CARBONATED

NON ALCOHOLIC
BEVERAGES

BY: Derese W.
 Introduction
 Carbonated beverages, also known as fizzy drinks or soft drinks, are
beverages that contain carbon dioxide dissolved under pressure.

 The carbonation process gives these drinks their characteristic bubbles

and effervescence.

types of soft drinks:

Carbonates
Still Drinks (Energy and sports drinks)
Dilutables
Juices / Nectars
 Introduction
Dilutables is the name given to concentrated syrups, squashes, and
cordials that are reconstituted with water by
consumers to prepare beverages in ready to-drink (RTD) forms

Juices and nectars are beverages made mainly from natural fruit juices,
juices contain pure, 100% juice, whereas nectars have around
50% natural juice content

Juices may or may not be sweetened,

but nectars are always sweetened, in one manner or another, to
make up for the nonjuice portion of the beverage
 Introduction
All soft drinks have the same few components. Other specialty
ingredient combinations give us the diversity we see on the shelves

Water
Makes up about 87 to 92% of the beverage volume

Pretreated to remove impurities, microorganisms, and other

undesirable attributes, such as off-tastes, odors, and turbidity,

It is also treated to regulate alkalinity and hardness

Provides essential hydration effects to enable body metabolism

 Introduction
Sweetener
Which is usually refined white sugar, though other natural or
artificial sweeteners are being used as alternatives

In a naturally sweetened soft drink, the sugar makes up about 8 to

12% of the beverage by mass

Act as synergist and give balance to flavour

Acidulant
May inorganic or organic acid that contributes to the sharpness,
sourness, flavor of the beverage
 Introduction
Acidulant
The balance between sweetness and sourness is what gives it the
basic typical taste profile of all flavored soft drinks

Without this sweetener and acid balance, the beverage would taste
totally wishy-washy and unexciting

Flavorant

Natural, nature-identical, or completely synthetic

Concentrated forms and give beverages their characteristic tastes

Plays an important role in overall sensory perception of the drink

 Introduction
Colorants
Natural ingredients or synthetic food dyes

Used in minute quantities individually or in combinations that give

us the rainbow spectrum of soft drink colors

Emulsion
Carrier for oil-based flavours or colours
Gives cloudy effect in drink to replace or enhance cloud from
natural juices

The cloudiness is achieved either by the inclusion of a

natural cloudy juice or by means of a clouding agent
Emulsion
Introduction
Clouding agent is usually an oil-in-water emulsion from which fine
globules of citrus or other natural oils are suspended in the liquid of
 the drink and give it the characteristic cloudy appearance

Carbon dioxide

Gives the fizziness to beverages

Also contributes to the acidity of the beverage and, as such, plays

an auxiliary role as a preservative against spoilage

Provides mouthfeel and sparkle to drink (carbonates only)

Preservatives
Introduction
To prevent microbiological spoilage and increase the shelf life of
the beverage

Sodium benzoate and potassium sorbate and, to a lesser degree,

sulfur dioxide

They are called bacteristatic agents, selectively, and to a certain

extent, prevent further growth of any microorganisms that are

 still present in small numbers in the drink when the

packages are filled
 Introduction
Preservatives

Soft drinks that do not contain preservatives are usually processed

under sophisticated hygienic conditions and treated in one manner or

another, such as by

pasteurization,

hot-filling, or

ozonation, so that any microorganisms present in the

beverage are killed before or during filling

 Introduction
Antioxidants
• Prevent oxidation, limit flavour and colour deterioration

Quillaia extract (saponins)

• Acts to provide heading foam, mainly of use in carbonates

Hydrocolloids (mucilaginous gums)

• Carrageenans, alginates, polysaccharides, carboxy methyl cellulose
etc
• Provide mouthfeel, shelf-life stability, viscosity

Vitamins/Minerals
• Used in ‘healthy-living’ drinks to provide nutritional requirements
 Introduction
There are many detractors of soft drinks that warn us of the harm that
they can cause like
obesity, dental caries, diabetes mellitus, hypocalcemia and bone
density, cancer, indulge etc.

Soft drinks can be sources of clean water, carbohydrates, and other

nutrients in many parts of the world where these drinks are unavailable

The soft drinks industry has a profound economical, social, and even
political impact on peoples’ lives and on world affairs in general
 Introduction
The manufacture of carbonated beverages can be broadly divided into

the following sub-processes:

Sugar dissolving to produce base syrup (where required)

Preparation and de-aeration of water

Preparation and blending of all ingredients

Thermal product treatment or pasteurisation

Carbonation

Filling and packaging

 Syrup preparation
 The soft drink industry is actually made up of two major
manufacturing systems that, bring soft drinks to the market

It is
flavoring syrup and concentrate manufacturing and
 soft drink manufacturing

 Syrup preparation is a crucial step in the production of flavored

carbonated beverages.

