ThermalProcessionTechnology 6751 02-03-2009 GB Tcm20-20299[1]

7/31/2019 ThermalProcessionTechnology 6751 02-03-2009 GB Tcm20-20299[1]

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Thermal Processing Technology


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Evaluation of the UHT systemsIn order to be able to produce a product with specicproduct qualities in the most cost-effective way it isessential to make the correct choice with respect toprocessing system and technology.

In many cases the choice is straight forward, but in other

cases there may be more options to choose between.Some of the more important questions to ask whenchoosing a system are:

What is the specication of the product to be proc-essed?Which are the quality requirements to the nal prod-uct?Viscosity specications of products and raw materi-als?

Specication of particulate and bre content/size and shape and variation in content?Acidity of product/high or low acid?Sensitivity to high temperatures/heat stability?Requirement for exibility/multi-purpose systems?Requirement for variable capacity?Requirement for direct or indirect systems?Skills of technical personnel/operators?

The systems are often exibly designed to allow forprocessing a range of products in the same plant.

Choosing the right process

It is quite common to process both low-acid (pH>4.5)and high-acid (pH


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Evaluation of the UHT systems

UHT process recommendation

Main advantages and limitations

Plant type Excellent NotRecommended

Infusion

Injection

High quality product

Fauling productSensitive ProductsCreamIce Cream

Low cost products

FibresCoffee / TeaVolatile aroma

Tubular Low cost productsVolatile aromaCoffee whitenersProduct with fibresJuiceCoffee / Tea

Plate Low cost productsVolatile aromaCoffee whitenersJuiceCoffee / Tea

Fibres

Plant type Excellent NotRecommended

Infusion

Injection

High quality product

Fauling productSensitive ProductsCreamIce Cream

Low cost products

FibresCoffee / TeaVolatile aroma

Tubular Low cost productsVolatile aromaCoffee whitenersProduct with fibresJuiceCoffee / Tea

Plate Low cost productsVolatile aromaCoffee whitenersJuiceCoffee / Tea

Fibres

Plant type Advantages Limitations

Infusion

Injection

Gentle & accurate heatingAccurate holdingSuperior product qualityLong operation time

Capital costLow regenerativeCulinary steam

Over-heatingHolding time

Tubula r High regenerat ionLong running timeParticulates and fibresNo gasketLow maintenance cost

Lower regenerative thanPlates UHTHigher degree of productDegradation

Plate High regenerationLow space requirementLow investmentLow running cost

Particulates or FibresGasketsHigh pressure drops

Plant type Advantages Limitations

Infusion

Injection

Gentle & accurate heatingAccurate holdingSuperior product qualityLong operation time

Capital costLow regenerativeCulinary steam

Over-heatingHolding time

Tubula r High regenerat ionLong running timeParticulates and fibresNo gasketLow maintenance cost

Lower regenerative thanPlates UHTHigher degree of productDegradation

Plate High regenerationLow space requirementLow investmentLow running cost

Particulates or FibresGasketsHigh pressure drops


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The C* value with a B* = 1:

Evaluation of the UHT systemsDesign that fits

0

0,1

0,2

0,3

0,4

0,5

0,6

0,7

0,8

Infusion

UHT

Injection

UHT

Plat e UHT T ubular

UHT

Infusion UHT 0.15Injection UHT 0.24Plate UHT 0.38Tubular UHT 0.74

The lower the better

Beta-lactoglobulin level:

0

500

1000

1500

2000

2500

3000

3500

R a w

m i l k

P a s t .

m i l k

P u r e -

L a c

I n f u s

i o n U H

T

I n j e c

t i o n U

H T

P l a t e

U H T

T u b u

l a r U H

T

Raw milk 3,400Past milk 2,900Pure-Lac 2,500Infusion UHT 1,800Injection UHT 1,500Plate UHT 400Tubular UHT 200

The higher the betterRunning cost of a UHT plant based on:

0

1020

30

40

50

60

70

80

90

InfusionUH T

InjectionUH T

Plate UHT TubularUHT

UHT plant 10,000 l/h10 hours/day300 days/yearSpare parts 3% of investment/yearOne service visit each 2500 hoursDepreciation over 10 yearsInterest 5%

US cents/100 litre production

0.1 - 1 mm 1 - 5 mm 6 - 25 mm

Fibres andspices

Smallparticles

Largeparticles

Infusion + - -

Injection + + -

Tubular heatexchanger + + (+)

SSHE + + +

In situprocessing + + +


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Rated on a scale from 1 to 5: 1 = excellent; 2 = good; 3 = acceptable;4 = possible; 5 = not recommended.

