A FRUIT JUICE POWDER MIX AND PROCESS FOR MAKING THE SAME
FIELD OF INVENTION
The present invention relates to fruit juice powder mix. The present invention relates to a
process for the production of fruit juice powders. The disclosed fruit juice powders are
capable to provide a true experience of real fruit juice i.e. fruit based beverage mix. The
present invention relates to dilutables concept for the production of fruit juice powders.
BACKGROUND AND PRIOR ART OF THE INVENTION
It is known that the powdered soft drinks are one of the more profitable solutions in food
service. They also support the sustainability initiatives, since they are easily dispensed
into reusable cups, minimising the packaging waste with reduced fright cost for
transportation. Market analysis indicates that within the packaged beverage category,
dilutables account for a significant US$ 300 Million (MM) turnover. The largest segment
by volume in this category comprises Fruit Flavored Instant Beverage Powders (other
segments being glucose powder and squash / concentrates).
While the street juice habit has generally been OOH, consumer research shows that there
is significant potential to be unlocked, if we are able to give real fruit powders that can
replicate the sensorial experience in terms of taste, texture and aroma.
The critical differentiating aspect will be containing natural juice powder and “natural
and /or Nature identical” flavours without any preservatives as opposed to artificial
flavours and artificial colours and the key unlock for volume explosion will happen if one
is able to drive conversion from unpackaged street juice.
India is the second largest producer of fruits after China, with a production of 44.04
million tonnes of fruits from an area of 3.72 million hectares. A large variety of fruits are
grown in India, of which mango, banana, citrus, guava, grape, pineapple and apple are the
major ones. Apart from these, fruits like papaya, sapota, annona, phalsa, jackfruit, ber,
pomegranate in tropical and sub-tropical group and peach, pear, almond, walnut,
apricot and strawberry in the temperate group are also grown in a sizeable area.
Although fruit is grown throughout of the country, the major fruit growing states are
Maharashtra, Tamil Nadu, Karnataka, Andhra Pradesh, Bihar, Uttar Pradesh and Gujarat.
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Fruit or Vegetable Juice is the liquid that is naturally contained in fruit or vegetable
tissue. Juice is prepared by mechanically squeezing or macerating fruit or vegetable. For
example, orange juice is the liquid extract of the fruit of the oranges. Juice may be
prepared in the home from fresh fruit and vegetables using a variety of hand or electric
juicers. Juice is one of the most popular drinks to go with breakfast in the morning.
Fruit juice, though tasty and refreshing, is not as healthy as whole fruit. When a whole
fruit is pressed or squeezed and filtered to make juice, some of the nutrients, most notably
dietary fibres and some of vitamins, are lost in the process. Many commercial juices are
filtered to remove fiber or pulp, but high-pulp fresh orange, lime, mixed fruit and water
melon juices are popular beverages. Common methods for preservation and processing of
fruit juices include canning, pasteurization, freezing, evaporation and spray drying.
In view of the above-said facts, there is a requirement of a natural fruit powder solution
with value added dietary fibres that supply the goodness of real fruits at an affordable
price.
DILUTABLES CONCEPT
India's daily turnover in vegetables and fruits is about Rs 2750 Million.
Production of fruits being highly seasonal and localized in favored agro-climatic
conditions and extreme perishability of the products cause several problems in
production, and post harvest management.
India is the second largest producer of fruits in the world, producing 46.8 million tons of
fruits and accounting for 10% of the world's fruit production. Approximately 20-25% of
the horticulture produce goes waste due to improper post harvest operations, improper
cold storage and transport facilities. The grower is getting hardly 0.25-0.35 of a consumer
rupee. The efforts are also on the Value Addition activities where the fruits and
vegetables are processed, that fetches higher remunerative prices of the produce.
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Costs of transporting fresh fruits are very high due to significant increase in petroleum
prices. Since many fruits contain much that is non edible in the purchase weight, cost
might not be a good indicator of cost per amount consumed.
The product will be positioned as fruit juice powders for in-home consumption in a
unique packaging format via Tropicana credentials. The product will be positioned as
fruit juice powders for in-home consumption in a unique packaging format via Tropicana
credentials.
