Standard Pasteurizer Presentation

March 10, 2011
District Michigan
MBAA
Technical Meeting
Grand Ledge, MI
Presentation Agenda
„ Pasteurization Basics
„ Tunnel Pasteurization Technology
„ Flash Pasteurization Technology
„ Technology Comparison
„ Questions and Discussion
Theory and Objective of Pasteurization
„ Elevated levels of heat will kill organisms
„
„
„
Heat beer to arrest biological contamination
Destroy viability of yeast
Prevent post fermentation
„ Brewers want Pasteurize not Sterilize
„
„
Minimum temperature for target organisms
Limited Pasteurization units
Time and Temperature
Curve
Maintaining the
time/temperature
profile is key to
preserving the
process or
protecting against
under and over
pasteurization
Pasteurization – Lethal Effect
„ A lethal effect of 1 PU (Pasteurization Unit) is
obtained when product can be held at 140F for 1
minute
„ Brewers typically target 10PU’s to 15PU’s
„
„
Control of PU’s is essential
Elevated PU’s can affect flavor degradation
Measuring Pasteurization Units
„ Measure at “Cold Spot” of container
„
Probe position in container
„ Pasteurizer internal calculation
„
Using sensing devices and programming
„ Calculate PU’s
„
„
Time above 120F
Time in holding tube at Pasteurization temperature
Measuring Heat Transmission
TIME IN MINUTES
2 4 6 8 10 12 14 16 18 20 22 24 26 28
60.0
57.2
P.
54.4
51.7
A
125
M
TE
120
48.9
115
46.1
110
43.3
105
40.6
100
37.8
95
35.0
90
32.2
85
29.4
80
26.7
75
23.9
70
21.1
18.3
65
INITIAL BEER TEMP. 40 °F (4.4 °C)
SPRAY AT 140 °F (60 °C)
T00384
TEMPERATURE °C
130
CO VE
LD . T
SP EM
OT
P
135
TEMPERATURE °F
Cold Spot is
usually
located at
¼” to 1”
above the
center of the
bottom of
the container
.
140
PRODUCT TEMPERATURE
°C °F
62.2
144
61.7
143
2.09
Average 12.35 P.U.'s
1.74
Cold Spot 8.60 P.U.'s
61.1
142
1.45
60.6
141
1.20
60.0
140
1.00
59.4
139
0.83
58.9
138
0.69
58.3
57.8
57.2
137
136
135
0.57
0.48
0.39
56.1
133
0.27
48.9
120
0.025
0
5
10
15
MINUTES
LETHAL RATE P. U. 'S / MINUTE
Lethal Rate Curve
PU’s calculated for
product temperature
above 120ºF.
Area under the curve
equals the number of
PU’s achieved.
Cold spot PU’s less
than Average.
Pasteurization Unit Graph
TEMPERATURE °C
40.0
30.0
50 52 54 56
58 60 62 64
66 68 70
10 PU’s
20.0
30 sec
10.0
= 157F
1
PU / MINUTE =
-1
LOG 140 - °F
12.5
(°F - 140)
= 1.20226
1
PU / MINUTE =
-1
LOG 60 - °C
6.94
(°C - 60)
= 1.393
PU / MINUTE
7.0
5.0
3.0
10 PU’s
2.0
10 min
1.0
= 140F
0.7
0.5
0.3
0.2
0.1
0.03
120
130
140
150
TEMPERATURE °F
160
Barry-Wehmiller Advanced PU Limit
System
PU Accumulation
PU Accumulation Rate
1000.00
10.00
175
170
165
160
155
150
145
140
135
130
125
120
1.00
0.10
0.01
Product Temperature [deg F]
PU / minute
100.00
Validating Measurement
„ Independent validation for tunnel
„
„
„
Several manufacturers of independent PU
measuring devices
Measure time and temperature
Calculate and report PU values
„ Machine internal validation for flash
„
„
Redundancy on sensors
Micro analysis
Verifying Pasteurization
Independent
measurement is
capable with tunnel
technology only.
Redundancy can
help reliability
Types of Beer Pasteurization Technology
Two basic types of beer pasteurization
1.
Tunnel Pasteurization
2.
Flash Pasteurization
Tunnel Pasteurizer
Tunnel Pasteurizer Overview
„ General Description
„ Pasteurizer Features
„ Pasteurizer Systems
„ Operational Controls
„ Reporting/Recording
Pasteurizer – General Description
„ Length - Width
„ # of Decks
„ Features
„ Systems
Pasteurizer Features
„ End Casings
„ Removable
Top Covers
„ Container
Water BlowOff
„ Condensate
Return System
Pasteurizer Process Systems
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Regeneration Capability
Heating System
Belt and Drive System
Spray System
Pump Systems
PU Control
Controls, Alarms
Tunnel Pasteurizer Regeneration
Cold containers
entering require heat
Hot containers exiting
require cooling
Zoning
Set Point Balance
Maximum Regen
Compensation
Exit Temperature
Single Heat Exchanger System
Single Heat Exchanger with plate Heat Exchanger.
