P R O C E S S I N G S Y S T E M S I nnovative Technology & Processing Lines In technical collaboration with HRS International Ltd., UK
HRS Process Systems Limited (HRS PSL) is part of the UK based HRS Grop which is a forernner in heat transfer technology with over a decade of expertise, providing sstainable and ctting edge heat transfer soltions to the process indstry. Armed with ISO 9001: 2008 certification, ASME U stamp accreditation, high rating from CRISIL and honored with the prestigios UK Trade and Investment India Bsiness Awards 2007 in the Innovation of the year category, HRS is dedicated to working closely with cstomers and helping them stay ahead with its nmatched process eqipment expertise. Or state-of-the-art facility near Pne (India) follows the best practices for manfactring or entire range of heat exchangers and heat exchanger based systems. HRS prodct range incldes ECOFLUX* Corrgated Tbe Heat Exchangers (CTHE), ECOFLUX* Smooth Tbe Heat Exchangers (STHE), HRS FUNKE Plate Heat Exchangers (PHE), UNICUS Scraped Srface Heat Exchangers and heat exchanger based systems; and pasterisers, aseptic steriliser and filler, evaporators, UHT systems for frits, vegetables, beverages, dairy and ntraceticals. In addition to worldwide presence, HRS Grop has a research centre in Spain, where development is carried ot on processing techniqes for the food indstry. This enables HRS to offer innovative soltions enhancing technological competitiveness. Throgh a proven track record in design, manfactring and impeccable services spport, HRS has become trsted name in the indstry! Why Choose HRS? Or Innovative Prodct Range l ECOFLUX* CTHE l ECOFLUX* STHE l HRS Fnke Plate Heat Exchanger l UNICUS* Scraped Srface Heat Exchanger l Hygienic Piston Pmp l Aseptic Filler Total Integrated Soltions for Food / Frit / Beverage / Dairy & Ntraceticals l Pasterisers l HRS Monobloc* l HRS ParaDice* l Evaporator l CIP Systems l UHT Systems l Ntracetical Processing Systems l Beverage Processing Lines l Ready-to-eat Food Processing Lines l l l l Global Expertise and References Over 9000 installed nits in a decade Qality heat transfer soltions ensring sstainability with a competitive edge Global manfactring facility for HRS Grop l Innovative Technology l Application Engineering l Cstomised Soltions l Impeccable Services Spport
Innovative Soltions for Food Indstry Food Systems Overview HRS provides an array of innovative, hygienic heat exchangers and well atomated systems for the food processing indstry. Or soltions are designed to meet the increasing demands for enhanced capacities, ninterrpted processes and at the same time meet the stringent qality norms, reglations and safety standards of the domestic and international markets. Hygienic Piston Pmp ECOFLUX* CTHE CIP Systems UNICUS* SSHE HRS Fnke PHE Plp Pasteriser Evaporator Ntracetical Processing Systems UHT Systems HRS Monobloc* (Aseptic Steriliser& Filler) Beverage Processing Lines HRS ParaDice*
ECOFLUX* Corrgated Tbe Heat Exchangers (CTHE) The development of corrgated tbes is perhaps the most exciting advancement in heat transfer technology. HRS has mastered the making of corrgated tbe to enable different flow regimes spiral at the core and eddies at periphery. This avoids the formation of the bondary layer, thereby boosting the heat transfer coefficient higher at low Reynolds nmber with minimm increase in pressre loss in an exceptionally compact space.. ECOFLUX* Corrgated Tbe Heat Exchangers are specially designed and manfactred according to international standards inclding TEMA, ASME, PED with design programs sch as ChemCAD, HTRI, SolidWorks, etc. These eqipments for the food processing sector are made to the gidelines of Eropean Pressre Eqipment Directive and also for Food and Drgs Administration (FDA & EHDGE). ECOFLUX* Models MI Series : Mltitbe heat exchanger is especially designed for food indstry. The inner corrgated tbes carry the process media and corrgated shell carries service media. AS Series : The annlar space version is a tbe-in-tbe-in-tbe heat exchanger. The innermost tbe and oter tbe carries the service media while the process media passes throgh the annls between these two tbes. Advantages Trblence is created at low flid velocities to enhance heat transfer Foling on tbe srface is minimized Smooth indented inner profile ensres easy cleaning High response to CIP enables heat transfer in viscos prodcts Uniform thermal processing K Series : Corrgated tbes are bndled into smooth profile shell. This heat exchanger is designed for varios indstrial applications. DT Series : The monotbe is tbe-in-tbe heat exchanger. While the inner tbe carries the process media, the oter tbe carries the service media. Pre-heating, Heating, Cooling, Chilling, Pasterisation, Sterilisation, Evaporation
