To be able to squeeze juice from hard fruits, such as apples and pears, they must be cooked for a long time. The fruits are cooked in large stainless steel boilers for 2 to 3 hours. During the cooking, the sugar from the fruits, therefore the juice itself, turns brown due to the Maillard reaction.
The juice from the fruit mass is separated from the pulp by being pressed through the filter bags of a large press. The pulp, which consists of the hard fibres, seeds and stalks of the fruits, stays in the filter bags. It’s a very nutritious animal feed.
The juice which comes out from the press is still quite diluted and doesn’t have a long shelf life. That’s why it needs to be thickened. The juice is being purified and afterwards – evaporated. After the evaporation, the juice contains 60% less water. It becomes a concentrate which can be conserved and stored.
The different concentrates are all stored separately in large storage tanks. This is necessary as the fruits we’re using are harvested only from September to November. During these months, we must build up a stock for a whole year! One storage tank holds between 25,000 kg and 620,000 kg of concentrate!
Every fruit syrup is a mixture of several types of fruit. The concentrates are mixed daily and according to the recipes, so that we end up with the desired fruit syrup. We keep an eye on the fruit syrup during the whole mixing process.
After the fruit syrup has passed the first checks, it can be poured into cups, glasses, cans, buckets, barrels, containers or tankers. Once filled up, the cups, cans and glasses must cool down before being packed in boxes. There’s an air-conditioned cooling room which allows this to happen evenly and quickly.
In the warehouse, there’s enough space for around 500 pallets. The consumer goods are usually produced and stocked. All business-to-business products are made based on a particular order, so they go directly to Frumarco’s customer.
Frumarco has its own laboratory in which product development, as well as various quality control procedures, take place. Product development is working in close collaboration with the Marketing department on new recipes and innovations in the field of fruit syrup. But it includes other activities as well – for example, it’s possible to develop special recipes for business-to-business customers, depending on their wishes. The viscosity of the syrup can be reduced by removing the pectin in it. Furthermore, we can give a helping hand in the process of developing new products in which fruit syrup is an ingredient, such as meat sauces and bread. Frumarco also works with a fixed consumer test panel where various products can be tested before being brought to market.