Jam means the product prepared from sound, ripe, fresh, dehydrated, frozen or previously packed fruits including fruit juices, fruit pulp, fruit juice concentrate or dry fruit by boiling its pieces or pulp or puree with nutritive value Fruit Jelly means the product prepared by boiling fruit juice or fruit(s) of sound quality, with or without water, expressing and straining the juice, adding nutritive sweeteners, and concentrating to such a consistency that gelatinization takes place on cooling. The product shall not be syrupy, sticky or gummy and shall be clear, sparkling and transparent. Marmallade This is a citrus fruit product prepared by cooking fruit pulp or extract with sufficient amount of sugar and using shreds of peel as suspended material. Marmalades are classified into : 1. Jelly marmalade 2. Jam marmalade Preserves A mature fruit/ vegetable or its piece impregnated with heavy sugar syrup till it becomes tender and transparent is known as preserve. When fruits are placed in a concentrated sugar syrup, the water moves out of the fruit and sugar moves into it until equilibrium is reached by osmosis. Apple, Cherry, anola, pineapple, pear, mango, papaya, strawberry, etc., can be used for making preserves. FPO specifications for preserves are given in Quality section Candies Vegetable & fruits A fruit or vegetable impregnated with cane sugar or glucose syrup, and subsequently drained free of syrup and dried, is known as candied fruit/vegetable. The most suitable fruits for candying are pineapple, cherry, aonla, karonda, papaya, apple, peach, peels of orange, ginger etc.

1. Submitted By
Kirti G.
Technology of
High Sugar
products

2. 2
1. Jam
 Products prepared from sound, ripe, fresh,
dehydrated, frozen or previously packed fruits
including fruit juices, fruit pulp, fruit juice
concentrate or dry fruit by boiling its pieces or
pulp or puree with nutritive sweeteners namely
sugar, dextrose, invert sugar or liquid glucose to a
suitable consistency.
 As per FSSA 2006,
“Jam means the product prepared from sound, ripe, fresh,
dehydrated, frozen or previously packed fruits including fruit juices,
fruit pulp, fruit juice concentrate or dry fruit by boiling its pieces or
pulp or puree with nutritive value.”

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The specific requirements for Jam are ;
• Total soluble solids (m/m) - Min. 65.0 %
 It may also contain fruit pieces and any other
ingredients suitable to the products.
It may be prepared from any of the suitable fruits,
singly or in combination.
It shall have the flavor of the original fruit(s) and
shall be free from burnt or objectionable flavors and
crystallization.
Characterstics

4. 4
FSSAI specifications for jamproduction
Content Concentration
Fruit Pulp 45%
TSS(Total soluble solids) 65%
Citric acid 5g
Preservative 40 ppm of SO2
 For a chunky texture, some pieces of fruit are added about 5 minutes before the
cooking is finished.
 If a stiffer or sweeter jam is desired, more thickener or pectin, honey or sugar may
be added.

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Fruit/ vegetable
for 1 kg pulp
Sugar (kg) Citric acid (gm) Water (ml)
Aonla
.75 - 150
Apple .75 2.0 100
Apricot .60 1.0 100
Carrot .75 2.5 200
Grapes .70 1.0 50
Guava .75 2.5 150
Karonda .80 - 100
IN THE HOME IT CAN BE PREPARED BY USING THE RECIPES
AS:

6. 6
Ripe Firm Fruits
Addition of Citric Acid
Washing
Addition of Sugar
(Add water if necessary)
Boiling
(with continuous Stirring
Peeling
Pulping
(Remove Seed & Core)
Judging the end point by further cooking upto
105̊C or 68-70% TSS or by Sheet test
Filling Hot into the
sterilized bottles
Cooling
Waxing
Capping
Storage (at ambient
temperature)
Flowchart for preparation of jam

7. 7
TECHNOLOGICALFLOWSHEETFORPROCESSINGOFJAM
Ripe firm
fruits
Peeling
Pulping
Additio
n of
sugar
Washing

8. 8
Boiling
Addition of citric
acid
Judging of end point by further
cooking up to 105 degree Celsius or
68% TSS or by sheet
test
Filling hot into bottles
Storage
Cooling
Waxing
Capping

9. 9
Ripe firm fruits received for jam production are sorted and graded according to their
color, sensory appeal. spoiled fruits are removed from the lot. This can be done
using hand picking, color sorters.
Jam Production Process
1. Inspection
For effective washing of fruits, 200 ppm of chlorine can be used in water. pH and
temperature should be maintained, to prevent fruits from getting damaged or
bruised. Dump and spray washers can be used in industries.
2. Washing
Fruits can be hand peeled as in case of citrus and apple, mechanical peelers and
automated peeling machines containing blades are generally used in industries.
Some fruits don’t require peeling. Pitting is some in fruits containing hard inner
stones.
3. Peeling