 The syrup is responsible for providing the desired flavor, sweetness,

and color to the final product
 Syrup preparation
 For flavored carbonated beverages, a syrup is prepared.

 This involves mixing ingredients such as sugars, flavorings, colorings,

and other additives with water

 The syrup is typically heated and stirred to dissolve the ingredients and
create a homogeneous mixture.

Most products are traditionally prepared as a syrup-plus-water mix,

in a ratio of 1 part syrup to between 3 and 6 parts water

The ingredients are carefully weighed out and added to the mixing
vessel
 Syrup preparation
Recipe Formulation:
This involves determining the specific ingredients and their
quantities needed to achieve the desired flavor profile
The recipe may include sugars, flavorings, colorings, acids, and
other additives
Mixing Ingredients:
The process may involve dissolving granulated sugars or
sweeteners in water or other liquid components
Flavorings, such as natural or artificial extracts, are added to
provide the desired taste.
Colorings, if needed, are incorporated to achieve the desired hue.
 Syrup preparation
The syrup is pre-prepared and fully tested before being sent to the
proportioner for mixing with water
through the uses of flow meters and subsequent carbonation

The syrup is usually dosed though a mass flow meter and the water is
dosed volumetrically using a magnetic induction flow meter

The accuracy of mass flow meters ensures the product is produced at

the required Brix, thus ensuring conformance to specification,
tight cost control and minimum wastage
 Fig. Product preparation using flow meters

Note: It is normal to water-flush between introducing each component to

ensure the feed lines are clear of the previous ingredient
 Syrup preparation
Heat Treatment:
to aid in dissolving the ingredients and ensuring a homogeneous
mixture.
Heating also helps to sterilize the syrup and extend its shelf life.

Cooling and Filtering:

 cooled down to room temperature.
 Cooling helps stabilize the syrup and prevent degradation of
flavors and other components.
 The syrup may also be filtered to remove any particulates or
impurities, ensuring a smooth and clear final product.
 Syrup preparation
Quality Control:
to ensure consistency, taste, and safety.
This may involve sensory evaluations, laboratory testing, and
analysis of factors such as
 flavor strength, color intensity, pH levels, and
microbial contamination.

 It's important to note that the specific recipes and techniques for syrup
preparation can vary widely depending on the
 desired flavor and
 the manufacturer's preferences.
 Syrup preparation
Nowadays plants are situated in hygienically designed rooms with the
advent of modern flow metering systems and
programmable logic controller made drastic changes to the way
we operate

Raw materials are kept in a separate room to minimise any risk of

contamination from packaging, etc.
The syrup room of old would have operated with
small mixing tanks using a wooden paddle
simple weighing equipment and measuring jugs
measured either by a mark on the side of the tank or by a dip
stick
 Syrup composition

Acids give the tart taste to a soft drink and the three principal acids

used are citric (common), phosphoric and malic acid, occasionally

tartaric, lactic, acetic, fumaric and ascorbic are used

These can be delivered either in powder form or as a liquid in bulk (for

modern metering systems)

The quantity used in a soft drink is dependant on the recipe

 Cont’d…….
Syrup composition
Sugar in all sugar drinks represents the second major ingredient

sucrose extracted from either beet or cane

Whether a company takes the sugar in a granular form for

dissolving on site, or as a liquid is usually dependent on the price

A typical soft drink will have some 10% sugar

Sugar is normally added to enhance taste

It is a carbohydrate that breaks down in the body to form the

energy source, glucose
 Cont’d…….
Syrup composition

For low-calorie drinks sweeteners are used instead of sugar

The main sweeteners in use are acesulfame-K, aspartame,

cyclamates and saccharin

The choice of which sweetener to use in any specific drink

depends on the
type of product, the taste, the availability and the price

These sweeteners can also be blended together including

sometimes with sugar

They are normally delivered in bag form on pallets

 Cont’d…….
Syrup composition

Preservatives inhibit the growth of micro-organisms

High levels of acidity, and carbonation also assists in inhibiting the

growth of yeasts and bacteria

Benzoic acid and sorbic acid, which are effective against most
yeasts and moulds

Flavourings, which may be natural or artificial in nature

allow a wide variety of drinks to be produced

They can be water miscible or water dispersible

 De-aeration of water
The presence of air in a product causes
product deterioration,
as well as giving a false reading of the level of carbon dioxide
present due to the partial pressures involved

The presence of air and carbon dioxide causes nucleation sites within
the products, giving rise to the phenomenon known as fobbing

