Systems and methods for filtering beverages

Abstract

A method for preparing a filtered beverage includes filtering a raw beverage using a cross-flow ultrafiltration device to produce a solids fraction and a liquid fraction, heating the solids fraction to a temperature of 60°C or greater to produce a pasteurized solids fraction, microfiltering the liquid fraction through a microfilter having a cutoff size of 1 μm or less to produce a microfiltered liquid fraction, and combining the pasteurized solids fraction and the microfiltered liquid fraction to produce a filtered beverage.

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of U.S. Provisional Patent Application No. 62 / 938,718, filed November 21, 2019, the disclosure of which is incorporated herein by reference in its entirety.

[0002] FIELD OF THE DISCLOSURE The present disclosure relates to systems and methods for filtering beverages, and in particular to systems and methods for filtering juice and producing non-concentrated juice. [Background technology]

[0003] Beverages prepared from fruits, vegetables and other plant parts, as well as dairy beverages, are often processed to reduce microbial load and extend shelf life. Such processing may include heating (e.g., pasteurization). However, heating the beverage may change its aroma profile and degrade beneficial micronutrients that may be present in the raw (unprocessed) beverage.

[0004] One example of a beverage that is commonly pasteurized to extend its shelf life is orange juice. Commercial mass production of orange juice began in response to the need to provide vitamin C-rich food for U.S. soldiers during World War II. The first frozen concentrated orange juice products were released in the late 1940s. Although concentrated juice provided a convenient and inexpensive source of orange juice for many consumers, the process used to produce the concentrate resulted in undesirable changes to the aroma and texture of the juice. Non-concentrated ("NFC") orange juice was developed to provide a product with improved aroma and texture. However, although NFC juice has improved aroma over concentrated juice, the need to pasteurize the juice to reduce the microbial load still results in the degradation of many of the aroma compounds and other thermally labile compounds in the juice, such as vitamin C.

[0005] Freshly squeezed, unpasteurized juices are becoming more popular among consumers due to their superior flavor profile. However, without any processing such as pasteurization, the microbial load of the juices results in a significantly shorter shelf life compared to pasteurized NFC juices. Summary of the Invention [Problem to be solved by the invention]

[0006] There is a need to provide a system and method for preparing beverages with reduced microbial load and improved shelf life.There is a need to provide a system and method for preparing NFC juices with reduced microbial load and improved shelf life. [Means for solving the problem]

[0007] A method of preparing a filtered beverage includes filtering a raw beverage using a cross-flow ultrafiltration device to produce a solids fraction and a liquid fraction, heating the solids fraction to a temperature of 60° C. or greater to produce a pasteurized solids fraction, microfiltering the liquid fraction through a microfilter having a cutoff size of 1 μm or less to produce a microfiltered liquid fraction, and combining the pasteurized solids fraction and the microfiltered liquid fraction to produce a filtered beverage. In some embodiments, the beverage is a fruit or vegetable juice.

[0008] The filtration system includes an ultrafiltration device defining an ultrafiltration retentate side and an ultrafiltration permeate side, the ultrafiltration device being configured in a cross-flow mode; a heater connected to and configured to receive flow from the ultrafiltration retentate side and including an exhaust line; a microfilter connected to and configured to receive flow from the ultrafiltration permeate side, the microfilter including a microfiltration upstream side and a microfiltration filtrate side and having a cutoff particle size of 1 μm or less, the microfilter being configured in a direct flow filtration mode; and a mixer connected to the exhaust line and the microfiltration filtrate side of the heater, the mixer being configured to receive flow therefrom. [Brief description of the drawings]

[0009] [Figure 1] A graphical representation of the size of the components in orange juice. [Figure 2A] FIG. 1 is a flow diagram of a filtration method according to an embodiment. [Figure 2B] FIG. 1 is a schematic diagram of a filtration system according to an embodiment. [Figure 3A] FIG. 1 is a flow diagram of a filtration method according to an embodiment. [Figure 3B] FIG. 1 is a schematic diagram of a filtration system according to an embodiment. [Figure 4A] FIG. 4 is a schematic diagram of an alternative cross-flow ultrafiltration membrane for use in the filtration system of FIGS. 2B and 3B, according to an embodiment. [Figure 4B] FIG. 4 is a schematic diagram of an alternative cross-flow ultrafiltration membrane for use in the filtration system of FIGS. 2B and 3B, according to an embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] The present disclosure relates to systems and methods for filtering beverages. In particular, the present disclosure relates to systems and methods for filtering fruit and vegetable juices, such as orange juice, and producing no-from-concentrate ("NFC") juice. The present disclosure provides systems and methods for preparing NFC juice, particularly orange juice, with reduced microbial load and increased shelf-stability. NFC juice produced by the methods of the present disclosure exhibits a flavor profile equivalent to fresh-squeezed, unpasteurized orange juice and a microbial load equivalent to pasteurized NFC orange juice.

[0011] The term "beverage" is used herein to refer to any liquid suitable for human consumption. Examples of beverages include fruit juices, vegetable juices, liquid dairy products (e.g., milk), fermented liquid dairy products (e.g., buttermilk), infusions or extracts (e.g., tea, coffee), fermented liquids (e.g., beer, wine, etc.), bouillons (e.g., vegetable bouillon, meat or bone bouillon, mushroom bouillon, etc.), and the like.

[0012] The term "juice" is used herein to refer to a liquid obtained from fruits, vegetables, or other plant parts (e.g., leaves, roots, tubers, etc.). Juice may be obtained, for example, by pressing or squeezing the fruits, vegetables, or other plant parts. Juice may include solids from the fruits, vegetables, or other plant parts.

[0013] The terms "raw beverage" and "raw juice" are used in this disclosure to describe a beverage or juice that has not been further processed after it is obtained to concentrate the beverage or juice or to remove or kill pathogens. For example, the beverage or juice has not been heated (e.g., pasteurized) or irradiated.

[0014] The term "sugar" is used herein to refer to mono- and disaccharides, such as glucose, fructose, sucrose, and the like.

[0015] The term "crossflow" is used herein to refer to a filtration mode in which fluid flows across the surface of a filter membrane, components larger than the filter membrane's size cutoff remain on the retentate side, and components smaller than the size cutoff may flow through the membrane to the permeate side. Continuous flow across the membrane may wash away materials on the retentate side.