Closed Loop System with hot water available on
demand.
Basic Concepts
Single Heat Exchanger System
„ Benefits of the Single Heat
Exchanger System
„ Low Maintenance
„
„
„
Only one heat exchanger
Plate Heat exchanger
Efficient use of energy
„
„
Condensate return
Less Pump
Horsepower required
Typical Heat Exchanger Skid – Large
Machine
Pasteurizer Main Belt
„ Intralox 400 and 1900 with
Enduralox
„ Twentebelt Combinox and
Eyelink
„ Regina 3120
„ Rexnord 5997 with DTS-C
UHMW Wear Strip Attachment
Allow for UHMW expansion
Easy install and replacement
Main Drive SEW Motor/gearbox
Spray and Pump System
„ Pressurized water flow rate
„
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„
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„
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designed to optimize thermal
heat transfer rates
Up to 6.8gpm/ft²
Thermal Dynamic Models
Manual Blow Downs
Even flow across the deck
Predictable Heat Transfer
Removable spray headers
3 1/2” header, 3/8” nozzles
Spray System Filter
Screens
Redundancies for Maintaining Spray Consistency
„
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Belt side guides
Belt mesh pattern
Dual pump inlet screens
Spray header design
Spray header blow down
Filter Screen External Access Doors
Spray System Blow Down
PU Limiting
„ Hot Zones
„ Add cold water
to zone reservoir
„ Re-heat on start
up
Advanced PU Control System
„ Advanced PU Control System controls the
pasteurization process:
„ Guarantee very tight PU control
„ Preserve the process curve in stop/start
conditions
„ Move process to container if container can not
get to process
Possible to have hot water on
one header and cold water on
another header from the same
manifold
Utility Control Technology ‘IntelliFlow’
„ The IntelliFlow System:
„
„
„
„
Used in conjunction with Advanced PU Control
Water temperature separation technology
Eliminates requirement for water re-heating
Provides benefits of PU control without added
utility consumption
Pasteurizer Control Items
„ Sensors, proximity switches, instruments
„ Safeties and Alarms
Pasteurizer Safety and Alarms
„ Hot zone pumps 2º below set point for 30 seconds
will stop belt
„ Pressure sensors all zones below 2psi for 15
seconds stops pasteurizer
„ All levels satisfied before pasteurizer will start
„ Belt speed monitored by checking starwheel pulse
duration to time set in recipe
„ Drive overloads – spring and proximity
Pasteurizer Recording Capability
„ Data collected from Sensors:
„ Temperature of all zone sprays
„ Speed of belt
„ Levels
„ Data collected in the pasteurizer PLC
„ Data sent to remote storage
„ Data can be extracted to workable files
„ Reports can be generated
Flash Pasteurizer
Volutherm Series
Flash Pasteurizer
Flash Pasteurization
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Pasteurization occurs prior to filling
Short Time High Temperature (HTST)
Heat Exchanger (plate or tube)
Fixed or Variable flow rates
Pasteurization calculated by Holding Time and
Temperature
„ High Efficiency (90% regeneration)
„ Controls are Key!
Flash Pasteurizer 180 Hl/Hr
Flash Pasteurizer 320 Hl/Hr
Flash Pasteurizer 360 Hl/Hr
Flexibility to design
units to fit various
applications
Juice unit with Heat
Exchanger mounted
on the floor for
accessibility on
larger pasteurizers
Often times machines
can be designed to
handle different
products on the same
unit
Flash Pasteurizer – 250 Hl/Hr
Flash Pasteurizer Features
ƒ Constant PU Variable Flow rate Unit.
ƒ Pressure Balance System.
ƒ 90% Energy Recovery.
ƒ Status and Process Alarms.
ƒ Digital Paperless Chart Recorder.
ƒ Fully Automatic Operation.
Flash Pasteurizer Design
Flash Pasteurizer
Components
Product Flow Meter
An Electromagnetic flow measuring system is used to monitor the flow of the
product at the discharge of the pasteurizer.
Product Flow Control Valve
(Detail View)
4-20mA Electrical Input Signal.
Resulting in a 0-100% Valve opening.
Product Temperature Measurement
PT100 Temperature probes monitor the temperature of the fluids
Within the pasteurizer.
As the temperature changes the resistance measured by a
Transmitter fitted inside the temperature probe changes.
