Beverage Processing System

Transcription

1 Beverage Processing System The Beverage Processing System provided by Ecomax Industries can be catered to suit client preferences, making them automatic or semi-automatic as required. Ecomax Industries also offers customized solutions where particular sub-systems and components are altered to suit client requirements. While we offer the entire beverage processing system as a product, Ecomax Industries also offers the sub-systems and components that comprise the processing system and sub-systems as individual products. The following are the sub-systems and components that can be made available individually and also altered to suit client needs: 1. Raw syrup making system: The raw syrup making system is a fully automatic sugar syrup blending system, which can readily be integrated into any beverage process unit. The components of the raw syrup making system include: a. Sugar dissolving tank - This is a unit in the skid system where raw sugar is dissolved in water to create a syrup. Outlets, air vents and nozzles are provided. A venturi arrangement for efficient mixing of sugar and water is provided with the necessary connections and foot attachments. b. Shell and tube condenser corrugated type/phe condenser - Shell and tube condenser/phe condenser is designed to heat water and syrup from an ambient to a desired temperature. The shell and tube are fabricated out of SS 304/SS 316. A mixture of water and syrup collected in a tank is circulated with the help of a pump and is then heated by live steam in this condenser. All products coming in contact with water and syrup will be fabricated from Stainless Steel material. c. Recirculation pump - The recirculation pump circulates a mixture of water & sugar through shell & tube heat exchanger & back into the tank. This ensures that the syrup continues to remain in the desired concentration. d. SS Control Panel - The control panel uses PLCs for multiple operations such as pre rinsing, Clean in place, flushing cycles and milk production. It houses a data logger, I/P converters, A/V indicators for production cycle monitoring hooters and other control elements. e. Steam setup - This is a setup of valves, temperature indicators, strainers, pressure gauges and other instruments to regulate the temperature and quantity of steam that passes into the hot water heat exchanger.

2 f. Condensate setup - The condensate setup is a system consisting of a steam trap and by-pass valves intended to remove condensation from the steam line. g. Pre-coat tank - The pre-coat tank contains a substance which is used for precoating the filter paper in the filter press. This substance works as a filtering media. It is fabricated of food grade SS 3014/SS 316. It is provided with suitable inlets and outlets. Agitator and vortex breaker are also provided. h. Filter press - It is used to remove solid impurities from a fluid that requires filtration. It consists of filter paper which removes particulate impurities which may be suspended in the sugar solution. i. Raw syrup transfer pump - This pump is used to circulate syrup through the filter press and then transfer the syrup to ready syrup tanks through a double section chiller. j. Inline strainer - It is a pipe in pipe duplex type Inline strainer, which filters sugar syrup coming out of a dissolving vat. k. Syrup cooling PHE - This is a double section PHE which cools heated syrup to a desired temperature. It consists of a cooling section and a chilling section. l. SS pipes and fittings - Pipelines are used to connect components with each other and are fitted with various valves and control elements that ensure safe, efficient and trouble free flow of process fluid. 2. Beverage preparation system: In this section, the concentrate or pulp and sugar syrup is mixed together, homogenised and sent forward for pasteurization. The components of the beverage preparation system include: a. Simple syrup holding tank - The tank is used to store sugar syrup before it is pumped into a blending tank. It is constricted with food grade stainless steel and consists of a cylindrical body, a top dish and a bottom dish. Appropriate connections, stainless steel legs, level gauges, an agitator, a spray ball and other accessories are provided. b. Syrup transfer pump - This pump is used to transfer sugar syrup from syrup holding tank to blending tank. c. Beverage blending tank - The beverage blending tank is used to blend water, juice pulp and syrup before being homogenized and pumped into ready beverage tank. It is constructed of SS 304 or SS 316 and is designed to be completely sanitary.

