Professional Documents
Culture Documents
INTRODUCTION ..................................................................................................................... 2
MICROBIOLOGY ................................................................................................................... 3
Bacteria ...................................................................................................................................... 3
Molds . ......................................................................................................................................... 4
Yeast.............................................................................................................................................. 4
Bacteriophages ......................................................................................................................... 4
Toxicity........................................................................................................................................... 4
EU classification ........................................................................................................................ 5
2
Microbiology • esophilic bacteria (loving the middle range) have optimum
M
growth temperatures between 68°F and 111°F.
The key to production of long-life products with aseptic
technology is a detailed understanding of the microbiology of • hermophilic bacteria (heat loving) have their optimum growth
T
food. Using the example of the dairy industry, the milk in the udder temperatures between 113°F and 140°F.
of a healthy cow is free from bacteria, but as soon as the milk • hermoduric bacteria (heat enduring) can tolerate high
T
comes into contact with the air it becomes contaminated with
temperatures — above 150°F. They do not grow and
micro-organisms.
reproduce at high temperatures, but can resist them without
If the temperature is favorable, the micro-organisms multiply being killed.
and very soon the milk will turn sour (or putrefy), developing an
unpleasant flavor. To prevent this from happening, the raw milk is Bacteria can only develop within certain temperature limits,
subjected to heat treatment. which vary from one species to another. Temperatures below
the minimum cause growth to stop, but do not kill the bacteria.
The term “aseptic” is usually defined as “free from or keeping They are, however, damaged by repeated freezing and thawing.
away” disease-producing or putrefying micro-organisms. In the If the temperature is raised above the maximum, the bacteria are
food industry the terms “aseptic”, “sterile” and “commercially soon killed by heat. Most cells die within a few seconds of being
sterile” are often used interchangeably. This is not strictly correct. exposed to 158°F, but some bacteria can survive heating to 185°F
Sterilization means 100% destruction of all living organisms, for 15 minutes, even though they do not form spores.
including their spores, and this is very difficult to achieve.
“Commercial sterility” means that the product is free from micro- A third way of classifying micro-organisms is by their oxygen
organisms which grow and consequently contribute to the requirement. The availability of oxygen is vital to the metabolism
deterioration of the product. Micro-organisms are extremely small of all organisms. Some bacteria consume oxygen from the
and can only be seen under a microscope. However, hundreds or atmosphere; they are called aerobic bacteria. However, to some
thousands of individual cells or groups of cells can form colonies bacteria free oxygen is a poison; they are called anaerobic
— which are visible to the naked eye — and some colonies bacteria and obtain the oxygen they need from chemical
have colors, shapes, textures or odors which make the organism compounds in their food supply.
identifiable. Some bacteria consume free oxygen if it is present, but they can
also grow in the absence of oxygen; they are called facultatively
Bacteria
anaerobic.
The term “bacteria” strictly means rod-shaped micro-organisms
only, but is also used in a loose sense to include all micro- The acidity of the nutrient substrate for bacteria is also important.
organisms except yeast and molds. The individual bacterium varies Sensitivity to pH changes varies from one species to another, but
in size from 0.5 to 3 micron. most bacteria prefer a growth environment with a pH around 7.
Furthermore, the salt and/or sugar concentration of a substrate
The groups of bacteria which are most important in the dairy
has an important influence on the growth of bacteria. The higher
industry are the lactic acid, coliform, butyric acid, and putrefaction
the concentration, the more growth is inhibited. This is caused by
bacteria. The bacterial count in milk coming from the farm varies
the high osmotic pressure which will draw water out from the cell,
from a few thousand bacteria/ml for high-quality milk; to several
thereby dehydrating it. Osmotic pressure is used as a means of
million if the standard of cleaning, disinfection and chilling is poor.
food preservation in sweetened condensed milk, salted fish and
For milk to be classified as top quality, the CFU (Colony Forming fruit preserves like jam and marmalade.
Units) should be less than 100,000/ml.