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Required amount of sugar and pectin is added to the fruit pulp/juice. Water can be
added ,if needed. sugar, binds to the water molecules and frees up the pectin chains
to form their network. Adding more pectin results in harder jam and using more sugar
can make it sticky.
Pulping is done to remove seed and core part. Various pulping machines are
available in market for fruits such as mangoes, peaches, tomatoes, bananas,
draw berries and celeries etc. The gap between the sieve and rotor can be
adjusted to suit different type of size and qualities of materials to be pulped.
4. Pulping
5. Addition of sugar
Boiling is the most important step in jam making, which require a lot more patience.
After keeping the above prepared mixture on heat, we need to wait till the sugar
dissolves. Slowly, whole room will get filled by the fruity smell and a netwok like
pectin
A foamy scum may form on the surface of the jam; this is normal and can be
removed by adding a little butter (about 20g) to break the surface tension or by
skimming it off with a spoon while your mixture is cooling.
6. Boiling

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7. Addition of citric acid
Specified amount of citric acid is added while boiling itself. We heat the mixture
upto 105 C or 68-70%TSS to ensure proper setting of jam. Sheet test can also be
performed to check jam. Sheet test – small portion of jam is taken in spoon and
cooked a bit, and allowed to drop, if product drops as sheet or flakes, jam is made
perfect, otherwise boiling is continued.
Jam is poured hot into the sterilized bottles , and it is allowed to cool down by putting
into water bath, waxing by paraffin wax or other waxes can be done, and finally metal
caps are vacumn capped on the jars.
8. Filling into bottles
Canned jam should be kept in cool, dry packets away from sunlight.
Shelf life of canned jam is around one year.
9. Storage

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Problems in Jam production
Problem Cause Prevention
Formation of crystals 1. Excess sugar. 1. Use a tested recipe and measure ingredients precisely
2. Undissolved sugar sticking to sides
of pot.
2. Dissolve all sugar as jelly cooks. If necessary, wipe side
of pan free of crystals with damp cloth before filling jars.
3. Tartrate crystals in grape juice. 3. Extract grape juice and allow tartrate crystals to settle
out by refrigerating the juice overnight. Strain juice
before making jelly.
Mold or Fermentation
(Denotes spoilage; do
not use.)
1. Imperfect sealing 1. Use new flat lids for each jar and make sure there
are no flaws. Pre-treat the lids per manufacturer’s
directions.
2. Use ring bands in good condition – no rust, no
dents, no bends. Wipe sealing surface of jar clean
after filling, before applying lid.
Sticky, gummy
product
1. Overcooking. 1. Follow recommended directions for each product. (Cook
only until syrup is quite thick and fruit is fairly
translucent.)
2. Improper storage. 3. Store processed jars in a dark, dry, cool place.
Refrigerate after opening.
3. Yeast or mold growth. 2. Process in a boiling water canner. Test seal before
storing. Pre-sterilize jars when processed less than 10
minutes in boiling water.
Surface graining &
Shrinkage
Evaporation of moisture during
storage of Jam
1. Store in a cool Place

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2. JELLY
Fruit Jelly means the product prepared by boiling fruit juice or fruit(s) of sound quality, with or
without water, expressing and straining the juice, adding nutritive sweeteners, and
concentrating to such a consistency that gelatinization takes place on cooling. The product shall
not be syrupy, sticky or gummy and shall be clear, sparkling and transparent.
As per FSSA,

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INTHEHOMEITCANBEPREPARED BYUSINGFOLLOWINGRECIPES:

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IMPORTANTCONSIDERATIONSINJELLYMAKING
A. Pectin
I. Alcohol test
II. Jelmeter test
A. Acid
B. Sugar
C. Judging of end
point
i) Sheet or flake test
ii) Drop test
iii) Temperature test
Drop test
Alcohol
test
Sheet
test
Temperature
test

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TECHNOLOGICALFLOWSHEETFORPROCESSINGOFJELLY
Fruit (firm not over
ripe)
Washing
Cutting into thin slices
Boiling with water ( for
about 20-30 min )
Addition of citric acid during boiling (
2gm per kg of fruit )
Straining of extract
Pectin test ( for addition of sugar
)

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Addition of sugar
Boiling
Judging the end point
Removal of scum or foam ( 1 teaspoonful
edible oil is added for 45 kg sugar )
Color and remaining citric acid added )
Filling hot into bottles
Waxing
Capping
Storage at ambient temperature