Innovative Soltions for Food Indstry HRS Fnke Plate Heat Exchanger (PHE) HRS has acqired exclsive rights by the way of license manfactring agreement for design, manfactre, spply and service of Plate Heat Exchangers, with FUNKE Warmeastascher GmbH! HRS Fnke Plate Heat Exchangers are sed for specialized applications in food and dairy indstry. The range incorporates pressed, herringbone patterned heat transfer plates, monted in an alternate inverse formation to create two channels, one for each flid. A large nmber of points of spport are created where the pressings intersect, which leads to a high level of trblence and sbseqently excellent heat transfer properties. Featres Well-researched in-hose design Variations in plate embossing for highest efficiency Available in a range of SS, exotic materials to sit the process needs Mlti section nits consisting two or more plate packs separated by intermediate plate or C-Plates Advantages Redction in operational downtime de to gleless clip type gaskets Secred seal with nmber of two-pronged clips that slide beneath the plate to hold the gasket Avoid cross contamination of two flids by doble seal arrangement Ideal for Heating, Cooling, Chilling, Pasterisation, Sterilisation UNICUS Scraped Srface Heat Exchangers UNICUS Scraped Srface Heat Exchanger is a specially developed patented prodct with a niqe scraping mechanism which optimizes the heat exchange area thereby enhancing the heat transfer coefficient for high viscosity / foling applications. This is specially advantageos for processing viscos, particlate prodcts. Heating, Cooling, Chilling, Pasterisation, Evaporation and Aseptic Processing of high viscosity, Fibros and particlate prodcts like frit jices / fibers / dices, frit plp, prees, food paste, yoghrt, pdding, vegetable pieces, sops Featres & Advantages Patented non-foling scrapping mechanism redces prodction loss Lower indced shear stress in the prodct, Prodct particle integrity is maintained Hygienic design to global food processing eqipment norms, inclding certifications High heat transfer coefficient, increase in trblence, even at low velocity for viscos prodcts Low maintenance cost as no rotating parts
Piston Pmp Clean-in-Place (CIP) Systems HRS piston pmp is hydralically operated positive displacement pmp that has been designed for pmping delicate and particlate foods. HRS Piston Pmp is of a completely hygienic design, and incorporates a separator fitted between the pmp and the hydralic chamber to ensre that there is no contact between the prodct and hydralic oil. The hygienic design combined with a perfect response to CIP cleaning makes this pmp sited to food processing applications where prodct integrity and shape mst be garanteed, to maintain both appearance and ntritional qality. The technology of Clean-in-Place (CIP) is vital in food indstry to have hygienic and aseptic process environment to meet food safety standards like HACCP and ISO. CIP allows cleaning of the interior srfaces of pipes, vessels, process eqipment and other associated fittings withot disassembly. Usally, CIP is carried ot with chemical soltions with castic soda or similar bases and acids like nitric acid, to clean the organic and inorganic solid deposits on the tbe srfaces, thereby eliminating prodct contamination Integrated Atomated CIP Station HRS excels in design and spply of bilt-in sophisticated CIP systems advantageos over the conventional system which enable optimm consmption of water, chemicals, steam and power, thereby decreasing efflent discharge. The CIP soltion is heated in heat exchangers sing steam and condensate setp. Mltiple tanks are provided each for water, castic and acid soltions. Selection of centrifgal pmps, CIP circit design and tank sizing is done on the basis of plant reqirements. In large systems, mix proof valves are provided to carry prodction and CIP in the same processing area. Featres Single skid monted eqipment for easy installation and mobility Sitable velocities can be maintained for effective cleaning Highly atomated with sensors, pnematic valves and PLC based controls CIP by single ser operation of whole plant from one location Data acqisition with SCADA Design conformation with 3A, USDA, FDA and PMO standards Featres Handle particlate prodcts delicately No prodct breakage; maintains prodct integrity\ Hygienic design, perfect response to CIP No seals in contact with prodct Self priming and will draw the prodct from the storage vessel Can work nder vacm Variants in a range of diameters to sit the process CIP Systems find applications across all types of food, frits, dairy, confectionary and many more indstries to ensre efficient, easy maintenance and hygienic process environment.