Dilutables would be a concept of ‘Do’ Fruit Mix which is a traditional, healthy and
convenient approach to increase fruit consumption for refreshment and health.
FEW OF THE CHALLENGES IN THE JUICE POWDERS ARE AS FOLLOWS
- Powder by using low /no maltodextrin as a carrier. Therefore low in fruit juice
taste.
- Dissolubility in water. Generally spray dryer produces fine powder which is
difficult to dissolve in water.
- Hygroscopic nature of the fruit powder tends to produce lumps.
- To avoid separation of the ingredients, Grinding of ingredients by using pin mill
in incorporated, which helps providing uniform particle size.
- Process juice is lack of fruit fibres.
- Generally drying methods losses natural colours during process.
The disclosed unique process of making powdered drink resolves most of these issues.
BRIEF DESCRIPTION OF FIGURES
Figure 1 & 2 shows process flow diagram for preparing fruit juice mix powder mix.
Figure 3 shows equipment system and process steps for preparing fruit juice mix powder
mix.
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Figure 4 shows fruits powder concurrent air flow system is the ideal system to get proper
sugar crystallization and therefore free flowing properties.
Figure 5 shows reconstitution Product Preposition (Mathematics of fruit juices)- finished
product 100 ml basis.
Figure 6, 7 & 8 shows the particle size distribution analysis for various sample of fruit
juice powder mix.
OBJECTIVES OF THE PRESENT INVENTION
The primary objective of the present invention is to a produce fruit juice powder mix
which is devoid of artificial colour, artificial flavour and preservatives. The disclosed
fruit juice powders are capable to provide a true experience of real fruit juice, i.e. fruit
based beverage mix.
The other objective of the present invention is to utilize the “dilutables concept” for the
production of fruit juice powder mix.
Yet another objective of the invention is to provide a natural fruit powder solution with
value added dietary fibres that supply the goodness of real fruits at an affordable price.
Yet another objective of the invention is to provide to minimize or omit carrier like
maltodextrin to maintain good taste parameters.
Yet another objective of the invention is to provide a free flowing fruit powder with no,
tackiness and less hygroscopic. Yet another objective of the invention is to provide a fruit
powder with desired shelf life of six months and no bitterness after taste with desirable
sweet tang balance.
SUMMARY OF THE INVENTION
The present invention relates to process for the production of fruit juice powders mix
having a true experience of real fruit juice in the form of fruit juice beverage mix. The
disclosed invention provides a natural fruit juice powder mix with value added dietary
fibres and retention of nutritional quality. The invention provides a free flowing fruit
powder with no tackiness, desired shelf life and no bitterness after taste with desirable
sweet tang balance.
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DETAIL DESCRIPTION OF THE INVENTION
While the invention is susceptible to various modifications and alternative forms, specific
aspect thereof has been shown by way process flow chart will be described in detail
below. It should be understood, however that it is not intended to limit the invention to
the particular forms disclosed, but on the contrary, the invention is to cover all
modifications, equivalents, and alternative falling within the spirit and the scope of the
invention.
The Applicants would like to mention that the examples are mentioned to show only
those specific details that are pertinent to understanding the aspects of the present
invention so as not to obscure the disclosure with details that will be readily apparent to
those of ordinary skill in the art having benefit of the description herein. The terms
“comprises”, “comprising”, or any other variations thereof, are intended to cover a nonexclusive
inclusion, such that a process that comprises a list of components does not
include only those components but may include other components not expressly listed or
inherent to such process.
In the following detailed description of the aspects of the invention, reference is made to
the accompanying drawings and graphs that form part hereof and in which are shown by
way of illustration specific aspects in which the invention may be practiced. The aspects
are described in sufficient details to enable those skilled in the art to practice the
invention, and it is to be understood that other aspects may be utilized and that charges
may be made without departing from the scope of the present invention. The following
description is, therefore, not to be taken in a limiting sense, and the scope of the present
invention.