Comparison between the most common used processing plants

PlateSteriliser

TubularSteriliser

SteamInfusionSteriliser

SteamInjectionSteriliser

High HeatInfusionSteriliser

InstantInfusion

Pasteuriser

SSHESteriliser

Milk Low cost1 2 5 4 3 5 5

High quality 3 3 1 2 2 1 5

Poor quality raw material 4 2 1 2 2 1 5

Heat resistant spores 3 3 2 2 1 5 5

Flavoured milk Fouling product(chocolate) 3 2 1 2 2 1 5

Volatile aroma 1 1 3 3 2 3 5

Difficult to sterilise (cocoa) 3 2 1 1 1 3 5

Sensitive colour 3 3 1 2 2 1 5

Cream Whipping cream 3 3 1 2 2 1 5Stabilised desserts 4 3 1 3 3 2 5

Cooked cream 2 2 1 2 2 4 5

Coffee whiteners Milk-based 1 1 2 3 1 3 5Vegetable oil-based (emulsified) 1 1 3 3 1 3 5

Fouling/high protein content andstabiliser

4 4 2 3 4 1 5

Juice With pulp, fibres > 1 mm 5 1 5 5 5 5 5With pulp, fibres < 1 mm 3 1 5 5 5 5 5

Without pulp and fibres 1 1 5 5 5 5 5

Yoghurt 1 1 4 4 4 4 4

Quarg 5 5 4 4 5 3 1

Baby food 3 3 1 2 3 1 1

Milk concentrate 4 4 2 3 4 1 2

Puddings Stabilised, high solids,starch 5 4 2 4 4 1 3

Stabilised with carrageenan 3 3 2 3 3 2 3

Soya milk Low cost 1 2 5 4 5 5 5High quality 3 3 1 2 1 1 5

Poor quality raw material 4 3 1 2 2 1 5

Coffee and tea 1 1 4 4 4 4 5

Soups and sauces 5 2 4 4 5 5 1

Other considerations Heat stability 3 3 1 2 3 1 3

Aseptic product 1 1 1 1 1 3 1


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AdvantagesGentle and accurate heating in the infusion systemFast heating 600C/sec.Accurate holding timeSuperior product qualityHigh product exibilityLow fouling rateLong operating time between CIP

Infusion UHT plant - SDH

Specications

Field of application Milk, avoured milk, coffeecream, cream, ice cream mixcustard, milk shake

Description A UHT plant designed for vefast heat treatment, with anefcient bacteria spore kill raand a very low chemical chanto the product. Often named tmost gentle UHT treatment othe market

Capacity 2,000 - 30,000 l/h(550 - 8,000 U.S. g/h)

Temperature 5-75-142-75-25C(41-167-288-167-77F)

Flexible handling of a wide range of traditional, direct UHT products

APV is a world leader in UHT technol-ogy with a comprehensive portfolio oftried and tested UHT plant solutionscomprising plate, tubular, injection andinfusion UHT plant technologies.

In addition to these basic technolo-

gies, variations such as scraped sur-face heat exchanger, high heat infusionand combi UHT plants are availableas well as Add-On, Pure-Lac, ESL,aseptic tanks, UHT pilot plants andInstant Infusion.

The UHT R and D centre based inSilkeborg, Denmark, operates a UHTpilot plant capable of running all the

main UHT systems. This pilot plantis used for product testing and new

process development as well as by ourcustomers wishing to test new proc-esses and optimize existing processparameters with the assurance ofproduction scalability.

APV introduced UHT infusion technol-

ogy in 1960 and is today the worldleader with a market share of some 90percent

Today we offer four main infusionsystems: Infusion UHT, 143C (289F)for 3 sec.; Infusion Pure-Lac, 135C(275F) for 0.5 sec.; Instant Infusion,135C (275F) for as little as 0,1 sec.;High Heat Infusion, 152C (306F) for

1 - 3 sec, giving an Fo of 40 - 70.