[0016] The term "direct flow" is used herein to refer to a filtration mode in which fluid flows into a filter, such as a cartridge filter, where components larger than the filter media size fraction remain on the upstream side of the filter and components smaller than the filter media size fraction may flow downstream. Direct flow filters are sometimes referred to as dead-end filters. Direct flow filters may be cleaned or flushed during a cleaning or flushing cycle in which the flow through the filter is reversed.

[0017] The terms "pasteurize" and "pasteurization" are used herein to refer to a heat treatment to eliminate pathogens in a product, typically a liquid food product. During pasteurization, the product is heated to an elevated temperature, such as at least 60° C. or at least 70° C., for a set time, for example, from multiple seconds to minutes. The specific temperature and time depend on the type of product, the pathogens of interest, and the desired rate of microbial load reduction.

[0018] The term "log reduction" is used herein to refer to the reduction in microbial count in a product given as a log10 value. For example, a 5 log reduction is used to mean a 100,000 fold reduction. Log reduction may be determined using any suitable method, such as microbial culture testing.

[0019] The terms "microorganism" and "pathogen" are used interchangeably and refer broadly to bacteria, yeasts, and molds. Examples of microorganisms and pathogens include spoilage pathogens such as spoilage bacteria (e.g., Acetobacter, Alicyclobacillus, Bacillus, Gluconobacter, Lactobacillus, Leuconostoc, Zymomonas, and Zymobacter), yeasts (e.g., Picobacter, Bacillus subtilis ... Examples of suitable fungi include fungi (e.g., Pichia, Candida, Saccharomyces, and Rhodotorula), filamentous fungi (e.g., Pichia, Candida, Saccharomyces, and Rhodotorula), and disease-causing pathogens (e.g., E. coli, Listeria, Salmonella, etc.).

[0020] The term "substantially" as used herein may be understood to have the same meaning as "significantly" and to modify the subsequent term to at least about 75% thereof, at least about 90% thereof, at least about 95% thereof, or at least about 98% thereof. The term "non-substantially" as used herein may be understood to have the same meaning as "not significantly" and to modify the subsequent term to the opposite meaning of "substantially", i.e., to 25% or less thereof, 10% or less thereof, 5% or less thereof, or 2% or less thereof.

[0021] The term "about" is used herein in conjunction with numerical values ​​to include normal variations in measurements expected by one of ordinary skill in the art, and is understood to have the same meaning as "approximately," and encompasses typical errors, such as ±5% of the stated value.

[0022] The terms "a," "an," and "the" are intended to refer not only to a singular entity, but to include general classes of which specific examples may be used for illustration.

[0023] The terms "a," "an," and "the" are used interchangeably with "at least one." The phrases "at least one of" and "including at least one of" following a list refer to every one of the items in the list and every combination of two or more items in the list.

[0024] As used herein, the term "or" is used in its general sense, including "and / or," unless the context clearly requires otherwise. The term "and / or" refers to one or all of the listed elements or a combination of any two or more of the listed elements.

[0025] Recitation of numerical ranges by endpoints includes all numbers subsumed within that range (e.g., 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, 5, etc.; values ​​up to and including 10 include 10, 9.4, 7.6, 5, 4.3, 2.9, 1.62, 0.3, etc.). When a range of values ​​is stated "up to" a particular value or "at least" a particular value, then that value is included within that range.

[0026] The words "preferred" and "preferably" refer to embodiments that may provide certain benefits, under particular circumstances. However, other embodiments may also be preferred, under the same or other circumstances. Further, the recitation of one or more preferred embodiments does not imply that other embodiments are not beneficial, and does not exclude other embodiments from the scope of the present disclosure, including the claims.

[0027] According to an embodiment, a system and method are provided for filtering beverages such as fruit or vegetable juices. In particular, the system and method may be suitable for filtering orange juice and producing NFC juice. The system and method utilizes filtering and heating only a portion of the beverage to provide a desired pathogen log reduction in the beverage. The final product is a processed beverage that may exhibit a flavor profile equivalent to a fresh-squeezed, unpasteurized beverage. The processed beverage may have a microbial load equivalent to a pasteurized NFC orange juice. The system and method may produce a higher quality, longer shelf-life beverage compared to a similar beverage processed in a conventional manner.

[0028] The U.S. Food and Drug Administration ("FDA") regulates juice processing using the Hazard Analysis and Critical Control Points ("HACCP") process. Specifically, FDA implements a 5 log pathogen reduction process performance standard, which means that producers must process juice to achieve a 5 log, or 100,000-fold, reduction in microbial counts. Producers may use controls that have been proven effective in reducing microbial counts and must demonstrate the efficacy of the reduction, for example, by periodic testing.

[0029] In particular, orange juice is known to be difficult to process, at least in part, due to the high concentrations of both suspended and dissolved solids and heat-sensitive components, including aroma compounds, vitamins, flavonoids, and other phytonutrients. Known processes used to reduce the microbial load of orange juice also result in altered aroma profiles and the destruction of at least some of the heat-sensitive components. The present disclosure provides systems and methods for reducing the microbial load while preserving a substantial portion of the heat-sensitive and aroma components.

[0030] According to an embodiment, the system includes a direct flow filter connected to and in fluid communication with (e.g., receiving flow from) the permeate side of the ultrafiltration device. The use of a direct flow filter with an appropriately selected pore size ensures that all or substantially all microorganisms from the fluid stream are captured and removed. The direct flow filter may remove at least 99%, at least 99.9%, at least 99.99%, at least 99.999% or at least 99.9999% of the microorganisms in the fluid stream. In other words, the direct flow filter may be used for pasteurization of the fluid stream. The direct flow filter may also be tested using a pressure retention test to confirm its integrity. A direct flow filter that passes the test ensures that the desired level of microorganism removal is achieved from the fluid stream. In other words, the advantage of using a direct flow filter is that a certain level or microbial load removal can be guaranteed from the pressure retention test.