Spores. The spore is a form of protection against adverse
Bacteria are single-celled organisms which normally multiply conditions, e.g. heat and cold, lack of moisture, lack of nutrients,
by binary fission, i.e. splitting in two. The simplest and most or presence of disinfectants. Only a few bacteria are spore
common way to classify bacteria is according to their appearance forming e.g. Bacillus and Clostridium. The spores germinate back
and shape. However, in order to be able to see bacteria, they into a vegetative cell and start reproduction when conditions
must first be stained and then studied under a microscope at a become favorable again. The spores have no metabolism and can
magnification of approximately 1,000 X. Based on a method of survive for years in dry air and are much more resistant to adverse
staining, developed by the Danish Bacteriologist Gram, bacteria conditions than bacteria. This includes heat treatment, and it
are divided into Gram negative (red) and Gram positive (blue). takes typically 20 minutes at 248°F to kill them with 100 percent
The three characteristic shapes of bacteria are spherical, rod- certainty. The UHT time/temperature combination reduces the
shaped and spiral. Diplococci arrange themselves in pairs, number of bacteria spores by a minimum of log 9, leaving very few
staphylococci form clusters, while streptococci form chains. bacteria spores in UHT treated products.
Another way of classification is according to temperature Enzymes. When milk leaves the udder it contains enzymes, the
preference: so-called original enzymes. Enzymes are also produced by the
• Psychotrophic bacteria (cold tolerant) reproduce at bacteria in the milk, the so-called bacterial enzymes. Enzymes are
temperatures of 45°F or below. not micro-organisms but are formed as a result of the metabolism
of micro-organisms. The ability of enzymes to trigger chemical
• sychrophilic bacteria (cold loving) have an optimum growth
P
reactions can be important when UHT products are produced.
temperature below 68°F.
3
Some of the bacterial enzymes are able to cause sweet
coagulation of milk products which destroys the product. The
Process Classification
A number of different expressions are commonly used in the food
majority of these enzymes are produced by Gram negative
industry in relation to food preservation. This section will, in brief
Pseudomonas bacteria developing mainly in cold raw milk stored
terms, describe the most common terms used.
for excessive time in milk cooling tanks, road tankers or milk silos.
This problem will be aggravated if the milk has been contaminated
because of unhygienic conditions or lack of cleaning-in-place
Pasteurization
Most commercial liquid food products undergo some form of heat
(CIP). The vast majority of enzymes will be destroyed by UHT
treatment and pasteurization is the most common. As it is usually
treatment, but a few may still be active in the final product.
bacterial growth that causes food to deteriorate, pasteurization
preserves the freshness of the food product. There are basically
Molds two ranges of pasteurization:
Molds belong to the fungi group of micro-organisms which are
• Low-temperature pasteurization. For milk, this is based
widely distributed in nature among plants, animals and human
on heating the product to 162-169°F and holding at that
beings. Molds normally grow anaerobically, and their optimum
growth temperature is between 68°F and 86°F. Molds can grow temperature for at least 15-20 seconds (or equivalent) (Fig.
in substrates with pH 2-8.5, but many species prefer an acid 1). The pasteurization may vary from country to country
environment. The most common species in milk do not survive according to national legislation. A common requirement
pasteurization conditions, and the presence of mold in pasteurized in all countries, however, is that the heat treatment must
products is therefore a sign of re-infection. The penicillium family guarantee the destruction of unwanted micro-organisms and
is one of the most common types of molds. Their powerful protein all pathogenic bacteria. The shelf life of pasteurized milk is
splitting properties make them the chief agent in ripening of, for limited (typically 5-7 days), and primarily depends on raw
instance, blue cheese. milk quality and storage temperature. During low-temperature
pasteurization the phosphatase enzyme is destroyed,
Yeast while the peroxidase enzyme is preserved. This serves as a
Yeast also belong to the fungi group of micro-organisms. They measure to control the process and distinguish it from high-
vary greatly in size. Saccharomyces cerivisiae, used for brewing of
temperature pasteurization.
beer, has a diameter of 2-8 micron, but other species may be as
large as 100 micron. • igh-temperature pasteurization. This is based on heating the
H
product to 185°F or higher for a few seconds (or equivalent)
Yeast has the ability to grow both in the presence and absence
(Fig. 1). The aim is to kill the entire population of bacteria
of oxygen. The optimum temperature is between 68°F and 86°F.
which are pathogenic for both man and animals, and almost
Optimum pH values are 4.5-5.0, but yeast will grow in the pH
all other bacteria as well. By careful monitoring of the process
range of 3-7.5.
parameters, a product with excellent quality can be obtained
From a dairy point of view, yeast are generally undesirable with minimum heat damage. The shelf life can be extended to
organisms. They ferment milk and cream, and cause defects several weeks in the cooling chain.
