On track for success with “Pulpy”

For the first time, Coca-Cola Hellenic is bottling Pulpy, a juice beverage featuring chunks of fruit. For this premiere, CCHBC chose its plant in Istra, to the north-west of Moscow, and for the process selected online blending with aseptic filling. For this purpose, Krones installed the new process technology required, and integrated it into an existing PETAsept line, whose filling technology was likewise modified. In the preceding year, the facility in Istra, which now has a total of five Krones lines up and running, put its first Contipure system into operation, thus completing a refocus in line philosophy toward monobloc solutions.

Still beverages with a pulp content are finding progressively more adherents among consumers worldwide. The Coca-Cola brand Pulpy is broadening its appeal, particularly in newly industrialising countries. In 2010, the chunky fruit juice was on sale in 14 different nations, while in 2011 Pulpy was already being produced and sold on 25 national markets. In China, India, Indonesia Pakistan, and in the Philippines, the growth rates regularly exceed expectations.

In the production process for Pulpy Orange Juice, it’s vital to preserve the pulp undamaged from the beginning of the process to the end, and to integrate into the system only those monitoring and operator control elements that are really necessary. On the basis of experience gained in other countries, CCHBC had several alternatives to choose.

Empirical feedback from actual operations had confirmed that aseptic inline blending offered very good preservation of the pulp, excellent dosing accuracy, and a possible high line output. Inline blending means that pulp and juice are aseptically prepared separately and then bottled together. “The paramount goal was make the operation as gentle on the product as possible and to minimise damage to the fruit cells”, emphasises CCHBC’s Country Engineering Manager, Natalia Polozova. “We didn’t even consider the option of not filling the product aseptically.” In addition, of course, CCHBC Istra already possessed three aseptic bottling lines from Krones, which could be used for this process. So the company decided in favour of the inline blending process, to be implemented in conjunction with Krones.

By modifying an aseptic line 1 to operate with inline blending, and by commissioning a line with Contipure preform decontamination system, Coca-Cola HBC Eurasia CCHBC has successfully upgraded its Istra facility, and significantly strengthened its position on the important Moscow market for all “new” sensitive beverages. For Natalia Polozova, the Engineering Manager of CCHBC Eurasia, this is “a crucial step forward.”