Pressing apples into juice
The apple's are tipped into a hopper and hand graded prior to dropping into a water bath. Once washed the apples are picked up by an elevator and dropped into the top of the machine where they are turned to a pulp. The pulp is slowly moved through a series of drums on a belt where the pressure is ever increasing which extracts every last drop of juice from the pulp. The juice collects in a tray under the machine and this is pumped over to a tank and left to settle over night. The pulp feeds off to the end of the machine into plastic bins and collection is arranged with a local pig farmer who feeds it to his pigs which are specially selected by Waitrose for their unique taste. It all sounds fairly simple yet it's rather labour intensive when it's only one person managing everything. We hope you enjoy the demonstration which is shown.
Having left the juice to settle over night it is then ready to be pasteurised. The pasteurisation process is quite simple. The juice is heated to a minimum of 78°C to 82°C and circulates through a system until it is pumped to a revolving filling unit which will distribute the correct volume into each bottle by the use of small black collars fitted above the filling nozzle. Each bottle is cleaned with a jet of water before being hand placed onto the line, it is then filled with hot juice via the revolving filling unit the bottle is capped and tamper proof sealed within seconds. The corresponding label with date code for the particular juice is then applied at the end of the conveyor where the bottles are hand packaged into case's. Each case is then laid on its side for at least 20 minute to allow the caps to be heat sterilised. Finally the juice is loaded on to pallets and added to the stock awaiting its turn for distribution.