UHT treatment


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AdvantagesGentle and accurate heating in the infusion systemFast heating 300C/sec.Superior product qualityHigh product exibilityLow fouling rateLong operating time between CIPOperator-friendlyPre-assembled and factory-testedAs option designed according to ASME, PMO, 3A

Injection UHT plant - SDI

Specications

Field of application Milk, avoured milk, coffeecream, cream, ice cream mix,custard, milk shake

Description A UHT plant designed to give avery fast heat treatment, with anefcient bacteria spore kill rateand very low chemical change tothe product

Capacity 2,000 - 30,000 l/h(550 - 8,000 U.S. g/h)

Temperature 5-75-142-75-25C(41-167-194-280-167-77F)

Flexible handling of a wide range of traditional, direct UHT products

AdvantagesHigh up-timeFlexible product rangeEasy inspection of product and medium surfaceHigh pressure toleranceLow energy costLow maintenance costOperator-friendlyPre-assembled and factory-testedAs option designed according to ASME, PMO, 3A

Tubular UHT plant - STH

Specications

Field of application Milk, avoured milk, coffeecream, cream, ice cream mix,custard, milk shake

Description Robust and exible UHT plant.Back pressure tolerance up to60 bar and heat regeneration ofapprox. 85%

Capacity 2,000 - 30,000 l/h(550 - 8,000 U.S. g/h)

Temperature 5-75-90-138-75-25C(41-167-194-280-167-77F)

Flexible handling of a wide range of traditional, indirect UHT products


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AdvantagesHigh energy recovery, giving low running costFlexible low viscosity product rangeLow pressure dropPare Clip gaskets (non-glue)Operator-friendlyPre-assembled and factory-testedAs option designed according to ASME, PMO, 3A

Plate UHT plant - SIH

Specications

Field of application Milk, avoured milk, coffeecream, cream, ice cream mixmilk shake, tea, coffee, juice,

Description A UHT plant designed for coefcient running and a heatregeneration of up to 96%

Capacity 2,000 - 30,000 l/h(550 - 5,500 U.S. g/h)

Temperature 5-75-90-138-75-25C(41-167-194-280-167-77F)

Flexible PHE-based heat treatment of a wide range of traditional, indirectUHT products

AdvantagesEffective processing of high-viscosity products anproducts containing particlesOperator-friendlyPre-assembled and factory-tested

Scraped surface heat exchanger UHT plant - SSHE

Specications

Field of application High-viscosity products

Description A UHT plant designed for roand exible running of produwith very high viscosity for wa tubular or plate UHT plant not suitable

Capacity 200 - 20,000 l/h(550 - 5,500 U.S. g/h)Temperature 5-75-90-138-75-25C

(41-167-194-280-167-77F)

For heat treatment/UHT of products with very high viscosity and/or particlecontent


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AdvantagesKill rate over Fo 40Increased operating time

High recovery (up to 72%)Reduced maintenance costsEfcient deaeration prior to heating

High heat infusion steriliser - SHH

Specications

Field of application Milk, avoured milk, coffeecream, cream, ice cream mix

Description A UHT plant designed to givea very high kill rate of bacteriaspores (Fo 40 to 70) and higherheat regeneration (approx. 65%)than a conventional infusion plan

Capacity 2,000 - 30,000 l/h(550 - 8,000 U.S. g/h)

Temperature 5-90-60-125-150-75-25C(41-194-140-257-302-167-77F)

Flexible heat treatment of a wide range of traditional direct UHT products

AdvantagesVery high degree of exibility, towards products and tperature proleCan run both direct and indirect UHTCan also run ESL/Pure-LacOperator-friendlyPre-assembled and factory-testedAs option designed according to ASME PMO 3A

Combi UHT plant - Combi

Specications

Field of application Milk, avoured milk, coffeecream, cream, ice cream mix,milk shake, tea, coffee, juice

Description Versatile UHT treatment using achoice of UHT systems - tubu-lar, infusion, ESL and high heatinfusion in the same plant. Ableto combine all APV UHT planttechnologies

Capacity 2,000 - 30,000 l/h(550 - 8,000 U.S. g/h)

