Innopas C

Innopas C
Pasteurizing Technology –
Safe and Effective
State-of-the-Art Technology –
The New Generation of Innopas C Pasteurizers
4
Pasteurizing with the New Innopas C –
The Safest and Most Effective Method of Preserving
6
Innopas C –
Compact Design with Maximum Flexibility
8
Easy to Transport – Quick to Install
10
Each Container is Well Underway
12
Reliable, Selective Treatment in Clean Surroundings
14
Saving Money with the Eco-Bus System
16
Regulated Temperatures and PUs Under Control
18
Intuitive Operation and Easy Data Acquisition
20
In Case You Need Assistance…
22
ReDiS – Remote Diagnostic Service –
The Eyes and Ears of Your Pasteurizer
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Innopas C
Pasteurization Technology from KHS –
Safety and Efficiency Right Down the Line!
3
Pasteurization Technology from KHS –
Safety and Efficiency Right Down the Line!
Do you want excellent pasteurizing results coupled with
optimized process flows, absolute taste stability, and at the
same time noticeably cut water and energy consumption
costs?
Then rely on KHS Innopas pasteurizing technology. It is
based on decades of experience, extensive know-how, and
continuous further development of proven technologies.
4
The specialists have repeatedly set milestones in the field
of pasteurization. Milestones including exact zone spraying
to ensure improved process quality and the Eco-Bus system
that reduces fresh water and energy consumption considerably by recuperating the water at various temperature levels.
The KHS PU control that ensures 100-percent
product safety and unaltered product taste
even during disruptions and enables the
double-deck version to process different
products and container types simultaneously.
All these features increase not only the
efficiency of your line but also the flexibility of
product changeover and thus overall product
design.
KHS’ most recent development is the completely new
modular concept of the
Innopas C incorporating
advantages such as a
smaller footprint, faster
shipping, less time required
for assembly, and an
innovative automatic waste
discharge system that offers
even more hygienic safety.
Place your trust in the KHS’
vast competence potential
in the field of pasteurization. Take advantage of it.
Get advice from the experts
5
Pasteurizing with the New Innopas C –
The Safest and Most Effective Method of Preserving
If you guarantee your customers consistently high
product quality coupled with maximum biological safety,
Cooling
Heating
you should rely on the new generation of pasteurizers
from KHS. Thermal treatment of sealed containers reliably
kills microorganisms and eliminates recontamination.
During pasteurization, the product is subjected to a
defined amount of heat that is controlled by a
temperature-time curve as the products pass through the
pasteurizer.
Knowing the temperature distribution inside containers during
heating and cooling is a basic prerequisite for successful
pasteurization.
The Innopas C is available with capacities ranging from
5,000 to 180,000 containers per hour depending on the
container size and the type of product.
6
Using the PU simulator, we are able to simulate the
temperature-time behavior for each product as early as the
project planning stage.
For you this means assured results by simulating
A tightly meshed temperature distribution grid inside the machine enables exact
calculation of the thermal effects to each individual container.
In addition to pasteurizing, the Innopas C can also be
implemented for recooling after hot filling or for heating
cold-filled beverages and other products.
This is made possible by the flexible basic concept.
Pasteurizer
Various applications of the Innopas C concept
Recooler
Heater
Innopas C
various operating conditions.
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Innopas C –
Compact Design with Maximum Flexibility
Five models of the Innopas C are available with seven
The Innopas product line offers single-deck and double-
different treatment widths of up to 7.2 meters and a
deck models equipped with single or double-lanes.
tightly meshed length grid.
Each deck and each track is equipped with its own active
This enables us to optimally your individual require-
spray and associated PU control.
ments and fulfill all of the special conditions
Your benefit: possible individual treatment of
prevailing in your plant.
various styles of container and types of product
simultaneously.
Five models in
conjunction with tightly
meshed length and
width grids make it
possible to meet locally
prevailing conditions
perfectly.
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Machine
type
Treatment width in decimeters
72
62
52
42
36
31
26
All components of each zone are clearly laid out in
a group around the associated spray pump. All sidemounted instruments are very easily accessible.
No servicing required underneath the machine.
Exceptionally easy to operate and service.
Piping and tanks are integrated in the bases of all
machines. No protruding components.
The result is a minimized footprint.
Clearly arranged layout around the spray pumps
required volume of water.
Minimum energy and water consumption even when
temperatures change in the individual zones.
Water supplied from the center of the machine
Innopas C
Optimum adaptation of water tank capacities to the
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Innopas C –
Easy to Transport – Quick to Install
The modular design makes it possible to assemble the
pasteurizer on-site within a minimum amount of time.
Installation can be completed within approximately
three days.
The pasteurizer is ready for operation quickly.
Each module is equipped with rollers.