Innovative Soltions for Food Indstry ParaDice * HRS ParaDice* is a niqe offering from HRS Process Systems for dices and ready-to-eat food processing indstry. This system is capable of processing frit dices / vegetable dices/ particlate foods withot any damage! The dices are pmped sing HRS Hygienic Piston Pmp and treated in the highly efficient ECOFLUX* DT Series Heat Exchangers. These particlate foods are pasterised for hot fill or aseptically processed for filling in aseptic containers. This niqe technology opens p a hge potential of applications for food processing, to ensre better shelf life, natral taste and strctre for a range of foods. Featres ECOFLUX* CTHE 'DT' series with specially designed 'dimpled pattern tbes for rapid, homogeneos heat transfer HRS Hygienic Piston Pmp BP Series is the core of the system for handling particlates Closed loop hot water system with ECOFLUX* CTHE for steam economy Sanitary type valves, feed/ balance tank Integrated CIP system PLC based control panel with SCADA Processing of dices/ particlate foods for end se in: and viscos - Frit bases, dices, extracts and toppings, cstards and pddings, sops, saces, ice cream with particles, salad dressing and spreads, fillings and coatings Processing of Ready-to-eat convenience foods, Indian crries, mixes, mash, prees Blanching and chilling of vegetables Continos rice cooking Advantages Retention of natral color and flavor of prodct Processing of whole dices, leaves withot breakage Hygienic design Gives better prodct shelf life Controlled process atomation for easy operation Energy efficient CIP for hassle free maintenance
Plp Preheater & Pasteriser Plp or pree typically has a higher fiber content and considerable plant celllar material in the sspension compared with jice. Concentrated plp has more fibres and sgar per volme compared to single strength plp. HRS PSL has revoltionized the frit plp, especially mango plp indstry with advanced systems for preheating and pasterisation of frit plp. HRS ECOFLUX* based pasteriser heats the prodct pto desired temperatre and holding it for few seconds for inactivation of microbes, followed by filling in cans to ensre high prodct shelf life. The atomatic control panel provided with the pasteriser allows minimm intervention of operator thereby redcing hman errors. HRS PSL also offers systems for chilling plp sing tower water and chilled glycol for frozen plp filling and storage. Featres ECOFLUX* MI series heat exchangers, skid and skid-monted balance tank Hygienic, screw type positive displacement pmp and sanitary type flow diversion valves CIP pmp for faster cleaning of entire system Closed loop hot water system consisting of ECOFLUX* CTHE 'K' series Integration with atomatic can filling station for ninterrpted prodction PLC based instrment control panel inclding SCADA provision Advantages Cstomized designs to sit varied capacities Indirect, fast and niform prodct heating sing pressrized water Long prodctive hors de to niqe designing of heat exchangers Branded system components and process control instrments De-aerator eliminates weight variation in filling Fast CIP and nearly zero maintenance Retention of natral color, flavor and aroma of prodct Frit prees, concentrates, confectionary bases Tomato ketchp, Plp of mango, orange, gava and many more frits
Innovative Soltions for Food Indstry Evaporator Handling of large volmes of liqid prodcts has always been a challenge in food applications. Concentrating frit plps for redction of volme by redction in water content gives longer shelf life to the prodct and makes it easy for blk transportation. The concept of evaporation has evolved from these reqirements. Evaporation is the process of vaporizing the water from a soltion to generate concentrated prodct. HRS provides well engineered Evaporation Systems incorporating or specialized range of heat exchangers to sit the prodct thermal stability, with capacities ranging pto 16 tons/ hr. Advantages Optimm tilization of thermal energy (Steam) can be achieved in mltiple effects with live steam Controlled operating condition for prodct levels and retention time Scaling retardation de to optimm velocity of liqid in tbes Easy to clean CIP system Operator friendly PLC based system Stability of operation and capacity of longer rn period giving better payback on investment Key Components Evaporator calendria Vapor Separator Srface Condenser Deaeration/ Vacm System Prodct Pmp / Condensate Pmp CIP Cleaning System Condensate Recovery PLC based Atomation Frits and vegetables plps, prees and concentrates