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Accordingly, the present invention relates to a process for producing “fruit juice powder
mix”, comprising the steps of: a) washing and cleaning of fruits, b) pulping of fruits of
step (a) in a two stage pulper and obtaining juice thereof, c) passing juice of step (b)
through strainer having mesh size 400-500 micron, d) preparing fruit concentrate at brix
66-72 Degree Brix, e) converting fruit concentrates of step (d) to powders by spray
drying process characterized such that the fruit juice is atomized and allow to fall under
gravity without being adhered to the walls of dryer chamber, collecting the dried fruit
powder at the bottom of the dryer, f) encapsulating by blending of fruit powder in the
presence of hydrocolloids, g) adding dried sugar in fruit powder of step (f), h) blending
with dried sugar and all other ingredients excluding flavor in blender coating, i) grinding
the blended fruit powder in pin mill for uniform distribution of ingredients, j) adding
flavor and transferring the bulk to the blender and blending thereof in order to obtain
desired fruit juice powder mix, k) passing fruit juice powder mix as obtained in step (j)
through metal detector, l) filing of the said produced fruit juice powder mix in containers
for storing/packaging.
A first aspect of the present invention wherein the fruit based beverage mix comprising of
fruit juice powder in the range of 5% to 90% w/w, with or without maltodextrin as a
carrier and other ingredients such as sugar, fruit fibers, natural color in the range of 2% to
90% w/w wherein said fruit based beverage mix is devoid of artificial color, artificial
flavor and preservatives.
Another aspect of the present invention wherein the fruit based beverage mix comprising
of fruit juice powder preferably of 10% to 70% w/w, more preferably 10% to 30 % w/w,
most preferably 10 to 20 % w/w, with or without maltodextrin as a carrier and other
ingredients such as sugar, fruit fibers, natural color in the range of 2% to 90% w/w
wherein said fruit based beverage mix is devoid of artificial color, artificial flavor and
preservatives.
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Another aspect of the present invention, wherein the fruit selected from the group
consisting of Orange, Mixed fruit , mango, banana, citrus, guava, grape, pineapple, apple,
papaya, sapota, annona, phalsa, jackfruit, ber, pomegranate peach, pear, almond, walnut,
apricot, coconut, sugar cane , strawberry or watermelon or mixture thereof.
Yet another aspect of the present invention, wherein fruit based beverage mix having
citrus fruit is selected from lemon, orange, kinno, sweet lime or combination thereof.
Yet another aspect of the present invention, wherein fruit based beverage mix having
tender coconut and citrus fruit is lemon, orange, kinno, sweet lime or Coconut-Orange,
Coconut-Pineapple, Coconut- Mixed fruit and Coconut–Litchi and combination thereof.
Yet another aspect of the present invention, wherein fruit based beverage mix having
ingredients are stabilizers, acidity regulators, salt, natural color, fibre from citrus fruit
pulp, gum Arabic and xanthan, natural and nature identical flavoring substances.
Yet another aspect of the present invention, wherein fruit based beverage mix having
stabilizers which are selected from the group consisting of gum Arabic (E414) and
xanthan gum (E415).
Yet another aspect of the present invention, wherein fruit based beverage mix having
stabilizers is in the range of 1 % to 5% w/w.
Yet another aspect of the present invention, wherein fruit based beverage mix having
acidity regulators is selected from the group consisting of citric acid and malic acid.
Yet another aspect of the present invention, wherein fruit based beverage mix having
acidity regulators are in the range of 0.1% to 3% w/w.
Yet another aspect of the present invention, wherein fruit based beverage mix having
natural color is selected from the group consisting of annatto, beet root powder, beta
carotene etc.
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Yet another aspect of the present invention, wherein fruit based beverage mix having
natural color is in the range of 0.001 to 1% w/w.
Yet another aspect of the present invention, wherein fruit based beverage mix having
fibers from citrus fruit pulp is made of citrus pulp/ fibers.
Yet another aspect of the present invention, wherein citrus fruit pulp is in the range of
0.1% to 5% w/w.
Yet another aspect of the present invention, fruit based beverage mix is orange based
beverage mix comprising of orange juice powder in the range of 5% to 99% w/w, without
maltodextrin as a carrier and other ingredients in the range of 2% to 95% w/w.