The input signal to the pasteurizer control system is electronic
4 – 20mA.
Product Temperature Control
Pressure Reducing Valve
A pressure reducing valve is designed for
maintaining the pressure downstream of the steam
supply valve to an adjusted set point value.
Set point approximately 2.0bar
The valve closes when the downstream
pressure rises.
Pneumatic Control Valve
The hot water that is used to raise the beer to the
required pasteurization temperature is heated using
steam controlled by the pneumatic controlled valve.
This valve uses a pneumatic control signal to adjust
The amount to which it opens and so the amount of
steam that can flow into the plate pack
Process Recording
„ Touch Screen HMI
„ Select recipes
„ Operational functions
„ Adjust parameters
„ Alarm displays
„ Digital Paperless Process Logger
„ Records temperatures
„ Records flow rates
„ Records pressures
„ CIP and Run modes
Process Recording
ƒTemperatures
ƒPressures
ƒCalculated PU’s
ƒProduction / CIP Flow rate
ƒProduction / CIP / SIP Mode
ƒProduct In Machine
Central System Operation
Central System Operation
Flash Pasteurizer – Benefits and Features
„ Performance tolerance to with in 1PU
„ Variable flow, variable temperature
„ Maximum regeneration
„ Quality monitoring, alarms, reports, archiving
„ Machine self-diagnostics
„ Operation safe-guards for PU protection
„ Gentle product handling (HTST)
„ Compact footprint, Low energy use
PROCESS COMPARISONS
Process Comparison Factors
„ Application Issues
„ Operational Issues
„ Quality Issues
„ Economic Issues
„ Equipment Issues
Application Issues
„ Tunnel
„ Wide range of products
„ Carbonated or non-carbonated
„ Container limitations
„ Flash
„ Wider range of products
„ Product limits for plate and frame
„ Carbonated or non-carbonated
Operational Issues
„ Tunnel
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Controls and Complexity can be less
More forgiving
Reduced requirement for micro control
Manual machine cleaning
PU Control required for line conditions
„ Flash
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Cleaning and Sanitation Increased
Line availability reduced
Enhanced microbiological testing
CIP systems are critical
Buffer systems for handling line conditions
Quality Issues
„ Tunnel
Taste affects possible with prolonged stops
„ Validation using independent device
„ Reduced requirement for micro control
„ Exit temperatures
„ Flash
„ Minimal taste affects
„ Potential for recontamination
„ Validation – trust sensors, redundancy
„ Ability to re-circulate
„ Disinfecting caps and containers – filler contact points
„
Economic Issues
„ Tunnel
High capital costs for new equipment and installation
„ Operating costs can be high
„ Reduced costs for monitoring quality
„ Increased line utilization
„ Flash
„ Capital cost can include warmer, filling room upgrades
„ High efficiency reduces utility cost (warmer?)
„ Less floor space required
„
Example Comparison for Flash and Tunnel
„ Example Selection:
„
Brewery
„
Bottle production line operating at 800bpm
ƒ Target PU’s at 10 +/- 2
ƒ Target BOT at 75°F
Example Comparison for Flash and
Tunnel
„ Equipment Cost
Flash Process
Volutherm 200B –
$300,000
Buffer Tank - $50,000
Warmer - $375,000
Clean Room – $275,000
Total equipment $1,000,000
Tunnel Process
New Double Deck sized
correctly to optimize utility
consumption and provide low
product exit temperatures
- $1,500,000
Example Comparison for Flash and
Tunnel
„ Utility Consumption
Flash Process
Volutherm 200B
Water - 140 gal/chase out
Steam – 8,000 btu/min
BWCo Warmer
Water – 0gpm normal
Steam - 31,500btu/min
Total Steam -39,500
btu/min
Tunnel Process
New Double Deck Tunnel
Water - 0gpm, running mode
- 100gpm run-out
24mins
Steam – 20,000 normal run
- 72,000 start-up
Avg. steam - ~
35,000btu/min
Example Comparison for Flash and
Tunnel
„ Floor space requirement
Flash Process
Tunnel Process
Volutherm 200B – 200 sq. ft.
Buffer tank and valves stand
- 80 sq. ft.
Warmer 826 SD
- 280 sq. ft.
New Double Deck Tunnel
1120 sq. ft.
Total - 480 sq. ft.
Summary of Process Comparison
„ Capital Cost – Similar when considering clean room
„ Utility Consumption – Similar when using warmer
„ Process Considerations – Culture change for flash
„ Cleaning Materials/Sanitizing Agents and Micro
Control requirements – Higher costs for flash
„ Available Packaging Line Time – Higher for tunnel
„ Floor Space – Flash has reduced space requirement
Time for a beer….
„Thanks for listening!