Acai Berry Processing Line
Complete Acai Processing from Fresh Berries to Market-Ready Products
EasyReal builds full-capacity lines for acai berry juice, and puree. The process begins with fresh or frozen berries, and handles every stage—sorting, crushing, enzymatic treatment, clarification, evaporation, sterilization, and filling.
Acai berries contain a dense oil-rich pulp and thick skins. This makes de-seeding and cold pulping essential for yield and flavor. Our acai pulping machines use precise rotor-stator systems to remove seeds while preserving nutrient-rich pulp with rotating working speed 1470 rpm.
We offer both batch and continuous pasteurization options. For puree, the product is sterilized at 95–110°C using tube-in-tube sterilizers. Juice is clarified by enzymatic hydrolysis and high-speed decanter centrifuges.
For powder production, the juice goes through vacuum concentration followed by freeze-drying systems, with moisture controlled below 5%.
All systems are designed to reduce oxygen exposure and preserve anthocyanins—the dark purple healthy compounds in acai. Our line uses 304/316L stainless steel, smart CIP cleaning, and full PLC+HMI automation for safety and uptime.
Serving Health Food, Beverage, and Nutraceutical Markets Across Continents
Acai berries are mostly harvested in Brazil and transported frozen or chilled. Once processed, they become key ingredients for health drinks, smoothie blends, dietary supplements, skin-care formulas, and freeze-dried toppings.
EasyReal’s acai processing line suits:
● Beverage manufacturers producing shelf-stable juice or juice blends
● Supplement factories making freeze-dried acai powder for capsules or sachets
● Export hubs needing aseptic packaging for international shipment
● OEM co-packers requiring flexible batch sizes and quick format changes
● Startups and research units developing functional food products
You can install this line in tropical regions near the harvest site or in overseas repackaging plants. Our modular layout adapts to plant size and final product targets. Whether you need 500kg/h or 10 tons/h, we offer a cost-effective solution with strong global after-sales support.
Tailor Output to Product Type, Packaging Format, and Market Channel
Choosing the right line depends on your end product and target capacity. Here’s how we guide our clients:
For Acai Juice Bottling (clear or cloudy):
Use enzymatic clarification, centrifugal separation, then pasteurize and hot-fill in glass or PET bottles. We recommend a 1–5 tons/h line with juice pasteurizer + bottle filler.
For Acai Puree (for B2B ingredient use):
Skip clarification. Keep pulp through coarse filters. Use tube-in-tube sterilizer + aseptic bag-in-drum filler. Choose from 500kg/h to 10 tons/h.
For Acai Powder (freeze-dried):
Add juice concentrator and lyophilizer. Keep moisture <5%. Use for capsules or smoothie powders. Recommend 200–1000 kg/day.
For Multi-Product Facilities:
We suggest a shared upstream section (washing + pulping) and two downstream paths—one for puree, one for juice.
We also help customers select electric vs. steam heating, batch vs. continuous processing, and container type (bag-in-box, drum, sachet, pouch).
Our engineers will study your raw material, budget, and logistics to design the most efficient solution.
From Harvest to Commercial Packaging – Full Technical Flow
1.Receiving & Sorting
Unload frozen or chilled acai berries. Remove impurities and foreign matter.
2.Washing & Inspection
Use bubble washer + roller sorting to remove soil and soft berries.
3.De-seeding & Pulping
Use high-speed acai pulper with mesh screens to extract pulp, remove seeds and skins.
4.Enzymatic Treatment (Juice Only)
Add pectinase at 45–50°C for 1–2 hours to break down cell walls.
5.Centrifugal Clarification (Juice Only)
Use decanter to separate juice from coarse particles.
6.Vacuum Evaporation (for Concentrate or Powder)
Boil off water under 70°C using falling-film evaporator.
7.Sterilization
Use tube-in-tube or plate sterilizer at 95–110°C to kill germs and enzymes.
8.Filling
Aseptic bag-in-drum, bag-in-box, bottle, or sachet—based on market needs.
9.Freeze-Drying (Powder Only)
Feed concentrate into lyophilizer for sublimation drying.
10.Packaging & Labeling
Use automatic cartoning, coding, and palletizing.
Acai Berry De-seeder & Pulper
This machine removes seeds and tough skins from acai berries. It uses a rotating blade + perforated drum. The rotor crushes berries gently. Pulp passes through mesh; seeds stay inside. We customize mesh size (0.4–0.8 mm) based on final product needs. Compared to standard fruit pulpers, our acai model resists clogging and maintains high yield for dense berries.