in cheese and butter. In the brewing, baking and distillation
industries, on the other hand, they are very valuable organisms. uring high-temperature pasteurization, both the phosphatase
D
and the peroxidase enzymes are destroyed, and this serves as
Bacteriophages a measure to confirm that the process has actually taken place
Bacteriophages belong to the group of micro-organisms called as specified.
viruses. Viruses have no metabolism of their own and therefore
cannot grow on a nutrient substrate. Viruses infect living cells in
plants and animals. Bacteriophages (also known as phages) infect
bacteria and are consequently a problem in all dairy processes
where bacteria cultures are used. They are very small in size — Temperature
0.02-0.06 microns — and can only be seen with an electron 283°F
ESL
microscope. 248°F
High pasteurization
Bacteriophages grow at temperatures between 50°F and 113°F.
They are killed by exposure to 145-190°F for 30 minutes and
tolerate pH values in the range of 3-11.
162°F
Toxicity Low pasteurization
Micro-organisms which are harmful to man or animals are called
pathogens. They can cause death or severe illness by the
secretion of toxins either directly into contaminated foodstuffs,
which are subsequently eaten, or by transfer to an animal host
offering ideal conditions for reproduction and further generation of
toxins. Some toxins are inactivated by heat treatment at 140°F for Time
one hour. Figure 1: Temperature profiles for pasteurization processes
4
Extended Shelf Life/Ultrapasteurization °F
302 High Heat Infusion
The term “extended shelf life,” or “ESL,” is being applied more
Direct Infusion
and more frequently. There is no single general definition of ESL. Indirect UHT
Basically, what it means is the capability to extend the shelf life
of a product beyond its traditional well-known and generally
accepted shelf life without causing any significant degradation
212
in product quality. A typical temperature/time combination for
high-temperature pasteurization of ESL milk is 257-266°F for 2-4
seconds.
Sterilization 122
Sterilization is another type of heating process used for products
to increase keeping quality without refrigeration. The heat
treatment takes place after the product is packed. The package, 0
10 20 30 40 50 60
with its content, is heated to approx. 248°F and held at that Minutes
temperature for 10 to 20 minutes, after which it is cooled to room
temperature (Fig. 3). Because of the lengthy heat treatment at Fig. 3: Temperature profiles for conventional in-container sterilization
5
Table 2: Present legislation according to EU directive 92/46
**IDF & EU suggestions for Dual Chemical Criteria
Process Evaluation
All UHT processes are designed to achieve commercial sterility. A logarithmic function can never reach zero, which means that
This calls for application of heat to the product and a chemical sterility defined as the absence of living bacterial spores in an
sterilant or other treatment that renders the equipment, final unlimited volume of product is impossible to achieve. Therefore,
packaging containers and product free of viable micro-organisms the more workable concept of “sterilizing effect” or “sterilizing
able to reproduce in food under normal conditions of storage and efficiency” is commonly used.
distribution. In addition, it is necessary to inactivate toxins and
The sterilizing effect is expressed as the number of decimal
enzymes present, and to limit chemical and physical changes in
reductions achieved in a process. A sterilizing effect of 9 indicates
the product. In very general terms it is useful to have in mind that
that out of 109 bacterial spores fed into the process, only 1 (100)
an increase in temperature of 50°F increases the sterilizing effect
will survive.
10-fold whereas the chemical effect only increases approximately
3-fold. In this section we will define some of the more commonly Spores of Bacillus subtilis or Bacillus stearothermophilus are
used terms and how they can be used for process evaluation. normally used as test organisms to determine the efficiency of
UHT systems, because they form fairly heat resistant spores.
The Logarithmic Reduction of Spores and
Sterilizing Efficiency Terms and Expressions to Characterize
When micro-organisms and/or spores are exposed to heat Heat Treatment Processes
treatment not all of them are killed at once. Q10 value. The sterilizing effect of heat sterilization increases
rapidly with the increase in temperature as described above.