Temperature 5-75-90-138-75-25C (andothers)(41-167-194-280-167-77F)

Ultra-versatile handling of a wide range of traditional indirect and direct UHTproducts

Non-aseptic avour dosing of the vacuum chamber poDestruction of heat resistant spores (HRS)

Operator-friendlyPre-assembled and factory-testedAs option designed according to ASME, PMO, 3A


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AdvantagesVery high degree of exibilityDirect and indirect UHTLow investmentOperator-friendlyPre-assembled and factory-testedAs option designed according to ASME, PMO, 3A

Specications

Field of application Milk, avoured milk, coffee cream, cream, ice cmix, milk shake, tea, coffee, juice

Description A UHT plant designed to be added on to an exis

ing heat treatment plant (pasteurizer or UHT)Capacity 2,000 - 30,000 l/h

(550 - 8,000 U.S. g/h)Temperature 5-75-90-138-75-25C (and others)

(41-167-194-280-167-77F)

Add-On, direct and indirect UHT system for an existing pasteurizer

Add-on UHT plant - Add-On

AdvantagesOver 10 hours between CIPHigh spore kill rate in bactufugateLow chemical changeOperator-friendlyPre-assembled and factory-tested

Specications

Field of application Bactofugate and whey creamDescription A UHT bactofugate sterilisation plant with extra

long running time between CIP cleaningCapacity 200 - 5,000 l/h

(55 - 8,000 U.S. g/h)Temperature 50-140-(50)C (cooling direct in the main produ

122-284-(122)F

An infusion UHT system designed to sterilise bactofugate

Bactofugate steriliser - SSU


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AdvantagesGentle and accurate heating in the infusion systemFast heating 600C/sec.

Accurate holding timeHigh bacteria spore kill rateSuperior product quality - low chemical change, pasteurizedmilk avourShelf life up to 45 days

Infusion Pure-Lac plant - Pure-Lac

Specications

Field of application Milk, avoured milk, coffeecream, cream, ice cream mix,milk shake

Description Infusion plant with very fast heattreatment involving pasteurisa-tion for 0.5 seconds at 135C(275F)

Capacity 2,000 - 30,000 l/h(550 - 8,000 U.S. g/h)

Temperature 5-75-135(0.5 sec)-75-5C(41-167-275(0.5 sec)-167-41F)

Pure-Lac the new milk with protected freshness and extended shelf life

AdvantagesGentle and accurate heating in the infusion systemFast heating 600C/sec.Accurate holding timeHigh bacteria spore kill rateSuperior product quality - low chemical change, pasteurizedmilk avour

Shelf life up to 45 days

Infusion ESL plant - ESL

Specications

Field of application Milk, avoured milk, coffeecream, cream, ice cream mix,milk shake

Description Infusion plant with very fast heattreatment involving pasteurisa-tion for 0.5 seconds at 129C(264F)

Capacity 2,000 - 30,000 l/h(550 - 8,000 U.S. g/h)

Temperature 5-75-129(0.5 sec)-75-5C(41-167-264(0.5 sec)-167-41F)

ESL - the new milk with protected freshness and extended shelf life

High product exibilityLow fouling rate

Long operating time between CIPOperator-friendlyPre-assembled and factory-testedAs option designed according to ASME, PMO, 3A

High product exibilityLow fouling rateLong operating time between CIPOperator-friendlyPre-assembled and factory-testedAs option designed according to ASME, PMO, 3A


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AdvantagesGentle and accurate heating in the infusion systemFast heating 600C/sec.

Efcient bacteria spore kill rateUp to 70% less vitamin lossPrecision-controlled holding time down to 0.09 sec.Very low chemical change

Instant infusion plant - SII

Specications

Field of application Baby food, milk concentrate58% TS) for spray drying

Description Infusion plant designed for vfast heat treatment and ultra-short, precision-controlled hoing time

Capacity 2,000 - 30,000 l/h(550 - 8,000 U.S. g/h)

Temperature 75-140(0.09 sec)-75C(167-284(0.09 sec)-167F)

Ultra-short, high-temperature treatment with precision-controlled holding tim

AdvantagesVery reliable system for product trials before upsccommercial productionHighly exibleQuick and easy installationOne unit with small footprintOperator-friendlyPre-assembled and factory-tested