Yet another aspect of the present invention, wherein fruit based beverage mix is lemon
based beverage mix comprising of lemon juice powder in the range of 5 to 85% w/w,
sugar in the range of 1% to 95% w/w with maltodextrin as a carrier in the range of 15%
to 25% w/w and other ingredients in the range of 2% to 5% w/w.
Yet another aspect of the present invention, wherein fruit based beverage mix comprising
of mix fruit juice powder in the range of 5% to 90% w/w with maltodextrin as a carrier in
the range of 10% to 90% w/w and other ingredients in the range of 2% to 5% w/w.
Yet another aspect of the present invention, the fruit based beverage mix having less
hygroscopic and free flowing characteristic property with uniform distribution of
ingredients.
Yet another aspect of the present invention, wherein the fruit based beverage mix having
average particle size in the range of 100 micron to 800 micron.
Yet another aspect of the present invention, wherein the fruit based beverage mix is
packed in sachet having shelf life of at least six months.
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Accordingly, the present invention relates to a process for the production of fruit juice
powders having a true experience of real fruit juice. Dilutables is a concept of ‘Do’ Fruit
Mix which is a traditional, healthy and convenient approach to increase fruit consumption
for refreshment and health. The fruit based beverage mix wherein fruit is selected from
the group consisting of mango, banana, citrus, guava, grape, pineapple, apple, papaya,
sapota, annona, phalsa, jackfruit, ber, pomegranate peach, pear, almond, walnut, apricot,
strawberry or watermelon or mixture thereof.
On finished product basis fruit powder used in the formulation is at least 80-85% of pure
fruit powders. In case of Orange the 100% orange powder without any maltodextrin has
been tried in products. The fruit powder mix can be prepared in various shaped powders
as fruit shaped such as compacted or shaped like orange, cube etc for play value using the
tableting machine. Generally 40-50% maltodextrin are added to fruit juice powder as a
carrier to obtain free flowing powder. However, maltodextrin has starch type taste and
deteriorate taste. Hence, in the present invention fruit powder mix have made with
minimum possible maltodextrins or even without addition of maltodextrins. The
disclosed formulation has at least 90% + as fruit powder. Unique process parameters and
specific equipment design has made it possible.
MAIN RAW MATERIALS for making drinks
Orange Powder Kinnu
Sugar
Citric acid
mallic acid
Flavour Symrise - 885166
Fruit fibre coarse
Fine Fruit fibre
Dietary fibres - Gum arabic
Dietary Xanthan
Natural Colour
Salt
Fort the purpose of the present invention, Hydrocolloids often called gums, which are
hydrophilic polymers, of vegetable origin, that generally contain many hydroxyl groups
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and may be polyelectrolytes. They are naturally present or added to control the functional
properties of aqueous foodstuffs. Most important amongst these properties are viscosity
(including thickening and gelling) and water binding but also significant are many others
including emulsion stabilization, prevention of ice recrystallization and organoleptic
properties. The degree with which the hydrocolloid solutions mix with saliva, determined
by their degree of chain entanglement, determines flavor experience.
TECHNICAL ISSUES
Stickiness is one of the critical issues encountered during drying and handling of juice
powder especially for water melon, sugar cane and coconut water powder mainly due to
high fruit sugar (fructose) content in the fruits. To control undesirable effects of the
stickiness property of a particular fruit material is essential. Thus planned an appropriate
characterization techniques i.e. sugar and fat profiling of the fruit powders for these
powders.
High content of sugars and organic acids exhibit sticky behaviour during spray drying.
Stickiness is a term used to describe the phenomena of particle–particle cohesion and
particle–wall adhesion in the spray drying process. Stickiness depends not only on the
properties of materials but also on the inlet variables applied in a spray drying system.
Deposition is another phenomenon in spray drying. It relates to the stickiness and the
design of a dryer system. Theoretically, there should be no deposition problem if the size
of the dryer chamber is large enough. Therefore, stickiness and deposition need to be
solved by other methods rather than by using a very large dryer chamber.
Particularly coconut is having very high sugar that to in the form of Fructose and
Glucose. The importance of sticky behaviour of fruit powders influence on process and
handling abilities and quality of the fruit powders. It is important to find out role of
stickiness in the fruit powders and evaluate the different stickiness characterization
techniques. There is a need to decide the instrumental analysis to know the stickiness
behaviour and find out glass transition temperature to minimize caking. i.e. surface
stickiness and glass transition.
