Tetra Pak® Pasteurizer PF

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Tetra Pak® Pasteurizer PF
Tetra Pak® Pasteurizer PF
Efficient pasteurization for ambient or hot filling Prepared Food production
Application
Maximizing versatility and efficiency
The Tetra Pak Pasteurizer for prepared foods is an investment efficient and versatile continuous processing unit. It
is aimed for indirect heating and cooling of desserts, fruit
preparation, soups, sauces, tomato preparations and baby
food as well as other low or high acid viscous products
with or without particles. The unit can be equipped
with different types of heat exchangers, depending on
application. The pasteurizer is available as a stand-alone
unit or as part of a complete line concept.
Tetra Pak Pasteurizer PF, makes it possible to produce
high quality products at low operation costs. Using heat
generation design, when applicable on water side, it
offers optimized energy consumption in a wide range of
regenerative heating.
®
Highlights
• Available with either tubular or plate heat
exchangers to optimize configuration for best
design and efficiency
• Featuring consistent high food quality, enabled
by full traceability with the Advanced Automation
Solution Tetra PlantMaster™
• Ensures uncompromising food safety, due to high
hygienic design elements according to EHEDG
• Optimizes operational efficiency, due to long running
time and minimized energy consumption
• Adaptable cleaning program to secure food safety
and optimized production efficiency
• Guaranteed performance, e.g. running time,
product loss etc.
Tubular heat exchanger with floating protection system
minimizes maintenance and eliminates cracks in the tube.
For corrosive products, such as ketchup, corrosion-resistant
material like SMO254 is used. Protection panels in stainless steel lower the energy losses with up to 15%. Straight
tubes enable visual inspection if needed. Plate heat exchanger with optimized chevron and distribution pattern
maximizes heat transfer efficiency. The plate heat exchanger
is easy to open, which minimizes downtime at service. For
products containing high salt content, e.g. soy sauce,
titanium plates are used.
The unit offers optimal versatility with possibility to produce
a wide range of products at different viscosities, smooth or
with particles up to 9 mm in diameter. Option with aseptic
hibernation function saves energy up to 75% during sterile
water circulation. The optional pressurised internal sterilisation loop minimizes energy consumption during start-up
and water circulation. Advanced automation for reduced
human error and maintained product quality. Logging of
process parameters enables traceability for food safety.
Working principle
Capacity
The module is fully automated using PLC control for safe
operation and production. The operation can be divided
into four steps:
• Pre-sterilization
• Production
• Intermediate cleaning
• CIP (Cleaning-In-Place)
The capacity range for Tetra Pak® Pasteurizer depends on
the application, see example in chart. For other capacities,
please contact your Tetra Pak representative for more
information.
Before production can start it is necessary to sterilize the
aseptic area of the unit by circulating pressurized hot water.
An internal sterilizing loop minimizes the energy consumption
and start-up time. After sterilization the unit is cooled down
step by step to production temperature. Finally, sterile water
is circulated through the production unit.
When the receiving equipment is ready production starts by
filling the unit with product, displacing the water to drain.
The water/product mix phase can be sent to drain or reject
tank. Thereafter continuous production is running.
If product supply or receiving equipment fails, sterile
water displaces the product and the pasteurizer goes into
sterile circulation. The product is heated in either tubular
or plate heat exchangers by an indirect hot water circuit.
The product passes through a holding tube for the required
period of time. A temperature guard automatically monitors
the product temperature after the holding tube.
If the temperature drops below the pre-set value, an alarm
will be activated, production will automatically cease and the
receiving equipment will close. Cooling to filling temperature
takes place in additional tubular or plate heat exchangers.
In order to prolong the production period between CIP, an
intermediate cleaning can be performed. When intermediate
cleaning is selected, the product is displaced by sterile water
before cleaning starts. During the intermediate cleaning
sequences, the holding tube is kept at the sterilization
temperature, thus the aseptic parts in the module remain
sterile. The intermediate cleaning can be performed either
with lye only or lye and acid flush. This enables longer
available production time on the pasteurizer before full
CIP is required. After each production run, the module
undergoes CIP with both lye and acid. The CIP sequences
can be configured for optimized cleaning result.
Processing parameters
Temperature program is specific for each application.
