New Pectinex Ultra Mash is the next generation of mashing enzymes for the first mash. It improves juice yields while preparing the way for a smooth clarification and filtration. This unique enzyme blend is one of the first achievements from joint work following the integration of Biocon’s enzyme business into Novozymes.

To produce apple juice, the first step is a mashing process in which the aim is to press the fruit to extract juice. During this process, enzymes can provide a real advantage by optimizing juice yields. Based on pectinases, a first mashing product such as Pectinex Mash degrades soluble pectin to improve the release of juice from the fruit matrix.

The enzymes are added to the apples during milling and then the mash is held in a tank for about an hour where the enzymatic process takes place before pressing. Pectinases can therefore facilitate the extraction of juice with the focus on maximizing juice yield. However, due to their varying modes of action, not all pectinases are able to resolve the challenges posed in downstream processing such as clarification and filtration.

Apple juice is naturally cloudy but clear apple juice concentrate is usually sold on the world market. Therefore all the solid particles have to be removed from the juice during processing.

That’s why Pectinex Ultra Mash is being launched by Novozymes in August 2008. It not only increases yields, but also reduces the difficulties encountered in downstream processing. It works for all kinds of raw materials and juice production processes.

The difference is clear
The difference between the old Pectinex Mash and the new-generation Pectinex Ultra Mash are shown clearly by the results of lab trials at Novozymes. Among other parameters, a haze meter was used to measure the cloudiness of the juice extracted during a first mash treatment. The clarity of the juice after the solid/liquid sep-aration (pressing and centrifugation) was signific-antly better. The new enzyme preparation gave a cloudiness reading (known as turbidity) of 108 EBC units (known as standard turbidity units) whereas old Pectinex Mash gave a reading of 210 EBC. This effect is also reflected in the lower serum viscosity achieved with the new enzyme preparation.

“The clearer the juice, the better the mash enzyme. Here we observed a very significant difference in the ability to clarify the juice,” says Dr Kurt Dörreich, commenting on the trial. He is based at Novozymes in Switzerland where he heads the global Center of Excellence and the Customer Solutions department for Juice and Wine. “Pectinex Ultra Mash gives high juice yields without attacking the cell walls and dissolving the structure of the fruit. It is advantageous for a first mash enzyme not to be too aggressive against the cell walls,” he adds.

Clear apple juice is sold on the world market and therefore all the solid particles have to be removed from the juice during processing.

“The juice from Pectinex Ultra Mash is easier to depectinize and filter,” adds Kurt Dörreich. “You can achieve very good flow rates during ultrafiltration. With a lower turbidity in the mashing stage, you have fewer problems to fix later in the clarification and filtration stages. The whole efficiency of the plant increases.”

Yields and profits
The total juice yield when using  Pectinex Ultra Mash also increased in the trials – by 1% compared to the old Pectinex Mash. This may sound like a small amount, but higher juice yields can be converted into higher profits. For example, a 1% increase in yields at today’s market prices gives an increased profit of approximately USD 2.5 per ton of apples processed into juice.

“In the apple juice industry, the juice yield is in the range of 91–96% with first mash enzymes, whereas a manufacturer will reach a yield of only 75% without mashing enzymes. When you do a second mashing with enzymes, the yield can even increase to 99%! Enzymes are important contributors to the profits of customers. Any yield increase adds up to more profits,” says Frédéric Issenhuth, the Global Marketing Manager for Juice and Wine at Novozymes in Switzerland.

The price of apples on the world market almost doubled in 2007 due to shortages of apples. As supplies become scarcer, juice producers look for ways to get more juice out of every apple. Apple orchards around the world have a limited output for juice production of 12.5 million tons of apples, while world demand is increasing. Novozymes estimates that this new-generation enzyme with a 1% higher juice yield gives the potential to create more than 100,000 tons of extra apple juice for the juice industry.

Pectinex Ultra Mash works well with all the existing equipment, whether belt press, hydraulic press, or decanter. Enzyme solutions help juice producers to become more efficient by maximizing press capacity and shortening processing times. This is especially important during the months that apples are harvested when juice producers only have a short time in which to process a large quantity of fresh fruit. Enzymes help to ease their workload.

Like the existing Pectinex Mash, Pectinex Ultra Mash is not derived from a genetic-ally modified microorganism. Unlike the existing Pectinex Mash, it has a better balance of enzyme activities that act on specific soluble pectins in the fruit mash, leaving the insoluble pectin almost untouched. With the promise of improved yield and better downstream processing, enzyme customers will be conducting mashing trials with Pectinex Ultra Mash to see the benefits for themselves. “Customers who are willing to run trials can be assured of the best technical support from Novozymes; we will demonstrate clear benefits,” says Vincent Gass, the launch captain.

Enzyme technology is used extensively during the first mashing of apples. To avoid problems later on, a first mash enzyme should not aggressively attack the cell walls and release too many solid particles into the juice. After pressing and centrifugation, the turbidity was 210 EBC in the case of old Pectinex® Mash (the tube on the left) and 108 EBC in the case of Pectinex Ultra Mash (the tube on the right). The black strip is less visible through the tube on the left because there are more solid particles left in the apple juice treated with the old Pectinex Mash. EBC is a standard turbidity unit. Source: Lab trials at Novozymes, 2008.

Benefits of improved Pectinex® Mash    • Fast mashing and juice viscosity reduction • Juice yield increased by approximatelxy 1% • Faster throughput for increased production capacity • Smoother clarification and filtration