[0031] According to some embodiments, the system and method includes separating the beverage into two streams (e.g., a solids stream and a liquid stream) and separately treating the two streams in a manner that ensures a certain microbial load reduction (e.g., 5 logs or more), where at least one of the streams (e.g., the liquid stream) is treated by a method that does not include heating or irradiation. According to some embodiments, the solids stream may be treated by pasteurization and the liquid stream may be treated by microfiltration. The streams may then be combined.

[0032] According to certain embodiments, the system and method reliably achieves a 5 log reduction. For example, the system and method may include an integrity test. An example of an integrity test includes selecting a filter cutoff size that provides a desired reduction (e.g., 5 log or greater) and checking the integrity of the direct flow membrane filter at the end of the membrane sanitization process. The check may include two steps: 1) thoroughly wetting the membrane cartridge with purified water, and 2) running a pressure retention test or a forward flow diffusion flow rate test at a given test pressure. For example, for a 0.2 μm absolute velocity cartridge, the pressure retention test may include: 240kPa( 35 psi ) The test pressure is generated between the compressed air source and the wetted membrane at a test pressure of 1000 g / m² and then monitored at a constant volume to measure the flow rate through the membrane for 10 minutes. 20kPa( 3psi ) A diffusion flow test may include detecting a pressure drop of less than 100 μm for the same membrane. 240kPa( 35 psi ) and a stable pressure over the test time, e.g. 25cm( 10 inch ) and 6.9cm ( 2.7 inches ) The method may include measuring the volumetric flow rate required to maintain a cartridge filter of less than 30 mL / min for a cartridge filter of this size and comparing the measured flow rate to a threshold value to identify whether the cartridge filter is defective (e.g., not functioning as intended).

[0033] In some embodiments, the system of the present disclosure is used to process a raw beverage. The raw beverage can be a fruit juice, such as orange juice. Figure 1 is a size representation of the main components of a fruit juice. As can be seen, components of various sizes can exist in the juice as suspended solids, colloidal dispersions, and soluble solids. The largest components exist as suspended solids and include pulp, whole cells, starch granules, and yeast cells, which are approximately 5 μm or larger in size. Components that are generally less than 1 μm in size and exist as colloidal dispersions include bacteria, cell wall fragments, color bodies, oil droplets, pectins, hemicelluloses, and proteins. Soluble components with particle sizes less than 0.001 μm include many of the components that contribute flavor or provide health benefits, such as bioflavonoids, vitamins, organic acids, sugars, and salts.

[0034] According to embodiments, the systems and methods of the present disclosure are suitable and advantageous for the processing of beverages such as raw juices, because the systems and methods of the present disclosure can reduce the microbial load of the raw juices without compromising the flavor and phytonutrients, such as vitamins, present in the raw juices. According to embodiments, the raw beverages are not concentrated or processed to remove or kill pathogens prior to processing in the systems of the present disclosure. For example, the raw beverages are not heated (e.g., pasteurized) or irradiated. In some embodiments, the raw beverages are not chemically treated prior to processing in the systems of the present disclosure. According to some embodiments, no components, including solids, meltable components, and microorganisms, are removed from the raw beverages after obtaining (e.g., juicing, squeezing, pressing, fermenting, etc.) and prior to processing in the systems of the present disclosure. In some embodiments, pectin is not removed from the raw beverages, such as juices. In some embodiments, the raw beverages are not filtered prior to processing in the systems of the present disclosure. In some embodiments, the raw beverages are not centrifuged prior to processing in the systems of the present disclosure.

[0035] A typical processing process is shown generally in the flow diagram of FIG. 2A. The raw beverage (e.g., juice) may first be separated into two streams: solids and liquids. The raw beverage may be separated into the solids and liquids using a suitable filtration device, such as an ultrafiltration device. The solids stream may contain most, substantially all, or all of the suspended solids of the raw beverage. In some embodiments, the solids stream has a low water content but has a water lift. The majority of the water, other liquid components, and dissolved solids may be contained in the liquids stream. The weight ratio of the solids to the liquids may be approximately 1:5, 1:6, 1:7, 1:8, 1:9, or 1:10, or any range therebetween (e.g., 1:5 to 1:10).

[0036] According to an embodiment, the solid and liquid fractions are processed separately after separation, and then the fractions are blended to produce the final product. Different processing methods may be used for each fraction. The processing methods may be selected to be effective in reducing the microbial load and to have little effect on the flavor and nutritional profile of the final (blended) product. The solid fraction may be treated to kill pathogens. The processing of the solid fraction may include, for example, heating (e.g., pasteurization), irradiation, or a combination thereof. The liquid fraction may be processed by a method that does not include heating or irradiation. The liquid fraction may be filtered to remove pathogens. The filtering of the liquid fraction may include, for example, microfiltration, thereby obtaining a microfiltered liquid fraction. According to an embodiment, the liquid fraction is not heated or pasteurized. For example, during the method, the temperature of the liquid fraction is not higher than 35° C., higher than 40° C., higher than 45° C., or higher than 50° C. The treated solid and liquid fractions are blended (e.g., mixed) to produce the final product.

[0037] In some embodiments, the solids content includes most or substantially all of the suspended solids of the original beverage. The solids content may include most or substantially all of the pectin present in the beverage, e.g., the original juice. The solids content may also include the naturally occurring enzyme pectin methylesterase. The moisture content of the solids content may be about 50% or less, 40% or less, 30% or less, or 20% or less by weight. The solids content of the solids content may be 50% or more, 60% or more, 70% or more, or 80% or more by weight.

[0038] In some embodiments, the liquids contain most of the water and water-soluble components (e.g., dissolved solids) of the original beverage. The liquids may have a water content of about 75% or more, 80% or more, 85% or more, or 90% or more by weight. The liquids may have a water content of less than 100% by weight, such as 99% or less, 98% or less, or 95% or less by weight. The liquids may have a dissolved solid content of 1% to 25%, 5% to 20%, 8% to 20%, or 10% to 15% by weight. In some embodiments, the majority of the dissolved solids are sugars. The dissolved sugar content of a material may be estimated using the refraction of light and expressed in Brix values ​​or degrees Brix (°Bx). One degree Brix is ​​equivalent to about 1 gram of sucrose in 100 grams of solution. The solids may have a Brix value of 10 or less, 8 or less, 7 or less, 6 or less, 5 or less, or 4 or less.