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Ripe but not over ripe fruits are selected slightly unripe yields more pectin than over
ripe fruits, because as the fruit ripens the pectin presents in it, decomposes into
peptic acid which does not form into jelly with acid and sugar, under ripe fruits for
their Pectin content and ripe ones for their flavour. Generally, fruits like guava,
apples are not required to peel, they are only washed and cut into thin slices of not
less than ½" thickness.
Extraction of Pectin or Fruit Extract:
Fruit slices are boiled with equal volume of water (i.e,. 2 Kg water to 1 Kg fruit in
case of guava and oranges) without stirring. In case of highly juicy fruits (i.e, berries
like grapes etc.) the fruits are merely crushed and boiled without addition of water.
Time required for boiling (optimum)Apple - 20-25 minutes
Guava - 30-35 minutes
Orange - 45-60 minutes
Jelly Production Process

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Pectin Content Test:
Pectin content of fruit extract may be determined by taking 1 ml of boiled fruit extract in a test
tube and add 3 ml alcohol (90%) in the test tube and leave for few minutes till clotting is formed.
If a single clot is formed, it indicates that the fruit extract contains rich pectin, where as if small
unstable clot is formed it indicates poor pectin.
Straining:
The pectin extract or fruit extract may be pass through bags of linen, flannel or through felt or
cheese cloth folded several times to obtain a clear extract. The bags or cloth should be first
scalded in boiling water, squeeze and use while still hot and wet (Bags containing fruit extract
should be squeeze otherwise the extract will not be due to fruit particles passing through the
pores in the bag).
Adding of Sugar and Cooking:
Generally equal quantity of sugar (i.e., 1 Kg sugar, 1Kg pectin extract) is sprinkled over the
pectin while it is boiling with continuous stirring to ensure complete dissolution of sugar. The
mixture is then filtered through a muslin cloth to remove impurities and boil all over again in a
brisk fire till it starts boiling, sprinkle 10 gms ready made fruit pectin mixed with small quantity of
sugar (10 gms) over the mixture and add citric acid just before the end point, i.e,. when
temperature reaches 221°F or total soluble solids reached 65°Brix as measured with a Brix
metre.

20. 20
Determination of End Point:
If refractometer and thermometer are not available the following simple test may be
adopted to ensure whether the jelly is set or not.
* Cold plate test:
A drop of the boiling liquid from the pan is taken and placed on a plate and allowed
to cool quickly. If the jelly is about to set, the mixture on the plate will crinkle when
pushed with the finger. The main drawback of this method is that while the drop on
the plate is cooling, the jelly mixture continued to boil in the pan with the result that
there is risk of over-cooking the product or of missing the correct setting point.
* Sheet or Flake test:
In this case a small portion of the jelly is taken with a large spoon or wooden ladle
and allowed to cool for a few seconds and let it drop. If the jelly drops like syrup, it
requires further concentration but if it falls in the form of flakes or sheet the end point
has reached.

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PROBLEMS IN JELLYMAKING
1. Formation of crystals
2. Failure to set :
3. Cloudy or foggy jellies :
i. Addition of too much sugar
ii. Lack of acid or pectin
iii. Cooking below the end-point
iv. Cooking beyond the end-point
v. Prolonged cooking
4. Syneresis or weeping of jelly :
i. Excess of acid
ii. Insufficient pectin
iii. Premature gelation
iv. Fermentation
i. Use of non-clarified juice or extract
ii. Use of immature fruits
iii. Over-cooking
iv. Over-cooling
v. Non-removal of scum
vi. Faulty pouring
vii. Premature gelation

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3. MARMALADE
 This is a citrus fruit product prepared by cooking fruit pulp or extract with
sufficient amount of sugar and using shreds of peel as suspended material.
 Marmalades are classified into :
1. Jelly marmalade
2. Jam marmalade
 The method of preparation for jam marmalade is
practically the same as that for jelly marmalade. In
this case the pectin extract of fruit is not clarified
and the whole pulp is used. Sugar is added
according to the weight of fruit, generally in the
proportion of 1:1. The pulp-sugar mixture is
cooked till the TSS content reaches 65 per cent.
Good quality jelly marmalade can be prepared from a combination of Sweet
orange/ Mandarin orange and sour orange in a 2:1 proportion. Shreds of
sweet orange (Malta) peel are used in the preparation.

