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Mango pulp and concentrate
Aseptic pulp at 16 °Brix, concentrate at 28–30 °Brix, RTS beverage base
Mango pulp and concentrate line by GEM Foodtech, Kolkata, India — capacity 2 to 30 tonnes of fruit per hour, final yield 61% of raw intake, delivered as a turnkey plant with installation and commissioning worldwide.
The commercial reality
Mango is a season business. The plant has ninety days to process a year of revenue, so throughput, ripening control and aseptic integrity decide whether the season is profitable. This line is built around a hot break that protects viscosity and an aseptic filler that lets you sell in October at October's price.
Process flow diagram
Generated for the standard configuration. Yours is redrawn to your product mix, capacity and site.
Process chart
Every stage with the equipment that performs it, the operating parameter and the control point that decides quality.
| # | Stage | Equipment | Parameter | Control point |
|---|---|---|---|---|
| 01 | Receiving and ripening | Industrial elevator | Ripening chambers, 18–22 °C, 4–6 days | Uniform ripeness at 14–18 °Brix |
| 02 | Washing | Fruit and vegetable washer | Chlorinated water, 3–5 ppm, recirculated | Soil, latex and pesticide load removed |
| 03 | Sorting and inspection | Inspection and sorting conveyor | Manual belt, 0.2 m/s | Unripe, spotted and damaged fruit out |
| 04 | De-stoning | De-stoner | Twin-shaft, stone out whole | Stone breakage below 1% |
| 05 | Pulping and finishing | Pulper and finisher | Two stage, 1.0 mm then 0.6 mm | Fibre and skin removed, pulp texture set |
| 06 | Hot break | Hot break system and pre-heater | Tubular, 92–95 °C, 60–90 s | Pectinase inactivated, viscosity held |
| 07 | Deaeration | Deaeration system | Vacuum, 60–65 °C | Dissolved oxygen out, colour protected |
| 08 | Concentration, optional | Evaporator, vacuum pan or multi-effect | Forced circulation, 55–65 °C under vacuum | 16 → 28–30 °Brix |
| 09 | Pasteurising | Pasteuriser, tubular or plate | Tubular, 95 °C, 3 min hold | Commercial sterility before filling |
| 10 | Aseptic filling | Aseptic and hot filling line | Bag in drum, 220 kg, sterile air | Seal integrity, zero recontamination |
Mass balance
Basis of 1,000 kg of raw material. Change the tonnage below and the whole table rescales.
| Stage | Output, kg/h | Yield | Loss, kg/h | Where the loss goes |
|---|---|---|---|---|
| Fruit received | 1,000 | 100% | 0 | — |
| After washing and sorting | 960 | 96% | 40 | Rejected fruit to feed or compost |
| After de-stoning | 780 | 78% | 180 | Stone and peel to biomass or animal feed |
| After pulping and finishing | 620 | 62% | 160 | Fibre and skin to by-product drying |
| Aseptic pulp at 16 °Brix | 610 | 61% | 10 | Line losses and CIP |
By-products: Stone, peel and finisher fibre — dried on a GEM belt dryer for cattle feed or mango kernel fat extraction.
Equipment schedule
Core machines for this line. Conveying, tanks, CIP and utilities are added to suit the layout.
| Equipment | Capacity range | Function |
|---|---|---|
| Industrial elevator | Handling | Lifts washed or raw material between floor levels without bruising. |
| Fruit and vegetable washer | Preparation | Removes field soil, latex and surface load with recirculated, filtered water. |
| Inspection and sorting conveyor | Preparation | Manual or optical removal of unripe, damaged and foreign material. |
| De-stoner | Separation | Separates stone and seed from pulp on mango, amla and similar fruit. |
| Pulper and finisher | Separation | Single or twin stage; separates pulp from skin, fibre and seed. |
| Hot break system and pre-heater | Thermal | Rapid heating that kills pectinase and holds viscosity in tomato and fruit. |
| Deaeration system | Thermal | Strips dissolved oxygen to protect colour, vitamin C and shelf life. |
| Evaporator, vacuum pan or multi-effect | Thermal | Concentrates pulp or juice under vacuum at low temperature. |
| Pasteuriser, tubular or plate | Thermal | Controlled hold at temperature with regeneration to cut steam use. |
| Aseptic and hot filling line | Packing | Aseptic bag-in-drum, hot fill, or can and bottle filling and seaming. |
Questions we get on this line
What pulp yield should I budget?
Between 58 and 63% of fruit received, depending on variety and ripeness. Totapuri sits at the lower end, Alphonso at the higher end.
Can the same line run other fruit?
Yes. Guava, papaya, banana and tomato run on the same backbone with a screen change and a revised heat profile.
What capacity range does the mango pulp line cover?
Standard GEM Foodtech builds cover 2 to 30 tonnes of fruit per hour. Larger duties are engineered to order — the right size is set by the raw material supply through the season, not the nameplate figure.
Is this supplied as a complete turnkey plant?
Yes. The Mango pulp and concentrate line is delivered end to end — feasibility, pilot trial on your own material, engineering, manufacture in Kolkata, installation, commissioning and operator training — or as individual machines to fit an existing plant.
Want this line costed for your tonnage?
Send the raw material specification and the capacity you are targeting. You get a flow diagram, an equipment schedule and a budget number.