The higher the air content the more difficult it is to hold carbon dioxide
in solution
 De-aeration of water
By vacuum the water before mixing with syrup rather than to the final
product

The most effective method of de-aeration is to atomise water into a

vessel held under a vacuum

In this way air is stripped out as the atomised water is exposed to
the vacuum

If a positive carbon dioxide pressure is applied in a sealed vessel the air
attaches to CO2, in a process known as nucleation, and
is then driven off through a vent
 Carbonation
 Carbonation is the process of dissolving carbon dioxide (CO2) gas
into a liquid, usually water, to create carbonic acid

Carbon dioxide is a non-toxic, inert gas that is virtually tasteless and is

readily available at a reasonable cost

It is carbonic acid (CO2 + H2O) in combination with the product that
produces the acidic and biting taste found
in carbonated water and soft drinks

Carbonation Equipment:
to introduce carbon dioxide into the beverage.
Carbonator is a pressurized vessel
 Carbonation
Pressurization:
The carbonator is pressurized with carbon dioxide gas, typically
obtained from a bulk supply or generated on-site.
The pressure applied forces the carbon dioxide to dissolve into the
liquid.
Mixing:
The carbon dioxide-enriched gas is mixed with the liquid, usually
water, in the carbonator.
The mixture is agitated to facilitate the dissolution of the CO2 into
the liquid.
The pressure helps to dissolve more carbon dioxide into the liquid
than would normally dissolve at atmospheric pressure.
 Carbonation
Two basic methods are the injection and dispersion of CO2 into the
liquid to be carbonated, and
the fine spraying of the product (for batch) into a CO2 atmosphere

The carbon dioxide is often sparged into the liquid under pressure; this
allows small bubbles of gas to be formed
which can be easily absorbed by the liquid
 Carbonation
Carbonation Control:
to achieve the desired effervescence and taste.
The amount of CO2 introduced into the liquid can be adjusted to
produce different levels of carbonation

Post-Carbonation Handling:
to ensure consistent carbonation levels and quality
 Mixing and Blending: before filling to achieve the desired
flavor and sweetness
 Carbonation Preservation: to minimize the loss of
carbonation during subsequent handling, filling, and
packaging processes.
 Carbonation
Several methods of carbon dioxide production are in commercial use

These include the

reaction between sulphuric acid and sodium bicarbonate,
the combustion of fuel oil,
the extraction of carbon dioxide from the flue gas of a boiler or
similar heating facility,
the distillation of alcohol and the fermentation of beer;
carbon dioxide is also a byproduct of fertiliser manufacture

Following manufacture the gas must be cleaned to ensure it is free

from impurities and is fit for purpose
 Carbon dioxide
Fermentation

When a simple carbohydrate-based solution is mixed with yeast and

oxygen in a fermenter, carbon dioxide vapour and alcohol are produced

The carbon dioxide can then be passed through a separator to remove

any trace carry-over of foam

Once the foam has been removed the carbon dioxide is compressed

It is then scrubbed with water in a packed tower, removing water-

soluble impurities such as
alcohol, ketones and other aroma chemicals produced during
fermentation
 Carbon dioxide
Direct combustion
A hydrocarbon fuel such as light oil or natural gas can be burned
specifically in order to produce carbon dioxide

The flue gas from this process, which contains less than 0.5% oxygen
by volume, is cooled and scrubbed
to remove any impurities that may be present

The resultant gas is then passed through an absorbent tower, where it

comes into contact with a carbon dioxide absorbing solution

 The absorbing solution, now rich in carbon dioxide, is pumped to a

stripper tower, CO2 in vapour form
 Carbon dioxide
Direct combustion

The absorbing solution is then recycled and reused

The resultant carbon dioxide vapour is then cooled and further treated
to meet the requirements for use within a beverage

Large manufacturers of aerated waters and carbonated soft drinks

produce their own carbon dioxide on site using packaged systems,
 thereby reducing their operating costs and minimising
logistical problems
 Carbon dioxide
Delivery to the customer

Carbon dioxide is delivered as a liquid, most frequently by road tanker

It is then transferred to pressurised vessels of 5–50 tonne capacity and

held at a pressure in the region of 20.5 bar at-17oC,
the temperature being maintained by the use of a small
refrigeration unit

To change the carbon dioxide from the liquid to the gas phase all that is
required is to vaporise the liquid by
heating it using either steam, water or electricity
 Carbon dioxide
Precautions
The user must take great care when using carbon dioxide to ensure that
it is fit for purpose

Scares such as the detection of residual benzene in CO2 and the risk of
contamination from nuclear plants have to be considered

