Efficient pasteurization for dairy applications Application Tetra Pak Pasteurizer for dairy applications is designed for continuous processing and pasteurization of market milk, cheese milk, yoghurt milk, cream, ice-cream mix and other low acid liquid dairy products. Tetra Pak Pasteurizer D provides a flexible solution with well-proven functions for all types of non-aseptic pasteurization. Highlights Heat treatment in the pasteurizer is typically based on Tetra Pak Plate Heat Exchangers Full production overview and control of the heating unit from the operator interface Target-based production with a possibility to queue actions and recipes Low-loss balance tank function for minimized mix phases Higher pressure in the downstream sections to minimize risk for contamination Easy maintenance Prepared for integration with Tetra Pak PlantMaster v6.4 High reliability for high efficiency Tetra Pak Pasteurizer D combines the best possible scope of supply with the lowest total cost of ownership throughout the complete production lifecycle. It also offers high food safety, with additional focus on efficiency, environmental load and reducing operational costs related to energy and water consumption for greater product savings. With intelligent automation, the pasteurizer enhances both machine and human capabilities to put the whole process in seamless synergy. The unit is created with operators at every level in mind, making it easy, safe and simple to maintain for minimal downtime.
Efficient pasteurization for dairy applications Working principle Tetra Pak Pasteurizer D is as standard automated to safeguard production. Production is strictly controlled by production recipes with processing parameters. Main process sequences can be divided into the following main steps: Disinfection Filling Production / circulation Emptying Intermediate cleaning Cleaning in place Before production the unit is disinfected by circulation of hot water for 20 minutes. After disinfection, the unit is cooled down and stabilised to production temperature. If there is a time gap between disinfection and production, the unit can be set in hibernation mode (optional). This is an energy conservation mode in which the energy consumption is decreased up to 85% compared to the hot water circulation mode by reducing the power, steam and water consumption. When downstream equipment is ready, production can start. Production starts by filling the unit with product via the balance tank. The product displaces the water/product mix to drain, white water tank or reject tank. The balance tank includes level control and CIP device, which safe-guards the gentle treatment of the product and ensures a high degree of cleanability. Before being homogenized in a Tetra Pak Homogenizer (option), the product is pre-heated in a Tetra Pak Plate Heat Exchanger (PHE) by the outgoing pasteurized product. Other matching optional sub-units include functions like deaeration, separation and fat-standardization. To ensure even heating of the product, final heating takes place in the PHE by means of an indirect hot water circuit. The product is held in a climbing holding cell for the required period of time. If the pasteurization temperature gets too low, the product is diverted back to the balance tank. After the holding cell, the product is cooled by the incoming product in the regenerative section of the PHE. As a safety feature the pressure on the pasteurized side is higher than on the non-pasteurized side. If required, the product is further cooled by ice water in the final cooling section. In order to prolong the production period between full cleaning in place (CIP) procedures, an Intermediate Cleaning (IC) can be performed. When IC is ordered during production, the product is displaced by hot water before the cleaning phase starts. During the IC sequences, the holding cell is kept above pasteurization temperature at all times. The IC is performed with lye, followed by hot water rinse. Production can then continue, by filling the unit with product. If product supply fails or a failure at the receiving unit occurs, the unit goes to product recirculation. After each complete production run, the unit is cleaned with both acid and lye. These can be supplied by a central CIP system or the chemicals may be automatically dosed directly into the balance tank by an internal cleaning system (optional). The operator interface is used for process monitoring and selection of required functions. The process controller controls and supervises both the basic process and optional units for deaeration, separation, standardization and homogenization. The unit will continuously log pasteuriza-tion temperature, pre-sterilization temperature, cooling temperatures, outlet temperature and the position of the flow diversion valve (optional). A data logging system in the unit keeps track of date of production, processed volumes, processing times, type of CIP performed etc. Using a serial protocol, or optional I/O connections, the process controller can communicate with objects like tanks for raw and finished milk. Processing parameters Market Cheese Yoghurt Ice cream Standard temperature programs milk milk milk Cream mix Inlet temperature (C ) 4 4 4 4-8/60 50 Pasteurization temperature (C ) 74 74 95 82 90 Holding time(s) 15 15 300 15 30 Separation and homogenization temperature (C ) ~55 ~60-~75 ~75 Outlet temperature (C ) 4 28-32 43 8-10 4 Dearation temperature (C ) ~59 64 (70-75) Heat regeneration standard/eco Heating (%) 85/93 85/93 85/93 80/88 80/88