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In few of the cases, food stickiness on spray drying processes in which cohesion of
particles is necessary for cluster formation (agglomeration). Better Agglomeration allows
better reconstitution properties. It is necessary to control particle size and to strike a
balance between agglomeration and stickiness to improve powder properties.
When insufficiently dried particles stick with one another or with the wall of spray dryer,
it causes a reduction in product recovery, and quality degradation especially for heat
sensitive materials like coconut, water melon, cane sugar etc. Since spray-dried powders
are amorphous and hygroscopic, they become sticky under the conditions of high relative
humidity or high temperature. Therefore, special precautions during storage, handling
and market display are required.
There are two processes which may have potential i.e. Coating by blending of ingredient
and other one is grinding of ingredients.
a) Coating – As fruit powders are very hygroscopic, generally one can’t pack fruit
powders along with other essential drink ingredients. Coating by using Gum
Arabic and sugar helps reducing hygroscopicity.
b) Grinding – Generally while processing, ingredients tend to separate, mainly sugar
and fruit powders due to different particle size, grinding process help reduce
differential particle size therefore separation of particles.
SPECIALIZED TECHNICAL ASPECTS FOR CUSTOMIZATION OF POWDERS
Common approaches are the use of a specially designed dryer such as a drying chamber
with double-wall, wall-sweeper slots and air brooms designs, cooling of the powder to
temperatures below which it becomes sticky, use of dehumidified air for cooling,
selection of suitable combination of drying parameters, treatment of material before
drying, and addition of some agents to prevent or reduce stickiness of the powder.
Stickiness of amorphous food powders due to viscous flow mechanism is governed by
temperature and water content. Consequence of glass transition on stickiness, caking and
collapse phenomena as influenced by water content.
Glass transition temperature (GTT) is the indicator for spraying characteristics. Lower the
GTT more difficult is the drying operation due to stickiness.
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Molecular weight( g/mol) Glass transition temperature
Degree C
Fructose 180 5
Glucose 180 31
Galactose 180 32
Sucrose 342 62
Maltose 342 87
Lactose 342 101
Maltodextrins
DE 36 500 100
DE 25 720 121
DE 20 900 141
DE 10 1800 160
DE 5 3600 188
Amylose 227
Amylopectin 227
Starch 243
DE : Dextrose Equivalent
During drying generally nutrition is getting lost therefore it is necessary to select right
type of drying techniques which can have less nutrition loss, powder is free flowing and
agglomerate to give good reconstitution.
ADVANTAGES OF THE INVENTION
1. Fruit based beverage mix is devoid of artificial colour, artificial flavour and
preservatives (generally all fruits and vegetable juice drinks are having
preservatives.
2. Taste and mouth feel is as natural as fresh juice.
3. Fruit powders used in final proposition is made in spray dryer with at least
90% of fruit powder.
4. There is no preservative used Fruit powders are hygroscopic in nature; the
disclosed process is making these powdered juice drinks less hygroscopic in
nature, therefore much more free flowing and easily dissolvable powders.
5. Generally during fruit juice processing fibres are separated and wasted. In the
disclosed invention real fruit fibres have been added in the products.
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6. Significantly Cost accretive business proposal – Sustainability idea.
Packaging cost reduces by 2.5 time, Freight cost reduces by 5 time , as here
you will be not transporting water along with fruit
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WE CLAIM
1. A process for producing “fruit juice powder mix”, comprising the steps of:
(a) washing and cleaning of fruits,
(b) pulping of fruits of step (a) in a two stage pulper and obtaining juice
thereof,
(c) passing juice of step (b) through strainer having mesh size 400-500
micron,
(d) preparing fruit concentrate at brix 66-72 Degree Brix,
(e) converting fruit concentrates of step (d) to powders by spray drying
process characterized such that the fruit juice is atomized and allow to
fall under gravity without being adhered to the walls of dryer chamber,
collecting the dried fruit powder at the bottom of the dryer,
(f) encapsulating by blending of fruit powder in the presence of
hydrocolloids,
(g) adding dried sugar in fruit powder of step (f),
(h) blending with dried sugar and all other ingredients excluding flavor in
blender coating,
(i) grinding the blended fruit powder in pin mill for uniform distribution
of ingredients,
(j) adding flavor and transferring the bulk to the blender and blending
thereof in order to obtain desired fruit juice powder mix,
(k) passing fruit juice powder mix as obtained in step (j) through metal
detector,
(g) filing of the said produced fruit juice powder mix in containers for
storing/packaging.