This makes them easy to move. Only a small amount
of space is required for fast installation.
Due to the compact modular concept, lift trucks and
Fast and easy installation
forklifts can be used for final assembly of the Innopas C.
Cranes are no longer necessary.
This facilitates the assembly work and saves time
The practical, well-thought out modularity of the new
and money.
Innopas C is impressive.
The electrical lines of the ASI bus control and the pneu Unlike conventional concepts, all pre-assembled housing
matic component supply lines are delivered to your site
modules fit in normal size containers.
preassembled, ready for connection.
No more partial load shipping.
Plug and play. Time-saving and reliable.
You can expect considerably shorter shipping times
and lower shipping costs.
The components are preassembled at the factory
The tunnel modules are rolled onto the tanks
to the assembly position.
The pasteurizer is ready for operation
within a minimum amount of time.
Innopas C
The tanks and the compact piping modules
form the base frame of the pasteurizer.
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Innopas C –
Each Container is Well Underway
Plastic or stainless steel belts are available depending on
the type of container and product.
The stainless steel belts have a high tensile strength even
under high-temperature conditions, are rugged, durable,
maintenance-free, and are characterized by a long service
life.
The ideal means of conveying glass bottles.
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The filler automatically sends a signal to the Innopas C
the transition ledgers, they are particularly well suited for
to change over the product and container.
conveying cans and plastic bottles. An integrated center
A gap is automatically created after the last container
guide makes it possible for the belts to travel close to the
of a particular batch is filled. Mechanical pushovers
housing wall.
ensure that the products are clearly separated.
Optimum utilization of treatment width.
Smooth production operation during product or
container changeover.
Stop states are detected in advance by integrating the
control technology of the Innopas C in the line.
Less downtime cuts energy and water consumption.
Mechanical pushovers at the infeed and discharge of
the machine and integration in the line control.
Prerequisite for automatic product changeover
without interrupting the pasteurization process.
Mechanischer Überschub am Auslauf
Innopas C
The plastic belts are easy to install and service. Thanks to
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Innopas C –
Reliable, Selective Treatment in Clean Surroundings
Stainless steel ball blasted housing and piping surfaces.
Less dirt clinging to surfaces and thus improved microbiological status of the pasteurizer.
The resulting use of fewer chemicals lessens the
burden on the surface structure and cuts costs.
KHS stainless steel ball
blasted welding seam
A fine strainer belt running the entire length of the machine
effectively discharges all particles of dirt.
A fine strainer belt running the entire length of the machine
replaces conventional replaceable sieves.
Any dirt is automatically discharged to a container at
the drive station.
Glass blasted
welding seam
Effective waste discharge, no strainer cleaning, no
clogging of spray nozzles, greater process reliability.
Open-type design of the return strand separated from
the water flow.
Fast and easy access.
Automatic waste discharge with brushes and sprays.
No manual cleaning during production.
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The return strand separated from the water flow.
Particles of dirt are not allowed to enter the filtrate zone.
The Innopas C is equipped with a newly developed fullcone nozzle.
A key advantage is the exceptionally accurate spraying pattern.
This nozzle, more rugged than conventional nozzles,
can be installed without twisting.
This ensures flawless operation.
A simple system of clamps makes the nozzles quick and
easy to remove for maintenance.
This saves time and money.
Spray nozzles instead of trickling pans!
Active pressure spraying on both decks.
The durable plastic version of the new KHS clamp nozzle
with a stainless steel clip.
No spraying shadows or clogging.
Reliable uniform treatment of all containers.
The exact spraying pattern produced by the anti-twist mounted clamp nozzles ensure reliable and optimum water distribution
Innopas C
Prerequisite for consistent product quality!
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Innopas C –
Saving Money with the Eco-Bus System
Central heat exchanger installed
under the machine as standard
The Eco-Bus system (optional) temporarily stores the
The minimized use of water and energy without negatively
water used in the various phases of operation in separate
affecting the pasteurization results is the vision made real
warm and cold water tanks at the best temperature level
by the Innopas C.
for each phase.
For you this means noticeably lower fresh water and
Using the Eco-Bus system alone cuts the fresh water
energy consumption.
consumption in half in practical operation.
Innopas
Buffer Tank System
Gap In
WWT
Warm water tank
HWT
Hot water tank
CWT
Cold water tank
The water used in the various phases of operation is stored temporarily at the best temperature level for each phase
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Buffer tank volumes designed independent of the segment
The Innopas C buffer tank system can also be used to
sizes provide maximum water storage capacities.
flexibly integrate the heat and cold produced by other
Optimum heat recuperation utilizing the machine
operational processes.
base area.
Greater economy throughout the entire system.