[0039] The water content of the original beverage may be about 70% by weight or more, 75% by weight or more, 80% by weight or more, 85% by weight or more, or 90% by weight or more. The water content of the original beverage may be up to 98% by weight, 95% by weight, 90% by weight, 85% by weight or more, or up to 80% by weight. The water content of the final product (processed filtered beverage) may be the same as the original beverage. In other words, the amount of either liquid or solid that may be removed from the original beverage by processing may be small. For example, the original beverage may have a first water content and the processed filtered beverage may have a second water content, which may be within ±10% of the first water content. In some embodiments, the water content of the processed filtered beverage is about 70% by weight or more, 75% by weight or more, 80% by weight or more, 85% by weight or more, or 90% by weight or more. The water content of the treated filtered beverage may be up to 98%, up to 95%, up to 90%, up to 85% or up to 80% by weight.

[0040] An exemplary system 1 according to an embodiment of the present disclosure is shown in FIG. 2B. The system 1 may include a source of raw beverage, e.g. raw juice. The source of raw beverage may be, for example, a tank, a squeezer, or a supply line. The source of raw beverage may be connected to an input 101 of an ultrafiltration device 100 via an input line 10. The ultrafiltration device 100 may be used to separate the raw beverage into a solids fraction and a liquid fraction. The solids fraction may include most or substantially all of the suspended solids of the raw beverage. The liquid fraction may include water, other liquids, and dissolved solids.

[0041] The ultrafiltration device 100 may be arranged in a cross-flow fashion, in which a fluid (in this case juice) is forced across the filter membrane such that components in the fluid smaller than the filter's cut-off size may pass through to the permeate side of the filter, while the remainder of the fluid, including components larger than the cut-off size, remains on the retentate side and continues to flow.

[0042] The ultrafiltration device 100 may be configured as a flat (e.g., rectangular) flow device in which one or more membranes are arranged along a plane, or as a cylindrical device including a wound roll of membrane. An exemplary flat (rectangular) ultrafiltration membrane device 123 is shown diagrammatically in FIG. 4A, and an exemplary peeled ultrafiltration membrane 123' of a cylindrical ultrafiltration device is shown diagrammatically in FIG. 4B. The ultrafiltration device 100 may contain ultrafiltration membranes 123, 123' that define a retentate side 113 and a permeate side 112. The ultrafiltration membranes 123, 123' may be a single membrane 23 disposed in a filter housing or cartridge, a manifold of membranes, or a wound roll of separate membranes 23. The ultrafiltration device 100 may have an inlet for receiving the input flow 111 and an outlet for the output flow of retentate 130 and permeate 120. The separation membrane 23 may be selected to remove (e.g., retain) solid particles or molecules larger than a particular cutoff size. The layers of the separation membrane 23 may be separated by spacers 141. The separation membrane 23 itself may also include a spacer layer 124 to facilitate the flow of the permeate 120.

[0043] The ultrafiltration device may be configured to retain most, substantially all, or all of the suspended solids of the original beverage on the retentate side of the membrane. The ultrafiltration device may be configured to allow most or substantially all of the flavor and aroma components of the original beverage and other small molecules, such as vitamins, to pass through the permeate side of the membrane. The size cutoff of the ultrafiltration membrane may be defined based on molecular weight. For example, the size cutoff of the ultrafiltration membrane may be selected based on the size of small molecules desired to be included in the liquid fraction, with larger particles, suspended solids, and microorganisms being included in the solid fraction. For example, small molecules desired to remain in the liquid fraction include sugars (e.g., monosaccharides and disaccharides have molecular weights in the range of 180-350 Da (Daltons)), flavor components, vitamins (e.g., most vitamins B and C have molecular weights in the range of 120-450 Da), flavonoids (e.g., certain flavonoids have molecular weights in the range of 300-700 Da), and / or other phytonutrients. On the other hand, larger particles such as cell wall debris and bacteria typically have a particle size greater than 0.5 μm (expressed in molecular weight, approximately 500 kDa (kilodaltons) or greater). The molecular weight cutoff of the ultrafiltration membrane can be 10 kDa or greater, 20 dKa or greater, 40 kDa or greater, 60 kDa or greater, 80 kDa or greater, or 100 kDa or greater. The molecular weight cutoff can be 300 kDa or less, 250 kDa or less, 200 kDa or less, 150 kDa or less, 120 kDa or less, or 100 kDa or less. In some embodiments, the molecular weight cutoff is in the range of 10 kDa to 300 kDa or 100 kDa to 200 kDa.

[0044] Referring again to FIG. 2B, the separated liquid fraction (permeate 120) exits the ultrafiltration device 100 at outlet 102 and flows along line 20 to a microfiltration device 200. The microfiltration device 200 may be configured as a direct flow filter. The microfiltration device 200 may contain a microfilter selected to retain most, substantially all, or all of the microorganisms present in the liquid fraction. The microfilter may define an upstream side and a filtrate side. The microfilter may be a cartridge filter, including a cartridge containing a suitable filter medium. Examples of suitable filter media include pleated filter media and microfiltration membranes. The cutoff size of the microfilter may be 1.2 μm or less, 1.1 μm or less, 1 μm or less, 0.9 μm or less, 0.8 μm or less, 0.7 μm or less, 0.6 μm or less, or 0.5 μm or less. The cut-off size of the microfilter can be 0.1 μm or more, 0.2 μm or more, 0.3 μm or more, 0.4 μm or more, or 0.5 μm or more. In some embodiments, the cut-off size can be in the range of 0.2 μm to 1.0 μm. By using a direct flow filter with an appropriately selected cut-off size, the permeate (filtered liquid portion) can be mixed to obtain the final product without additional processing, because the direct flow filter retains all or substantially all of the microorganisms upstream. According to certain embodiments, the microfiltration device 200 is configured as a direct flow filter having a cutoff size of 1.2 μm or less, 1.1 μm or less, 1 μm or less, 0.9 μm or less, 0.8 μm or less, 0.7 μm or less, 0.6 μm or less, or 0.5 μm or less, and provides removal of at least 99%, at least 99.9%, at least 99.99%, at least 99.999%, or at least 99.9999% of microorganisms present in the separated liquid fraction. In some embodiments, the microfiltration device 200 is capable of sterilizing the separated liquid fraction.