Aseptic Filler Aseptic packaging allows storing prodct processed in steriliser with excellent microbiological qality at ambient temperatre. This facilitates storage and transportation. The aseptic filler series from HRS Aseptic Filler 200 and HRS Aseptic Filler - 1000, designed and manfactred by HRS, provides soltion for filling liqid food in aseptic bags for the food processing indstry. Featres and Advantages Atomatic filling heads, complete strctre with stainless steel pallet conveying system Designed to fill high and low acid flids, concentrates and particlate prodcts The atomatic head design provides high filling speed, No rotating platform is reqired Flexible to fill aseptic bags (capacity ranging from 10 to 1000 L) throgh 1 or 2 spots Weighing conveyor platform with control on the filling process by load cell based system Pressred hot water/ sanitary steam responsible for sterilising the prodct lines (SIP), filling chamber and seals System of clamping bag edges to the filling heads to avoid tension between spot and bag Completely hygienic operations by atomatic CIP cleaning system Aseptic 3 way valve that allows only the sterile prodct into the filler High pressre sanitary steam is sed for sterilisation of the fitment, cap and exposed parts before each filling cycle Precise weight control and labeling of drms. Incldes mass flow meter and load cells in the filling and weighing platform Pnematic system allowing condensates discharge dring filling process PLC self control system to continosly check the conditions that provides high reliability in the filling process Aseptic filling for a range of foods sch as frit and vegetable plps, prees, particlates and concentrates For mango, tomato, orange, gava and many more
Innovative Soltions for Food Indstry HRS Monobloc Steriliser HRS Monobloc Steriliser is an integration of the Aseptic Steriliser and Aseptic Filler on a single skid flly atomated with PLC based controls. This system is one of the latest advancements in or prodct range to frther offer innovative and hygienic soltions thereby bringing global technology advantage to or cstomers. Designed to process pto 7000 kg per hor of frit plp / pree concentrate of high viscosity, the HRS Monobloc Steriliser comes with aseptic filler for bag-in-drm filling mechanism. The heart of the Aseptic Steriliser are the ECOFLUX* AS series Corrgated Tbe Heat Exchangers which enable processing of the prodct at desired temperatre range, a piston pmp for homogenizing and de-aerator with atomatic vacm control system spported with CIP pmp and peripherals. The filling section of the HRS Monobloc Steriliser is with the Aseptic Filler which has flly atomated, doble filler heads with bag clamping system, conveyor to spport the drms and a sanitary steam line for sterilisation of the filling chambers. For processing of frit plps sch as Mango, Gava, Papaya, Banana, Tomato and many more for Aseptic Sterilisation, Filling of prees & pastes Concentration of frit plp, prees Featres Compact nit of Aseptic Steriliser and Aseptic Filler Designed with ECOFLUX* CTHE for maximm energy efficiency Optimal velocities and trblence for consistent processing De-aeration tank for air bbble removal Homogenizer for niform particlates Bag-in-drm filling mechanism Integrated CIP dosing system Complete PLC based atomation Advantages Hygienic end prodct with better shelf life at ambient storage temperatre Better aroma retention de to HTST technology Continos processing for consistent qality Easy-to-operate with PLC controls Integrated CIP to enhance eqipment life Lower maintenance