0.34
Actual
Operation
0.30
0.28
0.26
0.24
0.22
0.20
100%
80%
90%
70%
Bottling line efficiency
Competition
KHS Eco-Bus
* Based on Central European cost structures
The Innopas C concept with its Eco-Bus system cuts operating costs considerably versus the competition
Innopas C
(power, water, heat)
Specific costs [€/hl]*
0.32
60%
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Innopas C –
Regulated Temperatures and PUs under Control
The current product temperature in each case is determined
by the exact position of the container and the temperature
of the spray applied at this position.
The process is monitored in each zone by two parallel,
separately queried temperature sensors and the measurement results are continuously compared.
Sensors mounted on gates and valves ensure flawless
pasteurizer operation.
Due to this built-in safety, the usual hourly check of PUs
The KHS PU control calculates the temperatures of all
containers in their current positions in the machine based
with the help of a thermograph is no longer necessary.
A random check of the control is sufficient.
on a dynamic heat transfer model defined for each type
of container.
The temperatures of the sprays are regulated throughout the entire process so that minimum tolerances are
adhered to during actual operation.
The efficient PU control guarantees consistently high product quality
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The KHS PU control can be adapted to incorporate
The process parameters are stored in the control for
additional minimum heat retention temperature and time
each product and are set automatically when the
requirements equally as well as to include other PU
product is selected.
formulas that describe the change in taste of the product
Other products and container types can be easily
for example.
added later.
Great flexibility handling your products.
High safety for uniform product quality thanks to
reproducible treatment settings.
the flow speed varies when connected to a line control.
KHS PU regulation can also be retrofitted to
The economy of the pasteurization process is
existing systems.
noticeably higher by connecting to a system control.
Contact our Service Dept. for details.
The control responds immediately to external influences
Innopas C
The PU control ensures perfect pasteurization results even if
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Innopas C –
Intuitive Operation and Easy Data Acquisition
The Innopas C operates fully automatically.
It is possible to place control terminal at the filler
or labeling machine for example. The simple control
of the pasteurizing process enables existing operating
personnel to also supervise the pasteurizer.
There is no need to station an operator at the
machine.
Clear visualization and easy touch screen handling.
Fast overview of current process statuses.
User-friendly man-machine interface for intuitive
By being able to install the operator terminal
panel at the filler, for example, the machine
operator on duty there is able to easily monitor
the pasteurization process.
and safe machine operation.
The clearly arranged layout of the process visualization provides a quick overview of all current
operating parameters and conditions
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You receive all product-related
information at a glance
The visualization includes many statistics.
This means that analyses can be carried out even
All information is recorded.
The visualization system can also be connected to
the in-house AIS.
Prerequisite for subsequent analyses and
quality control.
Easy access to all machine areas from the outside
reduces the time required for sanitizing and maintenance.
A portable maintenance platform (on both sides)
is available as an option.
Innopas C
during the ongoing production process.
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Innopas C – Special Features –
In Case You Need Assistance…
Faulty valve status signal
Air supply valve disrupted
Valve is jammed
Defective limit switch
Broken wire in the circuit.
(cable connections)
Check air supply
Have valve checked
Have an electrician check limit switch and
circuit
Selective operator prompting for fast assistance
The help system integrated in the Innopas C
Simply press the ”?” button and a help text will appear showing
offers you convenient assistance in correcting
the cause of a malfunction and instructions on
the problems shown by all malfunction
how to correct the problem.
indicators.
The structure of the help system is as follows:
1. Message
2. Identification of the malfunction
3. Cause
4. Remedy
This enables you to correct the problem quickly
and efficiently.
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ReDiS – Remote Diagnostic Service –
The Eyes and Ears of Your Pasteurizer
Leave the remote maintenance of the pasteurizer to
the KHS ReDiS single software. By turning a key-switch to
enable the software, error diagnostics and updates can
be carried out online quickly and efficiently.
The specialists from KHS are available immediately.
No time delay waiting for a technician to arrive.
All that is required for this service is an ISDN connection
or broadband access to the Internet as well as a system
implementation agreement.
Considerable benefits involving very little effort
Broadband Internet access
ISDN connection
Innopas C
for you!
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KHS Maschinen- und
Anlagenbau Aktiengesellschaft
Juchostrasse 20
D-44143 Dortmund, Germany
Tel +49 (231) 569-0
Fax +49 (231) 569-1541
E-mail [email protected]
Planiger Strasse 139-147
D-55543 Bad Kreuznach, Germany
Tel +49 (671) 852-0
Fax +49 (671) 852-2411
E-mail [email protected]
www.khs.com
30 1992-01-042/2 2 0805 HM
The information contained in this brochure
is non-binding.
Only the technical specifications of our quotes are
determinative with regard to design and scope of delivery.
Subject to design modifications.