[0045] According to certain embodiments, the microfiltered liquid fraction exhibits at least 5 log pathogen reduction compared to the original beverage. In some embodiments, the microfiltered liquid fraction is substantially free of pathogens. According to certain embodiments, the microfiltered liquid fraction is substantially free of pathogens without heat treatment, irradiation, or both heat and irradiation. In particular, according to certain embodiments, the liquid fraction is treated without heat treatment, irradiation, or both heat and irradiation, and is substantially free of pathogens without heat treatment, irradiation, or both heat and irradiation. Heat treatment is considered a process in which the temperature of the material is raised to 50°C or higher. Thus, according to certain embodiments, the temperature of the liquid fraction during the process does not reach 50°C or higher. The liquid fraction may contain most of the dissolved solids of the original beverage (e.g., sugars, flavorings, vitamins, flavonoids, and other phytonutrients).

[0046] According to some embodiments, the liquid portion comprises the majority of the sugar in the original beverage. According to some embodiments, the liquid portion comprises 50% or more, 60% or more, 75% or more, 80% or more, 85% or more, 90% or more, or 95% or more of the sugar in the original beverage. According to some embodiments, the liquid portion comprises the majority of the vitamin C in the original beverage. According to some embodiments, the vitamin C concentration in the liquid portion is 50% or more, 60% or more, 70% or more, 75% or more, 80% or more, or 85% or more of the vitamin C concentration in the original beverage.

[0047] The separated solids (retentate 130) exits the ultrafiltration system 100 at outlet 103 and flows along line 30 to a processor 300. The processor 300 is configured to couple to and receive the flow from the retentate side of the ultrafiltration system 100. The processor 300 can be, for example, a heater (e.g., a pasteurizer). Other possible devices include, for example, devices that can apply UV, high energy, or molecular radiation to the solids. In one embodiment, the processor 300 includes a pasteurizer. The pasteurizer can include a heating tank or a flow-through heater (e.g., a heat exchanger). The pasteurizer can be configured to heat the solids to a temperature sufficient to kill pathogens. For example, the pasteurizer can be configured to heat the solids to about 60° C. or more, 65° C. or more, or 70° C. or more. The pasteurizer can be configured to heat the solids to about 95° C. or less, 90° C. or less, 85° C. or less, 80° C. or less, 75° C. or less, or 70° C. or less. The pasteurizer may be configured to hold the temperature of the solids at the pasteurization temperature for a predetermined period of time. For example, the pasteurizer may be configured to hold the solids at the pasteurization temperature for 10 seconds or more, 30 seconds or more, 1 minute or more, or 2 minutes or more. The pasteurizer may be configured to hold the solids at the pasteurization temperature for 15 minutes or less, 10 minutes or less, 5 minutes or less, or 2 minutes or less. According to some embodiments, no flow is passed from the microfiltration device 200 to the processing device 300.

[0048] According to certain embodiments, the treated (e.g., pasteurized) solids exhibit at least a 5 log pathogen reduction compared to the original beverage. In some embodiments, the treated (e.g., pasteurized) solids are substantially free of pathogens.

[0049] The microfiltered liquid fraction may flow from the microfiltration device 200 to the mixer 400 via line 42, and the processed solids fraction may flow from the processing device 300 to the mixer 400 via line 43. The mixer 400 may be coupled to and receive the filtrate side of the microfiltration device 200 and the processing device 300. The mixer 400 may include a mixing vessel or may be an in-line mixer. The final product (processed beverage, e.g., juice) may be discharged from the system 1 via discharge line 50. According to certain embodiments, the final product exhibits at least a 5 log pathogen reduction compared to the original beverage. In some embodiments, the final product is substantially pathogen-free.

[0050] In some embodiments, the microfiltered liquid fraction is not mixed with the treated solids. Rather, the microfiltered liquid fraction may be collected and optionally packaged to provide a beverage comprising the filtered liquid fraction of the raw juice. According to an embodiment, the beverage product may be a filtered liquid fraction made by filtering a rubbed beverage, e.g., raw juice, using a cross-flow ultrafiltration device to separate the solids from the liquid fraction, and microfiltering the liquid fraction through a microfilter having a cutoff size of 1.2 μm or less, 1.1 μm or less, 1.0 μm or less, 0.9 μm or less, 0.8 μm or less, 0.7 μm or less, 0.6 μm or less, or 0.5 μm or less, and / or 0.1 μm or more, 0.2 μm or more, 0.3 μm or more, 0.4 μm or more, or 0.5 μm or more to produce a microfiltered liquid fraction. The filtered liquid fraction has been found to retain at least some or most of the color of the raw beverage (e.g., raw juice) while remaining mostly or completely transparent (e.g., free of haze). It has been found that the filtered liquid fraction made from fruit juice retains most of the aroma of the original beverage (eg, original juice) and also at least a portion of its flavor.

[0051] According to certain embodiments, the method further includes utilizing water recirculation to facilitate washing more sugars and other small molecules from the solids. A schematic flow diagram of such a process is shown in FIG. 3A, and a system diagram of a system configured for the process is shown in FIG. 3B. As can be seen in FIG. 3A, the process is otherwise similar to that described with respect to FIG. 2A, with the addition that reverse osmosis ("RO") is used to recycle the water. Second Used to separate the liquid fraction, the OR water is returned to the mixing tank and mixed with the solids. The added water dilutes the sugars and small molecules present in the solids, facilitating their removal in the subsequent ultrafiltration step.

[0052] As previously described, the separated solids (retentate 130) exits the ultrafilter 100 at outlet 103 and flows along line 30. However, instead of being directed to the processor 300, the solids are first mixed with RO water in a mixing tank 500 and then ultrafiltered again in the ultrafilter 100'. This cycle can be repeated multiple times until the sugar content in the solids reaches a desired value. Monitoring the sugar content in the solids can be used as an indication of the separation efficiency of separating sugars and small molecules from the solids. The processor 300 is coupled to and configured to receive a flow from the retentate side of the ultrafilter 100'. The processor 300 can be as described with respect to Figures 2A and 2B. The RO retentate (liquids with some water removed) is combined with the original liquid stream and microfiltered to produce a filtered liquid. The washed solids contain less sugars and small molecules than the original solids and are processed (e.g., pasteurized). The treated (eg, pasteurized) solids fraction is combined with the microfiltered liquid fraction to produce the treated juice.