However, in a given period of time a certain number is killed while This also applies to chemical reactions which take place as a
the remainder survives. If the surviving micro-organisms are once consequence of an increase in temperature. The Q10 value has
more exposed to the temperature treatment for the same period of been introduced as an expression of this increase in speed of
time an equal proportion of them will be killed. On this basis the reactions and specifies how many times the speed of a reaction
lethal effect of sterilization can be mathematically expressed as a increases when the temperature is raised by 50°F. Q10 for
logarithmic function: flavor changes is in the order of 2 to 3, which means that a
K · t = log N/Nt temperature increase of 50°F doubles or triples the speed of the
where N = number of micro-organisms/spores originally chemical reactions.
present A Q10 value calculated for killing bacterial spores would range
Nt =number of micro-organisms/ spores present after a from 8 to 30, depending on the sensitivity of a particular strain to
given time of treatment (t) the heat treatment.
K = constant
t = time of treatment
6
D-Value. This is also called the decimal reduction time and is The C* value is based on the conditions for a 3 percent
defined as the time required to reduce the number of micro- destruction of thiamine (vitamin B1); this is equivalent to 275°F for
organisms to one-tenth of the original value, i.e. corresponding to 30.5 seconds with a Z-value of 89°F. Consequently the C* value
a reduction of 90%. can be calculated as follows:
Z-Value. This is defined as the temperature change which gives a
C* = 10 ( T - 275 ) /89 · t/30.5
10-fold change in the D-value.
F0 Value. This is defined as the total integrated lethal effect and is Fig. 4 shows that a UHT process is deemed to be satisfactory
expressed in terms of minutes at a selected reference temperature with regard to keeping quality and organoleptic quality of the
of 250°F. F0 can be calculated as follows: product when B* is > 1 and C* is < 1.
7
4000
3000
region of
sterilization
2000
los
so
ft
hia
m
ine
HM
1000 =
80
F
10
900 %
0
µm
800
ol/
700
l
600
500
HM
F
th
10
400 re 60
sh
µm
ol %
o
d
l/l
300 ra
ng
e
of
los di
so sc
ft ol
200 or
hia at 40
m io %
Heating time or equivalent heating time in seconds
ine n
HM
=
F1
3%
/C
µm
*=
ol/
1
l
100
90
80
70
20
%
60
50
40
30
10
lac
%
tu
lo
se
20
60
0
m
ther ophilic
ther
g/
lac
l
tu
lo
mal
m
los
ss
of
e
dea spores
40
lys
0
in
th v
e
m
10
=
g/
alue B*=1
1%
l
9
8
/
UHT-
=9
7 region
6
5
1
212 230 248 266 284 302 320°F
8
Commercial Sterility
The expression of commercial sterility has been previously Deposit build-up
All powder products must be dissolved prior to UHT treatment, Product Shelf Life Storage
because bacteria spores can survive in dry powder particles even Pasteurized milk 5-10 days refrigerated
at UHT temperatures. Undissolved powder particles will also ESL 20-45 days refrigerated
damage homogenizing valves, causing sterility problems. UHT milk 3-6 months ambient
temperature
Heat stability. The question of heat stability is an important
parameter in UHT processing. The usual organoleptic factors limiting shelf life are deteriorated
taste, smell and color, while the physical and chemical limiting
Different products have different heat stabilities, and although factors are incipient gelling, increase in viscosity, sedimentation
the UHT plant will be chosen on this basis, it is desirable to be and cream lining.
able to measure the heat stability of the products to be UHT
treated. For most products, this is possible by applying the
alcohol test. When samples of milk are mixed with equal volumes
of an ethyl alcohol solution, the proteins become unstable and
the milk flocculates. The higher the concentration of ethyl alcohol
is without flocculation the better the heat stability of the milk.
Production and shelf-life problems are usually avoided provided
the milk remains stable at an alcohol concentration of 75%.
9
Choosing the Right Process
In order to be able to produce a product with specific product Spores cannot develop in high-acid products such as juice,
qualities in the most cost-effective way, it is essential to make the and the heat treatment is therefore only intended to kill yeast
correct choice with respect to processing system and technology. and molds.
In many cases the choice is straightforward, but in other cases
there may be more options to choose between. Some of the more Consequently high-temperature pasteurization at 194-203°F for
important questions to ask when choosing a system are: 15-30 seconds is sufficient to make most high-acid products
• What is the specification of the product to be processed? commercially sterile.
• What are the quality requirements to the final product?
In some cases where new products have to be processed it may
• Viscosity specifications of products and raw materials? be necessary to carry out trials on a small scale to observe the
• pecification of particulate and fiber content/size and shape
S performance of specific products in different types of systems.
and variation in content? APV has designed a pilot unit for this purpose.