2. A fruit based beverage mix comprising of fruit juice powder in the range of
5% to 90% w/w, with or without maltodextrin as a carrier and other
ingredients such as sugar, fruit fibers, natural color in the range of 2 % to 90%
w/w wherein said fruit based beverage mix is devoid of artificial color,
artificial flavor and preservatives.
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3. The fruit based beverage mix as claimed in claim 2, wherein fruit selected
from the group consisting of Orange, Mixed fruit , mango, banana, citrus,
guava, grape, pineapple, apple, papaya, sapota, annona, phalsa, jackfruit, ber,
pomegranate peach, pear, almond, walnut, apricot, coconut, sugar cane ,
strawberry or watermelon or mixture thereof.
4. The fruit based beverage mix as claimed in claim 2, wherein citrus fruit is
lemon, orange, kinno, sweet lime or combination thereof.
5. The fruit based beverage mix as claimed in claim 2, wherein tender coconut
and citrus fruit is lemon, orange, kinno, sweet lime or Coconut-Orange,
Coconut-Pineapple, Coconut-Mixed fruit and Coconut–Litchi and
combination thereof.
6. The fruit based beverage mix as claimed in claim 2, wherein ingredients are
stabilizers, acidity regulators, salt, natural color, fibre from citrus fruit pulp,
gum Arabic and xanthan, natural and nature identical flavoring substances.
7. The fruit based beverage mix as claimed in claim 2, wherein stabilizers is
selected from the group consisting of gum Arabic ( E414) and xanthan gum (
E415).
8. The fruit based beverage mix as claimed in claim 2, wherein stabilizers is in
the range of 1 % to 5% w/w.
9. The fruit based beverage mix as claimed in claim 2, wherein acidity regulators
is selected from the group consisting of citric acid and malic acid.
10. The fruit based beverage mix as claimed in claim 2, wherein acidity regulators
are in the range of 0.1% to 3% w/w.
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11. The fruit based beverage mix as claimed in claim 2, wherein natural color is
selected from the group consisting of annatto, beet root powder, beta carotene
etc.
12. The fruit based beverage mix as claimed in claim 2, wherein natural color is in
the range of 0.001 to 1% w/w.
13. The fruit based beverage mix as claimed in claim 2, wherein fibers from citrus
fruit pulp is made of citrus pulp/ fibers.
14. The fruit based beverage mix as claimed 2, wherein citrus fruit pulp is in the
range of 0.1% to 5% w/w.
15. The fruit based beverage mix as claimed in claim 2, wherein orange based
beverage mix comprising of orange juice powder in the range of 5% to 99%
w/w, without maltodextrin as a carrier and other ingredients in the range of
2% to 95% w/w.
16. The fruit based beverage mix as claimed in claim 2, wherein lemon based
beverage mix comprising of lemon juice powder in the range of 5 to 85%
w/w, sugar in the range of 1% to 95% w/w with maltodextrin as a carrier in
the range of 15% to 25% w/w and other ingredients in the range of 2% to 5%
w/w.
17. The fruit based beverage mix as claimed in claim 2, wherein mix fruit based
beverage mix comprising of mix fruit juice powder in the range of 5% to 90%
% w/w, with maltodextrin as a carrier in the range of 10% to 90% w/w and
other ingredients in the range of 2% to 5% w/w.
18. The fruit based beverage mix as claimed in claim 2, having less hygroscopic
and free flowing characteristic property with uniform distribution of
ingredients.
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19. The fruit based beverage mix as claimed in claim 2, having average particle
size in the range of 100 micron to 800 micron.
20. The fruit based beverage mix as claimed in claim 2, is packed in sachet having
shelf life of at least six months.
Dated this 25th day of March, 2013