Example flowchart Pasteurizer for standardized milk Capacities Milk, Yoghurt & Cheese milk pasteurization: 2,000 to 60,000 l/h Cream and Ice-cream mix pasteurization: 2,000 up to 15,000 l/h Main unit Product balance tank (BT) with level control Centrifugal product feed pump Flow control (frequency controlled feed pump, or homogenizer as timing device) Free-standing Tetra Pak Plate Heat Exchanger (PHE) with cooling, regenerative and heating sections, including protection sheets Climbing holding tube, mounted on a separate frame. Hot water unit, incl. brazed PHE, pump, steam valve and trap, expansion vessel, shut-off valves, etc Control panel in stainless steel, including process controller (PLC), solenoid valves and motor starters Automated PLC operated sequences Automated pasteurization temperature control Automated flow diversion, interlocked with temperature failure before and after the holding tube Automated product circulation when fault occurs Automated process interaction with up and downstream equipment, such as source and destination tanks and CIP Automated fault supervision and action for pumps, temperatures and flow diversion valve Registration of pasteurization and outlet temperatures Pneumatic, remote controlled sanitary valves Product piping and components in stainless steel Set of pipes, bends, valves, internal signal wiring, required for the pre-erection of the system
Efficient pasteurization for dairy applications Optional groups and selection of options Automation and control PLC Control system: Siemens or Rockwell 21 Industrial PC operator panel mounted in the control cabinet Free-standing PC as operator interface (HMI) Tetra Pak PlantMaster integration Uninterrupted Power Supply (UPS) Control panel air cooling Temperatures and holding time for milk Automatic control of high inlet and/or outlet temperature High pasteurization temperature (>95 C) Constant temperature to separator and/or homogenizer Extended holding time Continuous climbing holding cell Connections to sub units Deaerator, homogenizer, separator, standardization unit and spiral holding cell Production efficiency, safety and convenience Reduced steam and ice water consumption with Eco heating Hot divert with position feedback Supervision of differential pressure Coarse strainer after product feed pump Integrated leakage test Closed water loop for cooling of deaerator condenser Variable frequency drives on pumps Integrated surplus cream cooler Additional sub-modules The following Tetra Pak sub-units are possible to control from the pasteurization HMI: Deaeration unit Tetra Pak Separator Tetra Pak Bactofuge Tetra Pak Standardization unit Tetra Pak Homogenizer for full or partial homogenization Technical Data Approx. consumption data for Tetra Pak Pasteurizer for Dairy, 2, 000 35, 000 l/h and per 1, 000 l of market milk. During production Standard Eco Heating Steam bar* ~21 kg/h ~10 kg/h Ice water, 3 bar, 2C (outlet 7C ) ~2,200 l/h * Steam 3 bar: 50 kg/h peak during disinfection No ice water consumption during disinfection or during hibernation Instrument air: 50 Nl/m, total not depending of capacity Electricity: 7-15 kw, depending on capacity and options excl. connected sub-modules ~1,050 l/h Rinsing water during CIP, 3 bar ~945 l/h ~1,260 l/h Cleaning CIP from CIP station or from internal CIP system Internal CIP system with automated addition of CIP detergent into the balance tank via ratio dosing or header batch system CIP recipe editor with possibility to design unique cleaning recipes
Environment Tetra Pak Pasteurizer is built in a modular design, which makes it easy to rebuild and adapt for new duties The unit consists of parts that can be separated for recycling purposes Dimensions Approximate measurements including required service are in mm. Dimensional drawing shows optional sub-units for sepa-ration, standardization, homogenization and deaeration Specific measurements will vary depending on capacity and configuration
Layout Tetra Pak International S.A., 2018, GB We reserve the rights to introduce design modifications without prior notice. Tetra Pak, and PROTECTS WHAT S GOOD are trademarks belonging to the Tetra Pak Group. www.tetrapak.com