Beverage Processing and HRS There is a tremendos demand for ready-to-drink beverages in the market. Consmers are increasingly looking for convenience foods and drinks, and at the same time have an eye for health consciosness in a bsy rotine. Conseqently, the concept of packed frit jices has evolved. Primarily, this process involves pasterisation of jices to ensre the desired shelf life of the beverage. HRS is the major spplier of pasterisers for frit based beverage indstry. HRS designs trnkey beverage processing lines sing hygienic corrgated shell and tbe heat exchanger for pasterisation of frit jices to inactivate microorganisms and to ensre the desired shelf life of the beverages. Parle Agro, PepsiCo India, Coca Cola, Nestle, ITC have been or esteemed clients to name a few. HRS India has spplied beverage pasterisers incorporating ECOFLUX* MI Series heat exchangers ranging in capacity from 1,000 to 30,000 l/h. HRS offers pasterisers for filling in glass bottles, PET bottles and Aseptic packages. Prodcts being processed inclde plpy beverages i.e. mango, orange and lemon, and also isotonic jices. Featres & Advantages Compact size, aesthetic design and low floor space reqirement Prolonged prodction cycles de to self cleaning natre of corrgated tbes Close approach temperatre that retains the natral prodct flavor and ntrients Steady prodct temperatre control within + 0.5 degree Indirect heating by low temp hot water Heat enclosre to prevent radiation heat loss Flly atomated system avoiding manal intervention Positive pressre on prodct side over tilities for extra safety Precise flow control maintains constant holding time throghot prodction Energy recovery pto 90% depending pon filling temperatre in PET bottling / aseptic packaging Minimal prodct losses de to precisely programmed prodct startp and end p seqences Faster and efficient cleaning de to forward and reverse CIP cycles Low water consmption de to accrately atomated CIP system
Innovative Soltions for Food Indstry Complete Beverage Processing Line HRS is proficient in design and engineering complete beverage processing plant starting from preparation to pasterisation. An integrated frit based beverage processing line with mltiple sections incldes sgar syrp preparation, plp nloading, ingredient dosing sections, beverage blending section, ready beverage storage section, beverage pasteriser and a centralized CIP station. HRS designed sgar syrp preparation section incldes inslated sgar dissolving tank with sgar dmping, tblar heat exchanger for heating water and a jet mixing system to dissolve sgar into the hot water. The sgar syrp is filtered throgh a plate and frame filter press, cooled and stored in holding tank. In the beverage blending section, frit plp, flavors, sgar syrp and other ingredients are blended together and homogenized to be ready for transfer to beverage tanks prioir to pasterisation. The ready beverage is processed in HRS pasterisers manfactred with energy efficient ECOFLUX* tblar heat exchangers. Sgar Syrp Plp Essential Ingredients RGB Filling Key Components Blending Section Beverage Tank Steriliser / Pasteriser PET Filling Aseptic Filling ECOFLUX* Corrgated shell and tbe heat exchangers System material of constrction in SS316, SS316L, SMO254, SAF2205, AL6XN, Titanim Sanitary Centrifgal Pmps, Lobe pmps Imported sanitary pnematic actated valves Imported instrments and sensors for flow, pressre, temperatre and condctivity measrement PLC based control panel with toch screen HMI and SCADA for centralized control Compact blending systems for dissolving essential ingredients
Advanced Soltions for Dairy, Ntraceticals, Infant Food and Probiotic UHT Steriliser The heat transfer technology from HRS has revoltionized thermal processing soltions right from basic heating, cooling, chilling and condensation to more complex soltions like pasterization, sterilization, evaporation and many more sch processes. This has been particlarly very advantageos for the food, frit and dairy processing indstry. The UHT Sterilizer by HRS has a complete hygienic design to give the final otpt at the desired temperatres. It can be cstomized to sit varied capacity ranges from 1800 LPH to 18000 LPH (litres per hor) and comes with a special provision for ftre capacity