All batches supplied must have a certificate of conformance

The supply chain must be regularly audited, including the actual

carbon dioxide manufacturing plant, storage and distribution
 Carbon dioxide
Precautions
A full hazard analysis and critical control points (HACCP) survey of
the site-installed system
is required to ensure any inherent risks are minimised

Depending on the method of carbon dioxide production,

the certificate of conformation for each batch must include
analytical checks on the relevant listed compound

If too much gas is withdrawn from the top of the tank then
contaminants can build up due
to distillation of the liquid carbon dioxide within the tank
 Carbonation
Carbonation measurement

It consists of a jig in which the

container can be restrained and a
piercer which,
when used to pierce the
container, allows the gas
pressure to be read

The container is placed in

the jig and is first of all
pierced, then shaken, before
Fig. Measurement of carbonation
the pressure is measured
 Carbonation
Carbonation measurement

The release valve is then opened until the pressure gauge reads zero
and all the gas has been exhausted from the container headspace

 The release valve is then closed and the container shaken again

The pressure is retaken

The container is released from the jig and the temperature of the
contents taken
The carbonation chart is then used to determine the volumes of
carbonation
 Filling principles
A carbonated product made to specification has then to be filled into
the required container at a commercially viable filling rate

Clean and Sterile Environment:

to prevent any contamination
Strict sanitation practices

Efficient Carbonation Preservation:

 During filling, it is essential to minimize the loss of carbonation.
 by using specially designed filling equipment that
minimizes exposure to air and
 by maintaining a closed system during the filling process
 Filling principles
Precise Filling Levels:
to provide consistent product volume and carbonation
Filling machines are calibrated to ensure accurate and precise
filling
Overfilling can lead to excessive foaming, while underfilling may
result in insufficient carbonation and product quality issues

Achieved under gravity, the rate of flow being dependent on the head
difference between the filler bowl and the container

The rate of flow will increase if an overpressure is introduced

 Filling principles
The pressure from the top of the filling bowl to the outlet of the filling
valve provides the driving force to fill the container

Principles of gravity filling

1 Seal container to the filler
2 Both the container and the header tank
are under the same pressure P due to the
connecting vent tube.
3 Open the liquid valve A.
4 Filling starts
5 Filling stops when the vent tube is
covered by the liquid and the pressure
heads H equate
Fig. Principles of gravity filling
 Filling principles
with the container sealed to the filler bowl, valve ‘A’ is opened and
filling commences

By means of a vent tube the gas within the container is expelled,

 the rate of flow of liquid into the container being proportional

to the rate of flow of gas displaced

When the liquid reaches the vent tube it will fill the tube until the

pressure within the vent tube equates to the filling tube pressure
 Filling principles
When this equilibrium condition is achieved, the liquid flow stops and
the filling valve can be closed

As the container is lowered from the filler bowl the liquid within the
vent tube will drain back into the container
 Filling principles
Counter-pressure filler

Once the container is sealed to the filler bowl, the gas valve is opened
and the gas within the filling bowl headspace
flows under pressure into the container displacing air at
atmospheric pressure

Once the pressures are equated, the gas valve is closed and the liquid
valve opened

Flow commences, stopping when the pressures are equated

A short settling period is then allowed before the liquid valve is closed
and the gas within the container headspace is snifted (vented) off
 Filling principles
This settling period, and subsequent snifting are required because
otherwise, when the container is lowered from the filler bowl,
the pressurised gas within the headspace will be exposed to
the atmosphere
This would result in severe fobbing of the product within the container
until equilibrium conditions were reached
To overcome this potential problem, the pressure within the
headspace is gradually reduced by
snifting the gas off externally to the filler

Often this process is repeated several times in short bursts allowing a

short rest period between snifts
Fig. Bottle evacuation
Fig. Bottle evacuation
 Filling principles
It is important when planning the filling system that the appropriate
filling steps are matched to the beverage characteristics and container

The filling process can be split into several phases

1. evacuation
2. flushing with gas
3. pressurising with gas
4. filling at one speed or two speeds
5. fill level correction
6. settling and snifting
 Filling principles
Pressure Control:

Carbonated beverage filling machines are equipped with

mechanisms
 to control the pressure inside the containers during the
filling process.

This helps maintain the carbonation levels and prevents excessive

foaming or loss of carbon dioxide.

The filling equipment is designed to handle the pressure and

maintain a controlled environment.
 Filling principles
Sealing and Capping:
Once the containers are filled, they need to be immediately sealed
or capped
 to prevent the escape of carbonation and maintain product
freshness
The sealing process ensures a tight, leak-proof seal that preserves
the carbonation and prevents contamination.
Quality control checks:
 regular monitoring of carbonation levels,
 visual inspections for proper filling and sealing, and
 sensory evaluations to ensure the taste, aroma, and appearance of the product
meet the desired standards.