Standard equipment
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Product balance tank with level control
Frequency controlled product pump
Product flow meter
Centrifugal water pump
Water flow meter
Brazed plate heat exchangers for heating in
the water circuit
Centrifugal CIP booster pump
Valves, pipes, fittings
Frequency converters, mounted on the frame
Pre-wired signal/power cables
Tubular or plate heat exchanger, depending on
application
Control panel mounted on the main module
Pneumatic, remote-controlled sanitary valves
Product piping in AISI 316
Set of pipes, bends, valves, internal signal wiring, pipes
for signal wiring and fittings required for the pre-erection
of the system
Factory pre-assembled and tested before delivery
Engineering, programming
Technical documentation in European Economic Area
(EEA) official languages
Tetra Pak Pasteurizer PF
Example of production parameters for ketchup
Pasteurization
Sterilization
Ambient filling
Hot filling
Ambient filling
30
30
30
Deaeration temperature °C:
70-75
70-75
70-75
Homogenization temperature °C:
65-70
65-70
65-70
Pasteurization temperature °C:
95-98
95-98
>121
30
30
30
Product inlet temperature °C:
Holding time (Volumetric), seconds:
Product outlet temperature °C:
30
85-95
30
Pre-sterilization temperature °C:
98-110
98-110
>121
30
30
30
Pre-sterilization time, minutes:
* Temperature program for other products, please contact your local representative
Control panel
Tetra Pak® Pasteurizer PF uses a PLC based control system
Type Siemens. The HMI is Type B&R. The control system is
prepared for integration with Tetra PlantMaster™.
Optional equipment
Food safety
• SMO254 material in tubular heat exchanger and
titanium in plate heat exchanger for corrosive products
• Positive product pressure and pressure supervision
Cleaning-In-Place (CIP)
• Ratio dosing of CIP detergents
• Conductivity switch for supervision of CIP media change
• Back-flush cleaning of heat exchanger for products
containing fibres
Operational efficiency
• Automatic CIP of balance tank
• Energy hibernation (EH) for reduced energy
consumption
• Different levels of heat recovery
Special food treatment
• High temperature program for product safety
• Tetra Alrox® deaerator for product quality and long
running time
• Multiple holding tubes
• TetraPak® Homogenizer for product quality
Automation and control
• Air cooling unit
• UPS, Uninterrupted Power Supply
• Relay communication
• HMI 21.5’’ full HD TFT display and visualization
Flow charts
Tower/Cooling
water
PHE-based
From filler or
storage tank
Product reject
To filler or
storage tank
Product inlet
Steam
From filler or
storage tank
THE-based
Tower
water
Product reject
To filler or
storage tank
Product inlet
Ice water
Steam
Tower
water
Consumption data (For ambient filling of ketchup 5,000 kg/h)
Media
Design
pressure
Consumption
Pre-sterilization
Consumption
Production
Consumption
CIP
Steam
–
6 bar
1,065 kg/h *
762 kg/h
593 kg/h *
Instrument air
–
6 bar
50 Nl/min
50 Nl/min
200 Nl/min *
Potable water
15°C
3 bar
5,000 l/h *
600 l/h
11,290 l/h *
Ice water
2°C
3 bar
30,000 l/h **
30,000 l/h
2
Tower
water
Capacity
3
4
s
Amax30°CB
C
D 3 bar E
F
G – J*
Rev
odule
3200
2400
*5000
No orl/h
low consumption
during circulation. ** During pre-sterilization above 100°C.
izer PFS
or DD 500
1800
4800
3000 - 5000 l/h
or DD 750
5000Media
- 10 000 l/h
1800
5200
Voltage
Consumption
Note
ex 200, 200 bar 3000 - 5000 l/h
800 1310 1540 1000 1000 1530
Homogenizer not
3-phase power
380V/50Hz
25 kW
changer THE
5000 l/h
1650
included
1-phase power
220V/50Hz
1 kW
height of the equipment.
nal free space required for service and maintenance above.
tor: 1000mm
Module: 650mm
5
6
30,000 l/h
–
7
–
Description
1000
Dimensions (Example for 5,000 kg/h ketchup)
Homogenizer
Deaerator
1000
1540
1800
Feed Module
1200
3200
800
50
1310
1000
1700
Branded Processing Unit Layout
Tetra Pak® Pasteurizer PFS
Standard Layout THE
Serial No
We reserve the rights to introduce design modifications without prior notice, Tetra Pak, ,
PROTECTS WHAT’S GOOD, Tetra PlantMaster are trademarks belonging to the Tetra Pak Group.
www.tetrapak.com
-
Issued By
CEA
Appr. By
Date
Format
Template
Scale
Document No
© Tetra Pak International S.A., 2015, 40692, GB
760
1020
THE
1800
1
Design
temperature
ESTE 2014-10-24
A3
1:50
File N
326
-
32650-210