INTRODUCTION
A concentrated mixture of sugar and water, syrup is a necessary component of many industries, including the food, beverage, pharmaceutical, and cosmetics sectors. Syrup is an essential component for our everyday products, whether it is used as a taste enhancer, preservative, or sweetener. The production of syrup is a complex procedure that requires multiple processes to guarantee the highest-quality final result. This blog explores the crucial steps, salient characteristics, and technical details of the syrup-making process.
PROCESS
1. Sugar Melting Vessel
Introduction of Raw Material: The start of the syrup-making process begins with granulation of sugar being added to the sugar making vessel.
Heating and Melting: Next up, the sugar is melted by heating it to a predetermined temperature. In order to guarantee even melting and avoid caramelization, agitation is used.
Solution Formation: To create a sugar solution, water is slowly added to the melting pot. The solution's concentration is observed and changed as needed.
2. Manufacturing Vessel
Transfer: Next, the melted sugar solution is moved from the production vessel to the sugar melting vessel. A vacuum system can help with this transfer to guarantee effective movement.
Mixing and Heating: Extra ingredients (flavorings, stabilizers, and preservatives) are added to the manufacturing vessel. To make the mixture into a uniform syrup, it is heated and constantly stirred.
Concentration Check: To make sure the syrup satisfies the necessary requirements, its concentration and consistency is routinely examined
3.Online Sugar Syrup Pre-Filter
Filtration: An online sugar syrup pre-filter is used to filter the syrup before it enters the storage vessel. To guarantee the syrup's purity and clarity, this stage eliminates any undissolved particles and contaminants.
Control of Quality: To make sure the filtered syrup satisfies quality requirements, it is tested.
Transfer to Storage: From the manufacturing vessel to the storage vessel, the filtered sugar syrup is moved via a vacuum system. With this approach, the risk of contamination is reduced and the transfer is guaranteed to be swift and effective.
4. Storage Vessel
Holding and Conditioning: The storage vessel is used to hold the syrup. The purpose of this tank is to keep the syrup at the proper temperature while preventing contamination and microbiological growth.
Continuous Quality Monitoring: To make sure the syrup in the storage vessel stays within the intended parameters, quality parameters are checked on a regular basis.
5.Zero Holdup Filtration Unit
Final Filtration: A zero holdup filtration unit is used to filter the syrup one more time before it is packaged or processed any further. This device makes sure that the entire batch is uniformly filtered and that no syrup is left in the filter.
Sterilization: To make sure the syrup is free of any microbial contamination, this process may also include sterilization.This procedure guarantees the creation of a syrup of superior quality with constant qualities, suitable for packing or additional usage in numerous applications.
Salient Features
Batch Capacities:
Available in various sizes ranging from 50 litres to 20,000 litres.
Design and Manufacturing Standards:
The plant is designed and manufactured in compliance with cGMP (current Good Manufacturing Practice) and ASME BPE (Bioprocessing Equipment) guidelines.
Vessel Features:
- All vessels are vacuum rated and can be sterilized.
- Optional bottom entry stirrer to reduce overall height.
- Equipped with necessary accessories for reliable performance.
- Pre-mix vessels can be provided if required by the process.
Control Systems:
IPC & PLC based 21 CFR part 11 compliant fully automatic control panel with online printing facility.
Construction Materials:
Working platform and ladder with railing made from AISI 304 stainless steel.
All connecting pipelines, fittings, valves, and contact parts made from AISI 316 stainless steel, electro-polished and crevice-free.
Heating and Insulation:
Sugar Melting Vessel and Manufacturing Vessel can be provided with a jacket or limpet coil for steam heating, with an option for electric heating.
Vessels come with suitable rockwool/glass wool insulation and AISI 304 stainless steel cladding.
Measurement and Cleaning:
Loadcell provided for volumetric measurement.
Spray ball in all vessels for online CIP (Clean-In-Place).
Documentation and Compliance:
Complete set of documentation and certificates to ensure compliance with regulatory authorities.
Documentation provided includes DQ (Design Qualification), OQ (Operational Qualification), IQ (Installation Qualification), FAT (Factory Acceptance Testing), and SAT (Site Acceptance Testing).
Assistance with developing PQ (Performance Qualification) for the client.
Technical Specifications
Oral Liquid Manufacturing Plant is manufactured under GMP guidelines
The design of the plant is based on the parameters and requirement of end user
All the contact parts are made of AISI 316L stainless steel
Conclusion
A difficult and methodical process, syrup manufacturers guarantee the creation of high-quality syrup fit for a variety of uses. Every stage of the process, from choosing the best raw materials to packing the finished product, is meticulously supervised to preserve the syrup’s safety, consistency, and purity. Knowing the variations of this procedure emphasizes how crucial quality assurance and technology developments are to the production of syrup that satisfies industry standards. Syrup is a versatile ingredient that is still used in a lot of products, which highlights how important this thorough manufacturing procedure is. For more information, visit- sterinoxsystems (Pharmaceutical Equipment Manufacturer)