coconut Handbook Recombined Coconut Beverages Racambination isa goed method for supplying 2 close aemative to frash coconut beverages by combining the coconut with water and other ingredients ‘ver the years, recombination processes have been refined to become more ecient and sophisticated, high capacity systems, Recombined coconut products can be supplied to markets where fresh raw material and coconut beverages are not easily supplied For recombined coconut mk based products, a coconut mik source isthe key ingredient used in recombined beverages. It can range from powders tke spray-dried coconut mik powder, to bulk liquids tke coconut milk or cream, In genera, these products are consumed in the United States, Europe and (Oceania markets as dary alternatives. As such, extra care must be taken to ensure that other ingredients are dairy free as wal or recombined coconut water based products, coconut water concentrate isthe key ingrecient used in recombined beverages, Usually, coconut rik, cream and water are combineé with other ingredients ke Juices, purees, cocoa, cole, soymilk and more, forming endless possibites of recombined coconut based beverages. These ingredients can vary, depending on te drinking quality and target cost of producing the fnal productImage 9.1 Major components of coconut beverages “Te major ingredients used for recombined coco beverages are wate, addives, coconut source, fats and ol Water Water is the major ingredient in recombined coconut beverages, I is essential thatthe water component fuls the WHO standards for drinking water. These Include the sensory properties, physical, chemical and microbiological considerations of water. The following requirements for water qualty are basec on WHO guideline values and Tetra Pak specications (Table 9.1). Table 9. Wiater quality parameters PARAMETER RANGE Teste None: Smet NonePARAMETER RANGE urbiaity, 10 Max 2 mg/l. Colour, Pe Max 20 mg/L Organic matter Very low pa 785 ‘Total hardness a7 tron, Fe Max 0.2 m/l, Manganese, Mn Max 0.03-0.1 ma/t Nitrate, NOs Max 30 mg/L Nitite, Nop Max 0.02 mg/l. Sulphate, $04 Max 100 mg/l. Cchlovde, Max 50 mg/L Aggressive carbon adi, COz Max 2 mg/L. ‘otal count of bacteria, Max 100 CFU/mt, “etal cound of coliform bacteria per 100 mt. Ammonium, NH Traces ‘vmmonia, Ns Max 0.5 mg/L. Pospate, PO, Max 0.2 ma/L. Magnesium, Mg Max 50 ma/L Cau, Ce Max 100 mo/t. Sodium, No Max 200 mg/l. Total solids Max S00 mg/l. Chemical oxygen demand (COD), KMnOs Max 20 mg/L. Copper, Cu Max 0.05 mg/l. Zinc, 20 Max 1.0 mg/l, Additives ‘Alves serve several functions in recombined coconut Beverages, For Instance, the alton of minerals like calium and fortfeation with fat= and water- soluble vitamins can imprave the nuitonal value ofthese products. In action, dry additives lke sugar, stabllzers and emulsiners can be acded ctectyinto the mixing system for the desired mauthfel and taste prafle Coconut source The chosen coconut source can be dry oF quid, depending on the needs ofthe recombined product, Dry coconut sources, suchas spray-cried coconut milk powder, makes shipping, warehousing and handling easy. Its important to get the specications of the coconut powder used, as some ofthese powders are not suitable for dalry-ree coconut beverages. For example, coconut powders commonly contain the rik protein casein to prevent lumping ofthe fats during the spray drying process, Occasionally fats and ols are acded to improve the texture and mouthfel of the recombined coconut beverage Liquid forms of concentrated coconut sources are avalable as coconut mi, crear or water concentrate, These can easily turn into a beverage by clsting the liquid concentrate Factors to consider are wettabilty, dispersabilty,solubilty, clry content and suspendabilty of the chosen coconut source. Wettabiity ‘The degree of wettabllty is very much a function ofthe partcle volume, Agglomerated powers have improved wettablity because of their increased particle size. This improves capilarty Where mare water is drawn Into the powder particles. Ths causes the ponders to disperse and dssolve faster in water Dispersibility Good eispersibilty is obtained when powders are distributed in water as single particles without lumps. This is determined by the structure of powder pattides, 9s well asthe configuration of proteln and ll molecules, Solubiity Solubility is define by haw well the powder dissolves or forms a stable suspension, For cacanut mi product, this dapends a great deal on how the procuct s being processed, Suspendabilty ‘Suspendabilty refers tothe protein source's ably to stay in suspension. It sa functon of specific volume ané particle size. For beverages, maintaining the suspension of protein ane fortifeation lke calcium is importa. Recombination technologyRecombination process of coconut milk based beverages During the recombination process, a specfed amount of water is frst measured and heated to @ warm temperature in the tank, This allows the powder to dissolve more easy. Then, stabilizers, emulsifiers and coconut powder, milk, cream or concentrate ae steadly added to the tank. Agtation is applied unt all the power is dissolved, and the resulting solution stands fora period of tie. Thereafter, oil can be added into the mixture before i is reheates.Fooure 9.1 Mixing tank for recombination (© Tetra Pak International S.A, Dalry Processing Handbook 2015, If processing continues inthe tank, the agitators switched to hich speed for some minutes to disperse the fat and ol. Next, pasteurization takes place. A homogenization step i usually incorporated in the pasteurizer to break up fat and ol globules to minimize creaming inthe product, Finally, cooling to packing temperature occurs. In large scale production, recombination plants are bull for capacties as large as 20 000 L/h In larger pants, parallel lines are installed to meet higher capacity requirements, The production sequence in a lage