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Ripe fruits
Washing
Peeling outer yellow portion ( flavedo )
Cutting yellow portion into fine shreds ( 1.9-2.5
cm long and .08 - .12 cm thick )
Boiling
Straining the extract
Testing for pectin content ( alcohol test )
Addition of sugar
TECHNOLOGICALFLOWSHEETFORPROCESSINGOFMARMALADE

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Cooking to 103 to 105 ̊C
Addition of prepared shreds
Sealing
Cooling ( 82-88 degree Celsius)
Filling in sterilized bottles
Testing for end point
Boling till jellying point
Flavoring
Storage at ambient temperature

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Preparation of Marmalade
Sound, ripened fruit is sorted, washed, and prepared. The mode of preparation
varies with the nature of the fruit. The fruits are then cut in to slices and are
boiled for the preparation of extract.
Preparation of extract:
The extraction of pectin, filtration/ straining of the extract and analysis of the
extract is carried out in the same way as that of jelly preparation.
Preparation of peel shreds:
The outer layer of yellow portion of citrus fruits is peeled off carefully. The
stripped-off peel is cut into slices of about 2-2.5 cm long and 1-1.2 mm thick.
Boiling in water with 0.25% sodium bicarbonate or 0.1% ammonia solution can
soften the shreds. Before addition to the jelly, the shreds may be kept in heavy
syrup for some time to increase their bulk density to avoid floating on the
surface when it is mixed with jelly.

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Boiling:
The fruit extract is boiled before the addition of sugar. During boiling, the
impurities in the form of scum, are occasionally removed. When the temperature
of the mixture reaches 103o C, the prepared shreds of peel are mixed in it at the
rate of 5-7% of the original extract. Boiling is continued till the end point is
reached. The end point is judged in the same way as in the case of jelly. Like jelly,
marmalade also contains 65% TSS at 105o C. Boiling should not prolong for more
than 20 min, after the addition of sugar to get bright and sparkling marmalade.
Cooling:
The marmalade is cooled to permit the absorption of sugar by the shreds from
the surrounding syrup. If the marmalade is filled in hot, the shreds may come to
the surface instead of remaining in suspension. During cooling, the product is
gently stirred occasionally for uniform distribution of shreds. When marmalade
temperature reaches around 85o C, viscosity of syrup increases and a thin film
begins to form on surface, which prevents shreds from coming to surface.
Flavouring:
This is done by adding some flavour or orange oil to the product near the end of
boiling to supplement the flavour lost during boiling. Generally, a few drops of
orange oil are mixed in marmalade before filling into containers.

27. 27
Packaging and Storage:
Like jams and jellies, marmalade is also filled into jars and cans at a temperature
around 850 C. Storage of marmalade must be done in dry rooms (relative
humidity at about 75%), well ventilated, medium cool places (temperature 10-20o
C), disinfected and away from direct sunlight and heat. These measures are
necessary because marmalade is a hydroscopic product and, by water
absorption, favourable conditions for mould development are created.
Jam marmalade is practically made by the method used for preparation of jelly
marmalade except that the pectin extract is not clarified. The orange peel after
removing albedo portion is sliced into 0.3 cm thick pieces and treated in the
same way as recommended for jelly marmalade. The sliced fruit of orange,
lemon, or grape fruit after removing peel is mixed with little quantity of water
and boiled to soften. The boiled mixture is pressed through coarse pulper to
remove seed and to get thick pulp. The pulp is mixed with equal quantity of
sugar and cooked to a consistency of 65o Brix or consistency of jam. The
treated shreds are mixed in the jam when it is slightly cool. Some orange oil is
also mixed in the marmalade before filling into containers. Filling and packaging
is done in the similar way as adopted for packaging of jelly and jelly marmalade.
Jam Marmalade

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PROBLEMSiNMARMALADEMAKING
Browning during storage is very common which can
be prevented by addition of 0.09 g of KMS
(potassium metabysulphate) per kg of marmalade
and not using tin containers. KMS dissolved in a
small quantity of water is added to the marmalade
while it is cooling. KMS also eliminates the
possibility of spoilage due to moulds.