[0053] The system 1' shown in FIG. 3B includes the components of the system 1 shown in FIG. 2B and further includes components of a water circulation loop. In particular, FIG. 3B includes an RO membrane filter 600, which is in fluid communication with (e.g., receives flow from) the permeate side 112' of the ultrafiltration device 100' via line 21 through outlet 102'. The RO membrane filter 600 has a permeate side 612 in fluid communication with (e.g., delivers flow to) the mixing tank 500 (e.g., wash tank) via line 62. The mixing tank 500 also receives flow along line 30 from the retentate side (outlet 103) of the ultrafiltration device 100. The mixing tank 500 is in fluid communication with (e.g., delivers flow to) the ultrafiltration device 100' via line 50. The RO membrane filter 600 further has a retentate side 613 in fluid communication with (e.g., delivers flow to) the microfilter 200 via line 63. The retentate side 113' of the ultrafiltration device 100' delivers flow along line 31 to the processor 300 through outlet 103'.

[0054] According to some embodiments, by using a water recirculation loop, the relative sugar content in the liquid fraction can be much higher. For example, the liquid fraction can contain 85% or more, 90% or more, 95% or more, or 98% or more of the sugar of the original beverage. According to some embodiments, the liquid fraction has a vitamin C concentration that is 85% or more, 90% or more, 95% or more, or 98% or more of the vitamin C of the original beverage.

[0055] In some embodiments, the beverage is obtained by the methods described herein and includes a filtered liquid fraction having a suspended solids content of 5% or less by weight, or 2% or less by weight. In some embodiments, the beverage consists essentially of a pasteurized solids fraction and a microfiltered liquid fraction. In some embodiments, the beverage consists essentially of a pasteurized solids fraction and a microfiltered liquid fraction. In some embodiments, the beverage consists essentially of a filtered liquid fraction. In some embodiments, the beverage includes sugars and flavors that are not heat-treated or irradiated, and the beverage has a microbial load of 10 CFU / g (colony formation count per gram). In some embodiments, the beverage includes small molecules that are not heat-treated or irradiated, have a molecular weight of less than 1000 Da, and have a microbial load of less than 10 CFU / g. The small molecules may include sugars, flavors, and vitamins. In some embodiments, the beverage consists of a pasteurized solids fraction and a microfiltered liquid fraction. In other words, in some embodiments, the filtered liquid fraction is not blended with the solids.

[0056] Below is a list of exemplary embodiments of articles according to the present disclosure.

[0057] According to embodiment 1, a method of preparing a filtered beverage, e.g., a fruit juice, includes filtering a raw beverage, e.g., raw juice, using a cross-flow ultrafiltration device to produce a solids fraction and a liquid fraction; heating the solids fraction to a temperature of 60° C. or more, 65° C. or more, or 70° C. or more, and / or 95° C. or less, 90° C. or less, 85° C. or less, 80° C. or less, 75° C. or less, or 70° C. or less to produce a pasteurized solids fraction; microfiltering the liquid fraction through a microfilter having a cutoff size of 1.2 μm or less, 1.1 μm or less, 1.0 μm or less, 0.9 μm or less, 0.8 μm or less, 0.7 μm or less, 0.6 μm or less, or 0.5 μm or less, and / or 0.1 μm or more, 0.2 μm or more, 0.3 μm or more, 0.4 μm or more, or 0.5 μm or more to produce a microfiltered liquid fraction; and combining the pasteurized solids fraction and the microfiltered liquid fraction to produce a filtered beverage, e.g., a filtered juice.

[0058] Embodiment 2 is the method of embodiment 1, wherein the beverage comprises raw juice.

[0059] Example 3 is the method of Example 1 or 2, wherein the base beverage, e.g., base juice, has a water content of at least 70%, at least 75%, at least 80%, at least 85%, or at least 90% by weight and / or up to 95%, at least 90%, at least 85%, or up to 80% by weight, and the filtered beverage, e.g., filtered juice, has a water content of at least 70%, at least 75%, at least 80%, at least 85%, or at least 90% by weight and / or up to 95%, at least 90%, at least 85%, or up to 80% by weight.

[0060] Example 4 is the method of any one of Examples 1-3, wherein the base beverage, e.g., base juice, has a first water content, and the filtered beverage, e.g., filtered juice, has a second water content, the second water content being within ±10% of the first water content.

[0061] Example 5 is the method of any one of the preceding examples, wherein the solids have a moisture content of 50% by weight or less, 40% by weight or less, 30% by weight or less, or 20% by weight or less.

[0062] Aspect 6 is the process of any one of the preceding aspects, wherein the solids content is from 40% to 90% by weight, or 50% or more by weight, 60% or more by weight, 70% or more by weight, or 80% or more by weight, and up to 90% by weight.

[0063] Example 7 is the method of any one of the preceding examples, wherein the liquid content comprises 8% to 20% dissolved solids by weight.

[0064] Example 8 is the method of any one of the preceding examples, wherein the liquid portion has a vitamin C concentration that is 75% or greater than the vitamin C concentration of the base beverage.

[0065] Aspect 9 is the method of any one of the preceding aspects, wherein the cross-flow ultrafiltration device comprises a membrane having a size cut-off of 10 kDa or more, 20 kDa or more, 40 kDa or more, 60 kDa or more, 80 kDa or more, or 100 kDa or more, and / or a molecular weight cut-off of 300 kDa or less, 250 kDa or less, 200 kDa or less, 150 kDa or less, 120 kDa or less, or 100 kDa or less. In some embodiments, the molecular weight cut-off is in the range of 10 kDa to 300 kDa or 100 kDa to 200 kDa.

[0066] Example 10 is the method of any one of the preceding examples, wherein the microfilter is configured as a direct flow filter.

[0067] Example 11 is the method of any one of the above examples, wherein the microfilter has a cutoff size of 0.1 μm to 1.0 μm, 0.1 μm to 0.5 μm, or 0.2 μm to 0.3 μm.