plants essentially the same as in a small one, exeept that the larger fact requires more tanks for larger volumes of storage, melting of fats and ols, mixing, and buter storage ofthe fishes product. The degree of mecnanisation may also dif For instance, n large plants, weighing tanks are usec to accurately measure the ingrecient dosage required. On the contrary, the weighing tank can aften be replaced by 8 dosing purp or pre- weighed dry ingredients installer plans Image 9.2 Large seate productionIn large scale production, a high-speed blender is used to mix dry ingredients fist The dry blend is then eispersed into the water through a hopper that operates ata rate of upto 45 kg per minute \Wnen allthe powder has been added, the contents afte tank are left to stand for hydration of the powders. Meanwhile, the Blender i fed withthe next Batch of dry ingredients for recombination. I the production requires the addtion of ol it is rst measured inthe weighing funnel, then store inthe oil storage tank before i's ace into the minture, The agitator, specialy designed for optimum ol ispersion, runs for several minutes and finely dsperses the cllin the coconut blend, When all the ingradien's have bean mixed in one tank, the process is repeated in the next tank. The coconut blene and oll mixture i drawn from the fll mixing tank by 2 purmp which moves the mixture through duplex fers. This removes foreign objects such as pieces of string or sacking, ‘Mer pre-heating inthe heat exchanger, the product is pumped tothe homogenizer, where the dispersion of oil globules is completed. During the powder mixing operation, It may pick up large volumes of ai, which can cause fouling in the pasteurize ané hamogenization robles. To eliminate tis, a vacuums aerator vessel can be installed inthe production line before the homegenizer, Alternatively, 2 high Shear vacuum mbeer can be used for the recombination Before the product is lashed in the deaerator, iis preheated to 7-8°C above homegenization temperature, withthe vacuum adjusted so thatthe outgoing product has the correct homogenization temperature, Next, the homogenized coconut beverage Is pasteurized anc chilled in the plate heat exchanger then pumped to storage tanks for further processing or directed to packaging For further processing, three metheds are commonly used ~ pasteurization, in-container sterilization of caconut beverages and UMT treatment by direct or indirect heating. As such, the design of the plant is infuenced not only by is capacity, but also by the recombination process. In smaller plants where the mixing of material ina processing tank is ited, the procuct wil be naturally and satisfactorily deserated if @ reconstitution emperature f approximately 40°C is maintained. At this temperature, al the powder has been dissalved andthe resultant solution i allowed to stand for 20 minutes with the agitator switched off, The same procedure shoulé also be applied to large-scale pro- duction, In ation, the product is deaerated by ‘vacuum treatment that is connacte to the heating process Recombination process of coconut water based beverages In the recombination of coconut water based beverages, the process is relatively spler than the recombination of coconut ik based beverages, However, ‘there is a set oferta factors to take note of Normally, coconut water concentrate between the range of 18 - 65 °Brx Is used. To reconstitute coconut water, coconut water cancantrateis simply blended With water, Blending fs recommended tobe done cod to minimize any degradation reactions, such as browning and microbiological degradation, at this stage, other ingredients Ike jules and addtives are also adced. After mixing, the beverage is immediately fed tothe heat exchanger for pasteurization, eaeration an¢ chilling. Is then purnped to storage tanks for further processing (UMT) or direct to packaging.For further processing, three methods are commonly used - pasteurization, n-container sterilization of coconut beverages and UMT treatmant by direct Inolrect heating, As such, the design ofthe plants inuenced not only By its capacty, But also by he recombination proces. Handling coconut beverages ‘Wren handling recombined coconut beverages, Its necessary to ensure thatthe pracucts reach consumers in mint condition Firstly, the products should be packed as soon as possible after production, UMT treated coconut beverages must flow in a closed aseptic system to the aseptic carton or can filing machine, Pasteurized coconut beverages can be packed in paper-basee laminates, plastic packs or glass bottles. Far lng ite products, the package must always be airtight to protect the coconut beverages from oxidation. It should also be strong enough for stacking in crates or boxes. A buffer tank may be needee to compensate for temporary stoppages inthe procucton or packing Ines. In the case of sterilized coconut beverages, ths tank must be of aseptic design to prevent reinfection. ‘ter packing sterile coconut beverages, they canbe stored in any conciton, proved thatthe packages are intact. Pasteurized coconut beverages must be kept in old storage reams, while UHT treated and sterilized coconut beverages can stand without a refrigeration chain. Tis i because the lattar are much ‘more tolerant of ambient temperature and other conditions than pasteurized cocanut beverages, Last but not least, recombined coconut beverages are transported for market dstrbution. For UHT treated coconut beverages, the time factor Is not t00 Important as they can ba transported over lang distances and displayed for sale without refrigeration. On the other hané, when pasteurized coconut beverages are transported from place to place, they require a refrigeration chan of insulated distribution vans, chilled counters inthe shops, ane preferably, home refrigerators.‘Source URL: htp://coconuthandbook.tetrapak.com/chapter/recombined-coconut-beverages