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A mature fruit/ vegetable or its piece impregnated with heavy sugar syrup till it
becomes tender and transparent is known as preserve. When fruits are placed
in a concentrated sugar syrup, the water moves out of the fruit and sugar
moves into it until equilibrium is reached by osmosis. Apple, Cherry, anola,
pineapple, pear, mango, papaya, strawberry, etc., can be used for making
preserves. FPO specifications for preserves are given in Quality section
4. Preserves
Preparation involves primary operations like,
 selection of fruits,
 peeling,
 puncturing (to promote sugar penetration) and
 blanching.
Blanching may be done with or without additives to inactivate natural
enzymes and to reduce the oxidative discolourisation. The blanched fruits are
then treated for firming the texture of product. Now, sugar is added
concentrated, and packed after the addition of preservatives.
Preparation Methods

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Rapid process:
Fruits are cooked in a low sugar syrup. Boiling is continued with gentle
heating until the syrup becomes sufficiently thick. Rapid boiling should be
avoided as it makes the fruit tough. The final concentration of sugar should
not be less than 68 % which corresponds to a boiling point of 106 o C. This is
simple and cheap process but the flavour and colour of the product are lost
considerably during boiling.
Slow process:
In this method, the fruits are blanched until it becomes tender. Sugar, equal to the weight
of fruit, is then added to the fruit in alternate layers and the mixture allowed to stand for
24 hours. Then by boiling on second, third, and 4th day consecutively the strength of
syrup is raised to 70 % TSS. A small quantity of citric or tartaric acid is also added to
invert a portion of the cane sugar and thus prevent crystallization. The prepared preserve
is then packed in containers.
Vacuum process:
The fruit is first softened by boiling and then placed in the syrup which should have 30-
35% TSS. The fruit syrup blend is then transferred to a vacuum pan and concentrated
under reduced pressure to 70 % TSS. Preserves made by this process retain the flavour
and colour of fruit better than by the other two methods.

31. 31
The preserve is cooled quickly, drained free of syrup and
then filled in dry containers. Freshly prepared boiling syrup
containing 68% TSS is then poured into the jars/containers
which are then sealed air tight. In commercial scale
production, however, it is better to sterilize the cans to
eliminate any possibility of spoilage of product during
storage.
Packaging of preserve:

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5. CANDIEDFRUIT/ VEGETABLE
A fruit or vegetable impregnated with
cane sugar or glucose syrup, and
subsequently drained free of syrup and
dried, is known as candied
fruit/vegetable. The most suitable fruits
for candying are pineapple, cherry,
aonla, karonda, papaya, apple, peach,
peels of orange, ginger etc.
 The process for making candied fruit is practically similar to that for
preserves. The only difference is that the fruit is impregnated with syrup having
a higher percentage of sugar or glucose.
 A certain amount (25-30 %) of invert sugar or glucose is substituted for cane
sugar. The total sugar content of the impregnated fruit is kept at about 75% to
prevent fermentation.
Preparation:

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The fruit removed from the syrup is drained for about half an hour and
unwanted pieces are removed. The fruit or peel is then wiped with a wet sponge
or dipped for a moment in boiling water to remove adhering syrup. Then it is
dried in shade or in a dryer at about 66o C for 8 to 10 hours until the fruit is no
longer sticky to handle.
Draining and drying:
It is desirable that cane sugar and invert sugar in the final syrup should be in
equal proportion approximately. The syrup left over from the candying
process can be used for candying another batch of the same kind of fruit.

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PROBLEMSIN PREPARATIONOF PRESERVES/ CANDIDFRUITS
• Fermentation:
It is due to the low concentration of sugar used in the initial stages of preparation.
• Floating of fruits in jar:
It is due to filling of the preserve without cooling.
• Toughening of fruit skin or peel:
This is due to inadequate blanching or cooking.
• Fruit shrinkage:
This is due to cooking of fruits in heavy syrup.
• Stickiness:
It is due to insufficient consistency of the syrup, poor quality packaging and damp
storage conditions.

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6. QUALITYPARAMETERS
The FPO specifications includes: methods of preservation, permissible colours in the
preparations and also the minimum quality requirements of the final products. FPO
specifications for jam jelly, marmalade, preserve, candy and other sugar based products are
as follows:
Product Specification
Minimum % of TSS in final
product
Minimum % of prepared fruit in final
product
Fruit jam
Fruit jelly
Marmalade
Fruit preserve
68
65
65
68
45 (25% in case of strawberry jam)
45
45
55
Product Specification
Total Sugar (%) Reducing sugar as % of total sugar
Candied and
crystallized or
glazed fruit and
peel
Not less than 70 Not less than 25

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Permissible limits of preservativesin fruit beverages
S.No. Product Preservative Parts per million
(ppm)
01 Fruit jam, jelly, marmalade
and preserve
Sulfur dioxide 150
02 Crystallized, glazed fruits
(including peel)
Sulfur dioxide 150
Some important quality considerations
• Jelly made from sugar and chemical pectin shall be clearly declared as
synthetic jelly.
• When dry fruit is used for making jam it shall be clearly declared on the
label.
• When preserves are packed in sanitary top cans, the contents shall not be
less than 85% of the total space of the can.

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