Enzymatic Treatment Tank with Agitator
This tank heats acai juice to 45–50°C and holds it for 1–2 hours with gentle stirring. The agitator ensures enzymes mix evenly. It uses food-grade jacketed stainless steel and insulation. EasyReal’s tanks include CIP spray balls and temp sensors. Customers benefit from stable reaction time and reduced enzyme usage.
Decanter Centrifuge for Juice Clarification
Our horizontal decanter uses dual-speed rotation to separate pulp from juice. The acai juice enters through a feed pipe. The drum spins at 3000–7000 rpm to create strong G-force(Related to Flowrate). Fine pulp exits one side; clarified juice the other. This machine boosts juice clarity and improves filterability.
Falling-Film Vacuum Evaporator
This unit concentrates acai juice under low temperature. Juice flows down vertical tubes as a thin film. Inside, vacuum pressure lowers boiling point to 65–70°C. Steam jackets heat the tubes. The result is high-concentration juice with strong color and aroma. Compared to open pans, this system uses less energy and preserves nutrients.
Tube-in-Tube Sterilizer for Acai Puree
This sterilizer has concentric tubes. Steam will exchange heat will water firstly and then use how water to exchange heat with product. Hot water flows in outer jacket, heating the puree inside the inner tube. It maintains 95–110°C for 15–30 seconds. The design handles viscous acai puree without burning. After heating, the product enters a flash cooler. We use food-grade SS316L and digital PID control.
Aseptic Bag-in-Drum Filler
This filler places sterilized acai products into pre-sterilized aluminum bags inside drums. The filler uses steam injection + aseptic valves. Load cell ensures accurate filling (±1%). Operators monitor everything through touchscreen HMI. It prevents air contact and ensures 12-month shelf life at ambient temperature.
Handle Wild, Frozen, or Blended Acai with Minimal Adjustment
EasyReal’s system can process:
● Fresh harvested acai from local farms
● Frozen IQF berries in export facilities
● Acai pulp puree from third-party suppliers
● Mixed blends with banana, blueberry, or apple
Our fruit handling section adjusts for size and hardness. Pulpers and filters adapt mesh size easily. For powder lines, we offer different evaporation levels (25–65 Brix) and freeze-drying tray sizes.
End products include:
● Clear juice in PET bottles
● Acai puree in aseptic drums
● Concentrated juice for B2B supply
● Freeze-dried powder in pouches or capsules
We build multi-purpose plants that switch between juice and puree formats. Modular design allows future upgrades for new products or extra capacity.
Fully Automated Operation with Real-Time Monitoring and Recipe Control
EasyReal integrates a PLC + HMI smart control system across the acai processing line. Every key stage—heating, sterilizing, concentrating, filling—is tracked and controlled in real time. Operators can adjust temperature, flow rate, and pressure from a central touch screen.
Our HMI interface shows visual flow diagrams, alarm logs, batch timers, and maintenance prompts. The system includes:
● Siemens
● Color touchscreen HMIs with multi-language support
● Digital temperature controllers and flow meters
● Remote access module for online troubleshooting
● Batch recipe memory for repeatable results
The system stores historical data, so you can track batch quality, energy use, and cleaning cycles. This improves production traceability and reduces training time for staff.
This control system makes your acai production line more reliable, efficient, and safe—even in high-volume or 24/7 operations.
Partner with Shanghai EasyReal Machinery Co., Ltd. to Launch or Expand Your Acai Project
Shanghai EasyReal has over 25 years of experience in fruit and vegetable processing equipment. Our acai processing lines are now running in Latin America, Southeast Asia, and Europe, producing shelf-stable puree, bottled juice, and high-value powder.
We offer:
● Custom engineering design for your plant size and product type
● Installation and training support on-site or online
● Spare parts and maintenance plans for long-term reliability
● Global service network and English-speaking engineers
● Flexible line capacity options from 500 kg/h to 10 tons/h
Whether you are setting up your first acai production unit or expanding a multi-product factory, EasyReal delivers solutions that match your goals and budget. Our team works closely with you from raw material evaluation to turnkey line delivery.
Contact us today to start your acai processing project:
www.easireal.com/contact-us
Email: sales@easyreal.cn
We’ll help you build an efficient, flexible, and export-ready line.
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