• Acidity of product/high or low acid?
The trend for processors to focus increasingly on flexibility
• Sensitivity to high temperatures/heat stability? to process a range of products and the importance of being
• Requirement for flexibility/multi-purpose systems? able to produce high quality products, have driven the choice
of systems towards indirect tubular systems and direct steam
• Requirement for variable capacity?
infusion systems. The following sections deal with the various
• Requirement for direct or indirect systems? heating principles and UHT systems followed by a more detailed
• Skills of technical personnel/operators? comparison of the individual systems.
Fig. 7 illustrates three of the selection criteria — viscosity, The Heat Treatment Processes
capacity and content of particulates — for the most common APV invented the plate heat exchanger in 1923 and has
processing systems. pioneered new heat treatment principles ever since. Scraped
surface heat exchangers (Crepaco) were developed in the USA
The systems are often flexibly designed to allow for processing a while the direct steam infusion system was developed in Denmark
range of products in the same plant. (Pasilac). The tubular systems were developed partly in Denmark
and partly in Germany (Rosista), and later supplemented by the
It is quite common to process both low-acid (pH>4.5) and high- corrugated tubular heat exchangers in Spain (ICTC). In addition,
acid (pH<4.5) products in the same UHT plant. APV is known for electroheat thermal processing equipment
which is dealt with in a separate Technology Update.
However, only low-acid products require UHT treatment to make
them commercially sterile.
Viscosity cP
Capacity l/h
50,000 cP
500 cP
6,604 gal/h
200 cP
100 cP
50 cP
er
iz
eril
St
HE
SS
Increasing
r er er r particle size
ize iliz iliz ize
ril er er ril
St
e St St St
e
n on ar
te io i l
Pl
a ct us bu
je In
f
Tu
In
m m
ea ea
St St
10
Plate Heat Exchangers Corrugated Tubular Heat Exchangers
The plate heat exchanger is the most cost-effective and versatile APV has extended its range of heat exchangers with corrugated
method for indirect heating or cooling of liquid food products. tubular heat exchangers. By corrugating the tube wall it is
Today, APV’s comprehensive Para-flow range of plates is the possible to improve the heat transfer coefficient and consequently
basis for a wide range of plate heat exchanger applications in reduce the requirement for heating surface area. The corrugation
many industries. In the food and dairy industry, the plate heat causes increased turbulence and breaks the laminar flow in high
exchanger is one of the most indispensable pieces of equipment. viscosity products.
As illustrated in Fig. 8.1, the plate heat exchanger incorporates a Double tube, triple tube, quadruple tube and multi tube in tube are
number of parallel, closely spaced stainless steel, gasketed and the basis for the range as illustrated in Fig. 8. 3.1, 8.3.2, 8.3.3
corrugated plates which are compressed and locked together and 8.3.4. The design of the double, triple and quadruple tube
in a rugged frame. As product is pumped through the plate heat makes it possible to arrange direct regeneration, because both
exchanger, the flow is distributed through narrow, corrugated sides of the tube wall are a sanitary design.
flow passages which produce a high level of turbulence resulting
in high rates of heating or cooling with low hold-up volume. Through a variety in corrugation depth, pitch and angle it is
Product contact time is thereby reduced to a matter of seconds, possible to optimize heat transfer and pressure drop depending
minimizing thermal damage. on shear characteristics of the product. Furthermore, the
possibility of adjusting the annular space adds one further
A very important advantage of the plate heat exchanger is parameter for optimizing the design.
its extremely high regenerative capability, reducing energy
requirements for heating or cooling by more than 90%. Plate heat
exchangers provide a maximum amount of heat exchange surface
in a minimum amount of floor space. Fig. 8.3.1: APV Double Tube
Product in Product out
Product Product Flash cooling takes place in a vacuum expansion vessel where the
in out
vacuum is maintained by means of a vacuum pump. The vacuum
is controlled in order to ensure that the same amount of water is
Media in flashed off as was injected into the product as steam in order to
Fig. 8.2: APV Tubular Heat Exchanger
prevent dilution/concentration of the product.