expansion. The UHT Sterilizer is based on the principle of sterilization throgh hot water generated from steam. This process allows heating milk at ltra high temperatre to sterilize and then cool it to ambient temperatre for frther inpt to desired aseptic packaging line. Milk is intermediately directed to deaerator for removal of dissolved oxygen and homogenizer for prodct niformity. To ensre correct qality end prodct, this system is provided with special featres and PLC atomation controls to enable for flawless operation with minimal manal interference. The UHT sterilizer is programmed to perform CIP atomatically and efficiently. High CIP flow velocities ensre proper and effective cleaning of the eqipment, thereby ensring minimal downtime and ease of maintenance. Featres and Advantages Benefits Specially designed ECOFLUX* Corrgated Tbe Heat Exchanger based Aseptic Sterilizer Uniform thermal processing Sitable for working in high temperatres and pressres Longer prodction cycles HTST & UHT technology for better prodct shelf life Provision to direct intermediate milk to deaerator & homogenizer Regenerations efficiencies pto 90% Compact designs, cstomized soltions Low Maintenance cost Higher shelf life & prodct niformity Improved prodct qality with hygienic designs End prodct cold storage not mandatory thereby saving investment on infrastrctre Final prodct safety Integrated atomated CIP for easy maintenance High response to Cleaning in Place (CIP) Atomated with PLC control and sing mix proof valves / seat valves Minimal spares reqirement Integration with desired packaging system Milk Flavored Milk Cream Yoghrt & Fermented milk prodcts Dairy Formlations Infant Food
Innovative Soltions for Food Indstry Sbstittes Ntracetical Processing Demand for high qality Ntraceticals is on the rise mainly becase of the changing consmer lifestyle, need for bilding immnity throgh right ntrition and increasing awareness abot ntritional spplements. With its trsted process and engineering know-how, HRS provides Ntracetical processing systems for the food and healthcare indstries. The system is integrated with ECOFLUX* DT series based pasterizer and ECOFLUX* MI series water heater to form the powder mixing section, powder soltion processing section and oil storage and dosing section. The powder mix section incldes a tri-blender, mixing cm storage tank and tblar heat exchangers for water RO heating. Sperior qality pmps are sed for powder and essential ntrient mixing and dosing. This primary mix is processed frther for getting niform particlates and finally pasterised and cooled for sending it to next section. For large plants, an independent mltiple circit CIP system is engineered with the ntracetical processing system. This consists of pmps and steam set-p to circlate CIP liqid at desired temperatres. The entire integration can be done with separate control panels for main nit & CIP system. Featres and Advantages Sanitary design for aseptic processing environment to ensre final prodct safety Uniform processing, longer prodction cycles Cstom-bilt system to sit varied capacities Tri-blender for effective mixing Complete with SS tanks for batches and collection of diverted prodct High end PLC atomation sing mix proof valves and seat valves Sitable for high temperatre and pressre conditions Engineered with HRS process expertise to ensre higher shelf life High response to integrated closed loop CIP Probiotic Health Spplements Dietary and vitamin spplements Infant Food Sbstittes UHT/ HTST Milk sterilization Dairy formlations HRS advantage is extended to the dairy indstry throgh state-of-art systems sch as PHE based pasterisers, chillers, inoclation tanks and many more soltions for milk, cream, whey, whey cream, yoghrt, crd milk and allied prodcts.
ECOFLUX* CTHE ECOFLUX* STHE Plate Heat Exchangers Hot Water Systems UNICUS SSHE Hygienic Piston Pmp Food Systems CIP Systems Evaporator HRS PROCESS SYSTEMS LIMITED 201/202, Karan Selene, 851, Bhandarkar Institte Road, Pne - 411 004. India Tel. : +91 20 2566 3581 / 82 / 6604 7894 / 95 Fax : +91 20 2566 3583 E-mail : info@hrsasia.co.in Web : www.hrsasia.co.in