[0068] Example 12 is the method of any one of the preceding examples, wherein the liquid fraction has a first microbial content and the microfiltered liquid fraction has a second microbial content, the second microbial content being reduced from the first microbial content by at least 5 logs.

[0069] Example 13 is the method of any one of the preceding examples, wherein the microfiltration removes at least 99%, at least 99.9%, at least 99.99%, at least 99.999%, or at least 99.9999% of the microorganisms in the liquid fraction.

[0070] Example 14 is the method of any one of the preceding examples, wherein microfiltration sterilizes the liquid portion.

[0071] Example 15 is the method of any one of the preceding examples, wherein the liquid fraction has a first microbial content and the microfiltered liquid fraction has a second microbial content, the second microbial content being reduced from the first microbial content by at least 5 logs.

[0072] Example 16 is the method of any one of the preceding examples, wherein the base beverage, e.g., base juice, has a base beverage microbial content, and the filtered beverage, e.g., filtered juice, has a final microbial content, wherein the final microbial content is reduced by at least 5 logs from the microbial content of the base beverage, e.g., base juice.

[0073] Example 17 is the method of any one of the preceding examples, wherein the concentrating step does not include a concentrating step performed by evaporation.

[0074] Example 18 is the method of any one of the preceding examples, wherein the method does not include concentrating the liquid portion.

[0075] Example 19 is the method of any one of the preceding examples, which does not include heat treating the liquid portion.

[0076] Example 20 is the method of any one of the preceding examples, which does not include radiation treatment of the liquid content.

[0077] Example 21 is the method of any one of the preceding examples, wherein the blending occurs immediately after microfiltration. According to a preferred embodiment, there is no flow from the microfiltration device to the treatment device.

[0078] Example 22 is the method of any one of the preceding examples, further comprising an integrity test comprising testing the integrity of a filter membrane of the microfilter.

[0079] Example 23 is the method of example 22, wherein the integrity test includes a pressure hold test or a forward flow diffusion test at a given test pressure.

[0080] Aspect 24 is a filtration system including an ultrafiltration apparatus including an ultrafiltration retentate side and an ultrafiltration permeate side, the ultrafiltration apparatus being configured in a cross-flow mode; a heater connected to the ultrafiltration retentate side and configured to receive flow therefrom and including a discharge line; a microfilter connected to the ultrafiltration permeate side and configured to receive flow therefrom, the microfilter including a microfiltration upstream side and a microfiltration filtrate side and having a cutoff particle size of 1 μm or less, the microfilter being configured in a direct flow filtration mode; and a mixer connected to the heater discharge line and the microfiltration filtrate side and configured to receive flow therefrom.

[0081] Aspect 25 is the filtration system of Aspect 24, wherein the cross-flow ultrafiltration device comprises a membrane having a size cut-off of 10 kDa or more, 20 kDa or more, 40 kDa or more, 60 kDa or more, 80 kDa or more, or 100 kDa or more, and / or a molecular weight cut-off of 300 kDa or less, 250 kDa or less, 200 kDa or less, 150 kDa or less, 120 kDa or less, or 100 kDa or less. In some embodiments, the molecular weight cut-off is in the range of 10 kDa to 300 kDa or 100 kDa to 200 kDa.

[0082]

[0023] Aspect 26 is the filtration system of Aspects 24 or 25, wherein the microfilter has a size cutoff of 1.2 μm or less, 1.1 μm or less, 1 μm or less, 0.9 μm or less, 0.8 μm or less, 0.7 μm or less, 0.6 μm or less, or 0.5 μm or less, and / or the microfilter has a size cutoff of 0.1 μm or more, 0.2 μm or more, 0.3 μm or more, 0.4 μm or more, or 0.5 μm or more. In some embodiments, the size cutoff is in the range of 0.2 μm to 1.0 μm.

[0083]

[0023] Example 27 is the filtration system of any one of Examples 24-26, further including a second ultrafiltration device including a second ultrafiltration retentate side and a second ultrafiltration permeate side, the second ultrafiltration device configured in a cross-flow mode, a reverse osmosis membrane filter coupled to and configured to receive a flow from the second ultrafiltration permeate side, the reverse osmosis membrane filter including a reverse osmosis permeate side, and a second mixer coupled to and configured to receive a flow from the first ultrafiltration retentate side and the reverse osmosis permeate side, the heater configured to receive a flow from the second ultrafiltration retentate side. The reverse osmosis membrane filter further includes a retentate side coupled to and configured to deliver a flow to the microfilter.

[0084] Aspect 28 is a beverage comprising a microfiltered liquid fraction made by the method of any one of aspects 1-23.

[0085] Aspect 29 is the beverage of aspect 28 having a suspended solids content of less than 5% by weight, or less than 2% by weight.

[0086] Embodiment 30 is the beverage of embodiment 28, consisting essentially of the filtered liquid fraction.

[0087]

[0023] Aspect 31 is a beverage comprising a microfiltered liquid fraction made by filtering a base beverage, e.g., a base juice, using a cross-flow ultrafiltration device to produce a solids and liquid fraction, and microfiltering the liquid fraction using a direct flow microfilter having a cutoff size of 1.2 μm or less, 1.1 μm or less, 1.0 μm or less, 0.9 μm or less, 0.8 μm or less, 0.7 μm or less, 0.6 μm or less, or 0.5 μm or less, and / or 0.1 μm or more, 0.2 μm or more, 0.3 μm or more, 0.4 μm or more, or 0.5 μm or more, to produce the microfiltered liquid fraction.

[0088] Example 32 is the beverage of example 31, comprising small molecules having a molecular weight of less than 1000 Da that are not heat treated or irradiated and having a microbial load of less than 10 CFU / g. Small molecules may include sugars, flavor compounds, and vitamins.

[0089] Aspect 33 is a beverage made by the method of any one of Aspects 1-23 and comprising a pasteurized solids fraction and a microfiltered liquid fraction. EXAMPLES

[0090] A filtration system according to the present disclosure was tested for processing raw orange juice. The raw juice was unpasteurized fresh squeezed orange juice with an initial Bix value of 11.1. The processing system included an ultrafiltration cross-flow filter used to separate the solids and liquids, a microfilter to filter the liquids, and a pasteurizer to pasteurize the solids. A pump was used to run the juice through the system at 190 L / min. The system was configured as shown in Figures 3A and 3B.