11
Steam Infusion Scraped Surface Heat Exchangers
In the 1960s APV launched the first steam infusion system under APV’s product range includes a number of scraped surface heat
the Palarisator brand name. Since then significant developments exchangers specially designed to heat or cool viscous or sticky
and progress have taken place which have led to one of the most products, or products containing particulates.
sophisticated systems in the world.
The scraped surface heat exchanger consists of a smooth cylinder
After preheating, the product is pumped into the infuser — a through which the product is pumped, counter current to the
pressure vessel fitted with cones at both top and bottom as service medium in the surrounding jacket.
illustrated in Fig 8.5.
Rotating scraper blades keep the heating surface free from
deposits. The scraper blades are fixed to a rotating shaft called a
dasher (Fig. 8.6).
Product out Product in
All APV UHT systems are preassembled and tested in the factory
1. Product to product 3. Indirect heating 6. Sterile tank
with steam. This minimizes installation and start-up costs, and regenerative 4. Holding tubes 7. CIP unit
2. Homogenizer 5. Indirect cooling
ensures a safe and trouble-free plant commissioning. 8. Sterilizing loop
Indirect Plate Sterilizer Fig. 11.1: Flow diagram for Plate Sterilizer
UHT systems based on plate heat exchangers are used where the
manufacturer’s primary requirement is a dependable system for Energy recovery Plant volume at 90% regenerative
heating liquid products at minimum operating costs. In Fig. 11.1 a LOW MEDIUM HIGH LOW MEDIUM HIGH
flow diagram illustrates the principle design including some of the PLATE
damage. Fig. 11.2 compares some key data for plate and tubular PLATE PLATE
systems.
TUBULAR TUBULAR
Advantages:
• Excellent for low viscosity products
• High regenerative effect and low energy consumption
• High heat transfer area in minimal space
• Easy inspection
• Low hold-up volume
• High degree of flexibility
Fig. 11.3: APV Plate Sterilizer
• Variable capacity
• Large capacity plants
• Relatively low investment
Products:
• Milk, flavored milk
• Low CIP costs
• Fermented milk products, drinking yogurt
• Cream, coffee whiteners
Limitations:
• Limited capability for particulates or fibers • Soy milk
13
Indirect Tubular Sterilizer PRODUCT
3
203°F
3
284°F
FILLING
180
Common practice tube
80
5 10 15 20 25
• ow requirement for gasket material and easy gasket
L Operating Time of Plant [hour]
Products:
• Milk, flavored milk
• Fermented milk products, drinking yogurt
• Cream, coffee whiteners
• Whipping cream, ice cream mix
• Evaporated milk, desserts, puddings
• Soy milk
• Coffee, tea
• Juices, juices with pulp
Fig. 12.3: APV Tubular UHT Plant - STH
• Salad dressings
• Gravy, sauces, soups
• Combination plants for milk, juice, coffee, tea, etc.
14
Steam Infusion Sterilizer 167°F
STEAM
UHT systems based on infusion heating are used where the FILLING
2
manufacturer wants to produce a high quality product with as little 9 COOLING
WATER
In Fig. 13.1 a flow diagram illustrates the principle design 41°F 289°F 167°F 77°F <77°F
1 6 6
8 COOLING
The system can be supplied from 40 gal./hr. (pilot plant) to WATER COOLING
WATER
T
UH
302
L
ES
t
an
Fig 13.3 shows an APV Steam Infusion Sterilizer.
st
In
259
Advantages:
• entle and accurate heating in the
G 212
infusion chamber
• Accurate holding time
167
• Superior product quality Hot Filling/
Spray Drying
• Closed loop during pre-sterilizing
122
• High product flexibility
• Low fouling rate Filling
77
• Long operating time
Cold Filling
• Operator friendly 41
Time
Limitations: Fig. 13.2: Time/temperature profiles for various infusion based processes
• Relatively higher capital costs compared to indirect systems
• elatively higher operating costs due to lower heat
R
regeneration
• Requirement for culinary steam
Products:
• Milk, flavored milk, creams
• Soy milk products
• Vla, custard, pudding
• Soft ice mix, ice cream mix
• Baby food, condensed milk
• Processed cheese
• Sauces
15
High Heat Infusion Sterilizer VACUUM STEAM FILLING
PRODUCT
The growing incidents of heat resistant spores (HRS) are 194°F 257°F
The HRS are extremely heat resistant and require a minimum of WATER
Note that the vacuum chamber has been installed prior to the
infusion chamber. This design facilitates improvement in energy
recovery and it is possible to achieve 75% regeneration compared UHT of products with HRS (comparative temperature profiles with Fo= 40)
Advantages:
• Micro-biological product safety by elimination of HRS spores
• Very long operating time between CIP 122
• Capital investment costs Fig. 14.2: Time/temperature profiles illustrating High Heat Infusion processing
parameters
• Requirement for culinary steam
Products:
• Milk and milk products
• Desserts
• ther products as with conventional
O
infusion systems
16
Instant Infusion Pasteurizer
The infusion heating principle has increasingly been used for high
viscous and sticky products. However, some products have been
found to be very difficult or nearly impossible to handle unless
very short run-times were accepted.