3 d. Homogeniser - The homogenizer carries out the process of reducing the particle size of milk under conditions of extreme pressure, sheer, turbulence, acceleration and impact, to make it more stable and to give it a better texture. The effect is achieved by forcing the milk through a special homogenizing valve at a very high pressure. e. Mix transfer pump - The mix transfer pump is used to pump ready beverage from the tanks to a homogenizer. All components coming into direct contact with feed are SS 304 or SS 316 quality. The SS parts are finished to sanitary dairy standards. f. Ready beverage tank - The ready beverage tank is used to store homogenized beverage before being pumped into a pasteuriser. g. Ready beverage transfer pump - The pump will be used to pump ready beverage from tanks to pasteuriser system. All components which come into direct contact with the product are of SS 304 or SS 316 quality. The SS parts are finished to dairy standards. h. Master divert panel - The master divert panel is used to redirect process or cleaning fluid from and to different processing sections of the same plant. i. Control panel - The control panel is fabricated out of SS 304 sheets and houses starters, relays, fuses, motors and switches for various controls and instruments to maintain optimum flow and control of the skid. j. SS piping - Pipelines are used to connect components with each other and are fitted with various valves and control elements that ensure safe, efficient and trouble free flow of process fluid. 3. Pulp cutting section: The pulp cutting section is used to prepare a fruit pulp and water mixture for further processing into a beverage. The components of the pulp cutting section include: a. Pulp cutting table - This is used to open pulp tins and empty cans into a dump tank. It is also used as a platform to cut fruit manually with a knife. b. Dump tank - It is a collection tank for process fluid before it is transferred through pumps for further processing. c. Pulp transfer pump - The pulp transfer pump is used to transfer pulp to blending tanks. All the parts coming in contact with pulp product are made of sanitary SS 304 or SS 316 quality. 4. Concentrate dissolving system:

4 It is a blending tank in which water is introduced into the beverage concentrate and the mixture is agitated to produce a beverage. The components of the concentrate dissolving system include: a. Trolley mounted tank with agitator assembly - It forms part of the concentrate dosing system. It consists of a tank mounted on a trolley equipped with an agitator which allows for automatic mixing of concentrate and water to produce a solution of desired concentration to be introduced into the blending tanks with the aid of a pump that is also mounted on the same trolley. b. Pump to introduce concentrate - It is a pump that is attached to the trolley mounted tank with agitator and is used to pump the solution of desired concentration into the blending tank. 5. Skid mounted beverage pasteurization system: It is a system consisting of pumps, valves, pipes, pasteurizer, and control panel. The beverage is passed through the system until it reaches a desired temperature at which it is held for a pre-specified period of time for optimal pasteurization. The components of the skid mounted beverage pasteurization system include: a. Float balance tank - This is the first container, and point of entry, for the product to enter the skid system. Connections for no foam inlet, fluid outlet, and return/divert fluid are also provided. Level switches can be provided to ensure that no overflow occurs. b. Feed pump - It is a centrifugal pump which is used to feed blended juice into pasteuriser. c. Corrugated shell and tube heat exchanger/phe - It is used to heat process fluid to a desired temperature and subsequently cool the process fluid to a desired temperature, with the aid of heating and cooling media on the opposite side of tube/plate. d. Hot water PHE - This PHE heats water with steam. A steam inlet is provided which has a steam flow control valve and condensate outlet with steam trap and by pass arrangement. Thermo wells for hot water inlet and outlet are also provided. e. SS hot water pump - This pump circulates hot water through the milk heating and hot water generation sections of PHE.

5 f. Holding tube - Constructed with SS 304 or SS 316 pipes the holding coil is designed to hold the heated dairy product for a period sufficient enough for pasteurization. g. SS control panel - The control panel uses PLCs for multiple operations such as pre rinsing, clean-in-place, flushing cycles and milk production. It houses a data logger, I/P converters, A/V indicators for production cycle monitoring hooters and other control elements. h. Flow diversion valve - A flow diversion valve is used to divert insufficiently heated or cooled process fluid back into the float balance tank or to the blending tanks. i. SS 304 pipe and fittings - Pipelines are used to connect components with each other and are fitted with various valves and control elements that ensure safe, efficient and trouble free flow of process fluid. j. Steam control valve - It is a pneumatically operated, 2 port valve which is used to control the flow of steam into a hot water PHE in proportion to product temperature desired. k. Skid for pasteurizer - Fabricated out of SS 304 or SS 316 square tube, it is used to support all the equipment of a pasteurization system and the interconnecting piping in a compact layout. 6. Clean-in-Place System: The Clean-in-Place system can be integrated into other liquid processing systems for system cleaning purposes. CIP systems are available in two tank, three tank, and four tank types. Please visit our Clean-in-Place systems page for more details on the CIP system that can suit your requirements.