Multipurpose UHT pilot plant - SPP

Specications

Field of application All liquid food products

Description Up to ve heating systems -plate, tubular, injection, infusand SSHE UHT, or any combnation. Also runs Pure-LacESL

Capacity 80 - 150 l/h (designed for 100 l(21 - 40 U.S. g/h (27 U.S. g/h)Temperature 5-75-140-75-20C

(41-167-284-167-68F)

The most flexible pilot UHT plant on the market

Superior product qualityHigh product exibility

Low fouling rateLong operating time between CIPOperator-friendlyPre-assembled and factory-testedAs option designed according to ASME, 3A


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AdvantagesOptimum process control and safetyHigher number of running hours between CIPEasy CIPHigh heat recoveryOperator-friendly control systemLow running costsLow maintenance costsImproved product qualityImproved avourCombination of the ESL methods to tailor shelf life and avourESL processing lines can be combined with traditional pasteurisation lin

milk and cream

Specications

Field of application Milk, cream and other dairy and food productsDescription Fully automatic processing based on UHT, PHE,

THE, SSHE, membrane ltration etc., depending onthe product

Capacity AnyTemperature 70 - 140C (160 - 280F), depending on product

and pH

Flexible, precise and cost-effective processing

Processing lines for production of ESL products

Advantages

Wide range of end-productsExperience in long-term (30 days plus) industrial fermtion applicationsLoop or batch fermentationSolid experience from many years of aseptic technoloapplicationsSpecialised in application of customer-owned process

Sterile technology

Specications

Field of application Chemical, dairy, food, pharma-ceutical industries

Description Industrial fermentation for a widerange of products, based onAPVs long history in UHT-applications. Since the inception ofits rst loop fermenter in 1998,APV has developed and imple-mented continuous and batchfermentation processes requiringsterile conditions

Capacity Industrial fermentation applica-tions from pilot-scale to produc-tion-scale

Technology and technical expertise for large-scale production under sterile oraseptic conditions


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AdvantagesModular systemEasy and fast installationOperator-friendlyPre-assembled and factory-testedAs option designed according to ASME, 3A

Specications

Field of application All UHT-treated liquid aseptic productsDescription Modular design comprising tank body, valve ba

CIP system and PLC system, and controlled fro

the UHT plantCapacity 2,000 - 30,000 l

(550 - 8,000 U.S. g)

Aseptic tank system with PLC system

Aseptic tank - SST

AdvantagesMobile tank, easy to move

Easy and fast installationOperator-friendlyPre-assembled and factory-tested

Specications

Field of application All UHT-treated liquid aseptic productsDescription Small aseptic tank for the pilot UHT plant.Capacity 500 l

(132 U.S. g)

Aseptic tank system with PLC system

Aseptic tank - SPT


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The non-aseptic part of the portfolioof thermal processing technologiescovers a wide range of heat treatmentunits and systems designed to ope-rate at maximum efciency in modernprocessing lines within Dairy, Food,Beverage and Brewery Industriesaround the world.

An example is pasteurization wherethe primary function is to reduce thenumber of micro-organisms (patho-genic) in food so that they are unlikelyto cause disease. The secondary func-tion of heat treatment is the physicaland chemical changes of the productwhich inuence the quality of the

end product. The choice of time andtemperature combination is thereforea matter of optimization in which bothmicrobiological effects and qualityaspects must be taken into account.The portfolio behind is based on manyyears of experience and thousands

of project references with differentapplications around the world. Onthat background we have differentstandardized systems adapted tospecic applications and/or specicsegments (or regulations). For examplethe standard Pasteurizer congurationis primarily designed for the Europeanmarket while the PMO Pasteurizer isprimarily designed for the US market. By using Reusable Engineering we aimto be more competitive. Further designobjectives are energy savings andreduced waste products - all offeringhigher protability and reduced impacton the environment.

Safety is paramount, all food legisla-tions can be adhered to with APVPasteurizers and all systems aredesigned for sanitary conditions andmade cleanable.