In Fig 15.1 it shows the design of the infusion chamber with the
pump arrangement.
Advantages:
• an handle high fouling products with long running time (>20
C
hours)
• High degree of flexibility
• educed chemical changes in comparison to conventional
R
infusion
• Very high product quality
Product:
• Whey protein concentrate
• Egg-based products
• Baby food
• Processed cheese
17
Steam Injection Sterilizer 167°F
This system operates by direct injection of steam into the product STEAM
PRODUCT
through a specially designed nozzle as previously described
FILLING
2 COOLING
9 WATER
(Fig. 8.4).
4 7
1 6 6
The system is in its basic design, quite similar to an infusion
system where the infuser has been replaced with an injection 8 COOLING
COOLING
WATER
WATER
nozzle (Fig. 16.1).
Long operating times are possible because only a very small area
1. Plate preheaters 4. Flash vessel 7. Aseptic tank
in the nozzle is subject to fouling. 2. Steam injection nozzle 5. Aseptic homogenizer 8. Non aseptic cooler
3. Holding tube 6. Plate coolers 9. Condenser
Advantages:
Fig. 16.1: Flow diagram for Steam Injection Sterilizer
• Good product quality
• Long production runs
• Handles heat-sensitive products
Limitations:
• Higher capital costs than for indirect systems
• Higher operating costs due to lower heat regeneration
• Mostly used for low viscosity products
• Requirement for culinary steam
Products:
• Milk, flavored milk, cream
• Soy milk
• Ice cream mix
18
Scraped Surface Heat Exchanger Sterilizer Limitations:
Scraped surface heat exchangers (SSHE) are the most suitable • Relatively high capital cost
equipment for treatment of high viscosity food products and food • Relatively high energy requirements
products containing larger particles.
• igher maintenance costs due to scraper blades, bearings
H
In a typical aseptic plant, the product is pumped by a rotary lobe and seals
pump (or similar) to feed one or more heating cylinders, followed • High spare parts requirement
by a holding tube and one or more cooling cylinders. Capacities
• Limitation in respect to size of particulates
up to approximately 2,642 gal./hour are available but this depends
— to a large extent — on the physical characteristics of individual
products. Products:
• Milk concentrate
Since the nature of the products can vary considerably in terms • Yogurt
of viscosity, stickiness or size and fragility of the particles, each
system is individually engineered to suit a particular product. • Processed cheese
• Whey protein concentrate
Even though systems based on SSHE are relatively expensive, • Quarg products
both in terms of investment and energy consumption, they are still
very competitive compared with batch sterilizing systems. • Baby food
Fig. 17 shows an SSHE based sterilizer equipped with VT 4” • Compotes
cylinders. • Puddings, dips
• Sauces, soups
Advantages:
• Handles high-viscosity products
• Handles sticky products
• Handles particulates up to approximately 13 mm
• Handles heavy-fouling products
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Pilot UHT Plant
The constant pressure on manufacturers to produce quality • ontinuation of filling during intermediate CIP or interruption
C
products at the lowest possible cost creates a need for evaluating in UHT operations. Many UHT plants need intermediate CIP
the most suitable process system and optimizing processing after 8-12 hours of operation, depending on the UHT system,
parameters. Using production plants for tests on new products product quality and type of product to be processed. The
and processes is both uneconomical and difficult. aseptic tank ensures that this process can be performed
without interrupting the operation of the filling lines.