[0091] The ultrafiltration crossflow filter contained a rectangular flat sheet polyethersulfone (PES) membrane with adjustable spacers to form the flow path. During operation, most of the flow was directed through the flow path and back to the pump. Tests were performed on 48 kg raw orange juice, which was separated into 34 kg permeate and 14 kg retentate. The liquid fraction that permeated the membrane was collected at a rate of 0.4 L / min. The molecular weight cut-off of the ultrafiltration membrane was 150 kDa, which corresponds to a nominal pore size of 15 nm.

[0092] The microfilter was a direct flow filter (product number 1C230101-82, sold by Donaldson Company, Inc., Minneapolis, Minnesota) with a PES-WN 25cm( 10 inch ) , and a 0.2 μm filter was attached.

[0093] Reverse osmosis was performed using a cross-flow filter with an RO membrane with a molecular weight cut-off of 100 Da.

[0094] The initial sugar content (Brix value) of the retentate was 12.8. The sugar content of line 31 ("low sugar retentate") and line 21 (wash cycle permeate) was monitored after 1, 2, 3 and 4 wash cycles with RO water. The sugar content was estimated using a Brix refractometer (ATAGO 3810 PAL-1, sold by Atago Co., Ltd., Tokyo, Japan). The Brix values ​​are shown in Table 1 below.

[0095] [Table 1]

[0096] It was found that the sugar content of the retentate (Brix value) can be reduced from 12.8 to 2.2 by washing with RO water, which further reduces the amount of sugar that is pasteurized, which can further reduce off-flavors in the final product.

[0097] The permeate from the ultrafiltration crossflow filter (line 42 in FIG. 3B) was collected in a sterile clean plastic bag fitted with a sampling port. The permeate was observed to be substantially clear with a light orange color and to have an orange odor and taste, although somewhat attenuated. The permeate was found to have a Brix value of 10.9.

[0098] The permeate was further filtered using a direct flow microfilter. The microbial content of the filtered permeate was analyzed and the results are shown in Table 2 below, in comparison with the analysis of the raw juice.

[0099] [Table 2]

[0100] Sample 4℃( 40°F ) Microbial analysis was repeated again after one and three months of storage at refrigeration temperatures of 100°C. The one-month results are shown below in Table 3A, and the three-month results in Table 3B.

[0101] [Table 3]

[0102] [Table 4]

[0103] The retentate from the ultrafiltration cross-flow filter formed a solid fraction. The solid fraction was found to have a very light color and strong aroma, but a weak slightly bitter taste. The permeate was pasteurized in a pasteurization loop at a temperature of 90° C. for 10 minutes. The pasteurized permeate was cooled to 60° C. and bagged. The pasteurized retentate retained its color and aroma.

[0104] The pasteurized retentate was mixed with the filtration permeate to produce the final product. The final filtered product was tested in a blind taste test against the original raw juice. The effect of processing was found to be negligible.

[0105] All references and publications cited herein are expressly incorporated by reference in their entirety into this disclosure unless they directly contradict this disclosure. Although specific embodiments have been illustrated and described herein, those skilled in the art will recognize that the specific embodiments illustrated and described may be substituted with various alternative and / or equivalent implementations without departing from the scope of this disclosure. This disclosure is not to be unduly limited by the exemplary embodiments and examples set forth herein, which examples and embodiments are presented by way of example only, and the scope of this disclosure is to be limited only by the scope of the claims that follow.

Claims

1. 1. A method for preparing filtered juice comprising the steps of: filtering the raw juice using cross-flow ultrafiltration to produce a solids fraction and a liquid fraction; mixing reverse osmosis water with the solids to produce a diluted solids; filtering the diluted solids fraction using cross-flow ultrafiltration to produce a washed solids fraction and a second liquid fraction; separating water from the second liquid fraction using reverse osmosis and forming a reverse osmosis retentate; heating the washed solids to a temperature of 60° C. or greater to produce pasteurized solids; microfiltering the liquid fraction and the reverse osmosis retentate through a microfilter having a cutoff size of 0.1 μm to 1 μm to produce a microfiltered liquid fraction, the microfilter being configured in a direct flow filtration mode; combining said pasteurized solids fraction and said microfiltered liquid fraction to provide said filtered juice; Including, During the process, the liquid portion does not reach a temperature of 50° C. or greater.

2. The method of claim 1, wherein the cross-flow ultrafiltration device comprises a membrane having a cut-off size of between 10 kDa and 300 kDa.

3. 3. The method of claim 1, wherein the raw juice has a raw juice microbial content and the filtered juice has a final microbial content, the final microbial content being at least 5 log reduced from the raw juice microbial content.

4. a first ultrafiltration device including a first ultrafiltration retentate side and a first ultrafiltration permeate side, the first ultrafiltration device being configured in a cross-flow mode and including a membrane having a cut-off size of 10 kDa to 300 kDa; a heater configured to receive flow from the first ultrafiltration retentate side and including a discharge line; a microfilter coupled to and configured to receive flow from the first ultrafiltration permeate side, the microfilter including a microfiltration upstream side and a microfiltration filtrate side, the microfilter having a particle size cut-off of 1 μm or less, and configured in a direct flow filtration mode; a mixer coupled to and configured to receive flow from the heater exhaust line and the microfiltration filtrate side; a second ultrafiltration apparatus including a second ultrafiltration retentate side and a second ultrafiltration permeate side, the second ultrafiltration apparatus being configured in a cross-flow mode; a reverse osmosis membrane filter coupled to and configured to receive flow from the second ultrafiltration permeate side, the reverse osmosis membrane filter including a reverse osmosis permeate side and a reverse osmosis retentate side; a second mixer coupled to and configured to receive flow from the first ultrafiltration retentate side and the reverse osmosis permeate side; Including, A filtration system, wherein the heater is configured to receive flow from the second ultrafiltration retentate side, and the microfilter is configured to receive flow from the reverse osmosis retentate side.

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