( m5 × x aroma , 5 )

m 3=
( m5 × x aroma ,5
x aroma ,3 )(
=
100 ×0.98
0.4
=245 kg )
Applying component mass balance for water:

( m3 × x water , 3 )=( m4 × x water , 4 ) + ( m5 × x water ,5 )

( 245 ×0.6 )=( m4 ×1.0 ) + ( 100× 0.02 )

m4 =145 kg

Evaporator:

It is given that only 60% of pulp can be extracted from mango. Applying component mass
balance for pulp:

( m1 × x pulp,1 ) ×0.6=( m3 × x aroma ,3 )

( m1 × 0.2 ) ×0.6=( 245 ×0.4 )
m1=816.67 kg

Applying component mass balance for water:

( m1 × x water , 1) =( m2 ,water ) + ( m 3 × x water , 3 )

( 816.67 × 0.8 )=( m2 , water ) + ( 245 ×0.6 )

m2 ,water =506.336 kg

Applying component mass balance for pulp:

( m1 × x pulp,1 ) =( m2 , pulp ) +( m3 × x aroma ,3 )

( 816.67 × 0.2 )=( m 2 , pulp ) + ( 245× 0.4 )

m2 , pulp =65.334 kg

m2=m2 , water +m2 , pulp =( 506.336+65.334 ) =571.67 kg

Number of mangoes required:

No . of mangoes=
( 150816.67
×10 kg )
kg
=5444.47
−3
f. Perform a material balance for each unit and an overall material balance for
the plant:
Spray drying unit:

Applying component mass balance for aroma substances:

( m3 × x aroma ,3 ) =( m5 × x aroma , 5 )

m 3= ( m5 × x aroma ,5
x aroma ,3 )(
=
100 ×0.98
0.4
=245 kg )
Applying component mass balance for water:

( m3 × x water , 3 )=( m4 × x water , 4 ) + ( m5 × x water ,5 )

( 245 ×0.6 )=( m4 ×1.0 ) + ( 100× 0.02 )

m4 =145 kg

Evaporator:

It is given that only 60% of pulp can be extracted from mango. Applying component mass
balance for pulp:

( m1 × x pulp,1 ) ×0.6=( m3 × x aroma ,3 )

( m1 × 0.2 ) ×0.6=( 245 ×0.4 )
m1=816.67 kg

Applying component mass balance for water:

( m1 × x water , 1) =( m2 ,water ) + ( m 3 × x water , 3 )

( 816.67 × 0.8 )=( m2 , water ) + ( 245 ×0.6 )

m2 ,water =506.336 kg

Applying component mass balance for pulp:

( m1 × x pulp,1 ) =( m2 , pulp ) +( m3 × x aroma ,3 )

( 816.67 × 0.2 )=( m 2 , pulp ) + ( 245× 0.4 )

m2 , pulp =65.334 kg

Entire plant:
Applying overall mass balance:
 Total mass∈¿ m1=816.67 kg

Total mass out=m2 +m4 +m5= (517.67+ 145+100 )=816.67 kg

III. CONCLUSION
 Main objective is to design a process that starts with the collecting of mangoes and
ends with the packaging of 100 kg of mango juice powder.
 Evaporation and drying are the main unit operations involved in this production
process.
 Steam, cooling water and drying air are required as utilities for this proposed
process.
 Weight of one mango is about 150 grams and total number of 5444.47 mangoes are
required to produce 100 kg of mango juice powder.

IV. REFERENCES
 Raj Process. (2022). Retrieved 4 April 2022, from https://raj-turnkey.com/fruit-
processing-concentration-plant.html
 Mango juice production process and fruit juice production machinery. (2022).
Retrieved 5 April 2022, from http://www.fruitprocessingline.com/mango-juice-
production-process-and-fruit-juice-production-machinery/
 Commercial Processing of Mangoes - The Mango Factory. (2022). Retrieved 5 April
2022, from https://www.themangofactory.com/nutrition/commercial-processing-of-
mangoes/