Therefore, APV has developed a new generation of pilot plants,
which gives manufacturers the possibility of performing tests on a • educed investment. Since the filling machines are the most
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small scale with easy operation, flexibility and scaling up accuracy. expensive part of an aseptic processing line, it is important
The continuous UHT pilot plant has a capacity of 16-59 gal./ that they are utilized to their full capacities. To this end, the
hour and is designed for indirect tubular and direct steam infusion aseptic tank is installed. By increasing the operating time of
heating. However, the following options can be included in the the fillers, a small increase in the capacity of the UHT plant
standard system and/or any combinations: creates the possibility of lengthening the production run
• High Heat Infusion significantly.
• Indirect Plate The aseptic tank is equipped with steam-shielded aseptic valve
• Direct Steam Injection clusters and supplied with sterile air at constant pressure. This
provides for a perfect balance between supply and demand from
• Pasteurization
the aseptic tank.
• Deaeration/Deodorization The aseptic tank is also fully automated, using programmable
• Scraped Surface Heat Exchanger logic controllers (PLC), and the control system can be connected
either to the UHT control system or to one of the filling machines.
It is also possible to provide variable temperature and holding
time profiles. This makes the pilot plant extremely versatile. The
plant can be supplied with a 132 gallon sterile tank, which will
form a link between the pilot plant and a filling machine.
Deaerator
Deaeration is essential for production
of high quality products. While the
Fig. 18: APV UHT Pilot Plant products in the infusion systems are
deaerated in the infusion chamber,
Sterile Tank this is not the case when indirect
It is not always possible to feed a sterile product directly from the heating systems are used. In these
processing plant to the filling machine. This is where the aseptic cases, the dearation can be solved
tank comes in as a buffer between processing and filling units. through the installation of the APV
Parasol Deaerator, designed to remove
Besides serving as a buffer and storage tank for the sterilized dissolved or entrained air under vacuum. The product is sprayed
product, the aseptic tank also adds an important degree of as a thin film in a parasol form into a vessel, maximizing product
flexibility to the production process as it provides for: surface area and deaeration efficiency. The APV WI+ centrifugal
• Continuation of production regardless of interruption in filling pump is used to ensure pumping of high viscous products under
rate. Usually one UHT line is connected to several filling vacuum. The APV WI+ pump is equipped with an APV UNIversal
machines with variable capacity. If the filling rate is not at a inducer acting as a helical screw pump mounted to the pump
maximum, the UHT plants need to have a variable capacity shaft in front of the impeller, which reduces the risk of cavitation
or the product must be recirculated if allowed by local especially when pumping high viscous products. The air content
regulations. can be reduced to as low as 0.5 ppm oxygen.
20
Comparison Between Different
Systems
As illustrated in the presentation of the various technologies
on the next page, there is a wide choice and there are several
considerations to be made before the final decision is taken.
APV’s team of experts is available to advise on selecting the most
appropriate technology for each specific requirement.
Product Development
New products are developed more rapidly than ever before in
order to satisfy demands in the consumer market. Simultaneously,
the lifecycle of the individual products tends to shorten. These
conditions force the producers to intensify and accelerate product
development. Capabilities in aseptic processing and related
disciplines enable APV to support customers to develop new
Fig. 21: An APV production management system value-added products at the highest possible speed.
The world leading process technology — a result of many
This can be achieved through product testing in APV’s test and
years’ development and experience — is built into our software
development centers around the world or by means of an APV
packages. The control system has already been tested in many
Pilot Plant installed at the customer’s site.
similar applications, and they are always pretested prior to delivery
Filling and Packaging APV is keen to work in partnership with customers in order to
accelerate the product development process.
In order to preserve their high micro-biological quality, aseptically
processed products must be aseptically packed. Even at room
It is the objective of APV to deliver innovation, quality and
temperature, the packaged product then has a shelf life of several
reliability to the dairy, food and beverage industries in order to
months. In aseptic filling and packaging, the aseptically processed
contribute to the safety and high quality products to the customer.
product is filled under aseptic conditions into commercially sterile
21
Comparison Between Different Systems
Table 4: Comparison between the most commonly used processing systems rated on a scale from 1 to 5:
1 = excellent; 2 = good; 3 = acceptable; 4 = possible; 5 = not recommended
For more information about our worldwide locations, approvals, certifications, and local representatives, please visit www.apv.com.
SPX Corporation reserves the right to incorporate our latest design and material changes without notice or obligation.
Design features, materials of construction and dimensional data, as described in this bulletin, are provided for your information only and should
not be relied upon unless confirmed in writing.