Options

PHE or THESeparator (non APV supply) (for separation of cream and standardization of milk)APVhomogeniser (for subdivision of particles or droplets and to create a stable emulsion or dispersion for further processing)APV Dearator (to avoid problems caused by dispersed air)APV CompoMaster (for milk fat standardization)Bactofuge (non-APV supply) or APV Microltration (to remove bacteria and spores from milk)

Specications

Field of application Any

Description The plant is designed for costefcient running, delivering upto 96% heat regeneration. Theplant is made as a unit

Capacity Any

Temperature Processing temperatures, thermi-sation, pasteurization (low/high)

AdvantagesFully automated linesHigh energy recovery for low operating costFlexible low-viscosity product rangeLow pressure dropOperator-friendlyAs option designed according to PMO and 3A

Engineered heat treatment system

Pasteurization and other non-aseptic systems


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AdvantagesHigh energy recovery for low operating costFlexible low-viscosity product rangeLow pressure dropPare Clip gaskets (non-glue)Operator-friendlyPre-assembled and factory-testedAs option designed according to ASME, PMO, 3A

Specications

Field of application Milk, avoured milk, coffeecream, cream, ice cream mix,milk shake, tea, coffee, juice,

Description The plant is designed for costefcient running, delivering uto 96% heat regeneration. Thplant is made as a unit

Capacity 100 - 30,000 l/h(27 - 8,000 U.S. g/h)

Temperature 5-72/85-5C(41-162/185-41F)

AdvantagesCan run bres and particlesHigh energy recovery, giving low running costFlexible low viscosity product rangeLow pressure dropOperator-friendlyPre-assembled and factory-tested

Specications

Field of application Milk, avoured milk, coffeecream, cream, ice cream mix,milk shake, tea, coffee, juice,

Description The plant is designed for costefcient running with a heatregeneration of up to 90%. Itis further designed for robustrunning and can stand pressudrops of up to 60 bar. The plais made as a unit

Capacity 100 - 30,000 l/h27 - 8,000 U.S. g/h

Temperature 5-72/85-5C41-162/185-41F

Plate pasteurization plant

General plate pasteurisation plant for the dairy and related industries

Turbular pasteurization plant

General tubular pasteurisation plant for the dairy and related industries


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AdvantagesVery high accuracy (computer controlled PU regulatioLowT between product and heating mediaLarge heat regeneration (up to 94%) with low-temperalling

Waste-saving design (beer/water zone)Turn down ratio 40% of nominal capacityConstant overpressure downstreamConstant monitoring and control of nal product

Controlled beer pasteurisation - PU pasteurizer

Specications

Field of application Brewery

Description The PU pasteurizer enablescontinuous, gentle and effec-tive heat treatment of beer andother carbonated drinks. ThePU pasteurizer ensures preci-sion temperature control at highworking pressures

Capacity 50 - 500 hl/h (1,000 - 10,000U.S. g/h)

Gentle and accurate heat treatment that protects delicate aromas and flavour


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The APV Innovation Centre coope-rates closely with APV companies

and customers around the world inorder to provide a constant stream ofinnovative, world-class solutions thatadd decisive competitive value to thebusinesses of our customers.

Located in Central Jutland, the heartof Danish dairy farming country, theCentre is the focal point of APVsdairy process development activities.

The APV Innovation Centre extendsits reach far beyond this, however,offering a raft of services for the food

These include after sales service,laboratory analyses, technical infor-

mation and training of APV employ-ees and APV customers.

The APV Innovation Centre lever-ages the extensive industry experi-ence and expertise of a permanentstaff of food technologists, processengineers and production engineerstogether with knowledge gained overmany years throughout the worldwide

APV Group to contribute activelyto all types of development, testingand application of APV equipment

to provide added value by minimisinwaste and energy requirements, or

by converting commodity ingredientinto new, competitive products.

Important keywords for the Centreare innovation, optimum plant di-mensioning, high-quality products,and up-to-date knowledge of marketrequirements. The trials are custom-tailored and can be performed in theInnovation Centre or on customer

site. All work on behalf of individuacustomers is subject to the strictestcondentiality and the highest stand

>

Research and development APV Innovation Centre


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Your local contact:

APV, An SPX BrandPasteursvej 18600 Silkeborg, Denmark Phone: +45 70 278 278 Fax: +45 70 278 330

For more information about our worldwide locations, approvals, certications, 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


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Documents

ThermalProcessionTechnology 6751 02-03-2009 GB Tcm20-20299[1]