Reliable Industrial Pasteurisers for Sale

Best Pasteurisers machines manufacturer by Sarom Global

High-Performance Co Brand Tunnel Pasteurizers from Sarom Global

1. What is Pasteurization?

Thermal processing, specifically pasteurization, is a process that involves heating liquids to a high temperature for a short period, followed by rapid cooling, to kill off harmful microorganisms and extend shelf life. Another method of pasteurization is the hot filling process, which involves heating beverages to high temperatures before filling them into packaging to eliminate harmful microorganisms. This method was first developed by Louis Pasteur in the 19th century and has since become a crucial step in the beverage industry to ensure product safety and quality.

Definition and Importance: An overview of pasteurization, its history, and its role in ensuring product safety and extending shelf life.

2. Benefits of Pasteurization in the Beverage Industry

Pasteurization offers numerous benefits to the beverage industry, including improved health and safety, extended shelf life, and enhanced product quality. One of the key benefits is microbial safety, which ensures that harmful microorganisms are eliminated. Additionally, it plays a crucial role in maintaining beverage quality by ensuring consistency in quality assurance testing and significantly enhancing shelf stability.
Health and Safety: How pasteurization reduces harmful microorganisms and enhances product safety.
Shelf-Life Extension: The impact of pasteurization on the longevity of beverages.

3. What is Tunnel Pasteurization?

Tunnel pasteurization, a form of thermal treatment, is a method used in the beverage industry to extend shelf life and ensure product safety. It involves passing beverages through a tunnel-like chamber where they are heated at controlled temperatures, significantly enhancing both shelf stability and sensory attributes. This process is an unsung hero of beverage production, quietly enhancing our drinking experiences for decades. Tunnel pasteurization is a crucial process in the beverage industry, especially when it comes to ensuring quality and extending the shelf life of products like beer. By using a conveyor belt system, beverages are gradually heated and then cooled, effectively eliminating spoilage microorganisms without compromising the sensory attributes of the product.

Definition: A detailed explanation of tunnel pasteurization and its significance in the industry.

4. The Tunnel Pasteurization Process

Gradual Heating and Cooling: Understanding the step-by-step process of tunnel pasteurization.

Tunnel pasteurization is a multi-step process that involves gradual heating and cooling of beverages to extend their shelf life and maintain quality. The process begins with the loading of filled bottles or cans onto a conveyor belt system, which transports them through a tunnel-like chamber. The tunnel is divided into several temperature zones, each with a specific temperature and time parameter. The first zone is the preheat zone, where the beverage is gradually heated to the desired pasteurization temperature. The second zone is the heating zone, where the beverage is held at the pasteurization temperature for a set period. The third zone is the cooling zone, where the beverage is rapidly cooled to prevent overcooking and maintain quality.

Precise Control Over Each Step: How precision in the process ensures quality and safety.

Precise control over each step of the tunnel pasteurization process is crucial to ensure quality and safety. The temperature and time parameters in each of the temperature zones must be carefully calibrated to achieve the desired level of microbial reduction. The conveyor belt system must be designed to ensure that each bottle or can is treated equally, with no hot spots or cold spots. The tunnel pasteurizer must also be equipped with sensors and monitoring systems to detect any deviations from the set parameters. By maintaining precise control over each step of the process, tunnel pasteurization ensures that beverages are consistently produced with extended shelf life and maintained quality.

5. Benefits of Tunnel Pasteurization

Extending Shelf Life: How tunnel pasteurization specifically contributes to longer shelf life.

Tunnel pasteurization plays a significant role in extending shelf life by eliminating harmful microorganisms that can cause spoilage. This microbial reduction is achieved by applying heat at precise temperatures for specific durations, allowing tunnel pasteurizers to kill off bacteria, yeast, and mold, ensuring that beverages remain safe for consumption over a longer period. This process is particularly effective for beverages packaged in glass bottles, aluminum cans, and PET bottles. The gradual heating and cooling process used in tunnel pasteurization helps to prevent the growth of microorganisms, thereby prolonging shelf life. Additionally, tunnel pasteurization enhances shelf stability and sensory attributes, making products more appealing in a competitive market.

Improving Beverage Quality: The role of tunnel pasteurization in enhancing the quality of beverages.

Tunnel pasteurization not only extends shelf life but also improves beverage quality. The process helps to maintain the flavor, color, and nutritional content of beverages by minimizing the impact of heat on the product. The gentle and controlled application of heat ensures that the beverage is not overcooked or damaged, preserving its natural characteristics. Additionally, tunnel pasteurization helps to prevent the formation of off-flavors and aromas, resulting in a better-tasting beverage. By ensuring consistent flavor and quality, tunnel pasteurization helps beverage manufacturers to maintain their brand reputation and customer loyalty.

6. Equipment and Setup

Tunnel Pasteurizer Design and Construction: Key design elements and construction materials.

A tunnel pasteurizer is a complex piece of equipment that requires careful design and construction to ensure optimal performance. The tunnel must be designed to accommodate the specific needs of the beverage being pasteurized, including the type of packaging and the desired level of microbial reduction. The tunnel must also be constructed from materials that can withstand the high temperatures and humidity involved in the pasteurization process. Common construction materials include stainless steel, aluminum, and fiberglass. The tunnel must also be equipped with a conveyor belt system, heating and cooling systems, and sensors and monitoring systems to detect any deviations from the set parameters. By carefully designing and constructing the tunnel pasteurizer, manufacturers can ensure that their beverages are consistently produced with extended shelf life and maintained quality.

Water Treatment and Management: Essential practices for maintaining water quality in tunnel pasteurization.

Water treatment and management are critical components in the tunnel pasteurization process, ensuring that the water used is of the highest quality to prevent contamination and maintain the safety of the beverages. Here are some essential practices for maintaining water quality in tunnel pasteurization:

Regular Water Testing: Consistent testing of water quality is vital. Parameters such as pH, temperature, and microbial load should be regularly monitored to ensure they meet the required standards. This helps in identifying any potential issues before they affect the pasteurization process.

Water Treatment: To remove impurities and contaminants, various water treatment technologies can be employed. Filtration, disinfection, and reverse osmosis are common methods used to ensure the water is clean and safe for use in tunnel pasteurization.

Water Recycling: Recycling water within the tunnel pasteurization process is not only environmentally friendly but also cost-effective. By reusing water, manufacturers can significantly reduce the amount of fresh water required, thereby conserving resources and reducing waste.

Cleaning and Sanitizing: Regular cleaning and sanitizing of the tunnel pasteurizer and its components are essential to prevent contamination. This ensures that the equipment remains in optimal condition and that the beverages produced are safe for consumption.

Maintenance of Equipment: Routine maintenance of the tunnel pasteurizer and its components ensures that the equipment functions efficiently. Regular checks and servicing can prevent breakdowns and ensure that the pasteurization process runs smoothly.

By adhering to these practices, beverage manufacturers can maintain high water quality, which is crucial for the effectiveness of tunnel pasteurization. This, in turn, helps in maintaining beverage quality and extending shelf life.

7. Industry Applications

Tunnel Pasteurization in the Beverage Industry: Exploring the diverse applications of tunnel pasteurization across various sectors.

Tunnel pasteurization is a versatile and widely adopted process in the beverage industry, extending far beyond just beer and soft drinks. Its applications span various sectors, each benefiting from the enhanced shelf life and maintained quality that tunnel pasteurization provides. Here are some of the diverse applications:

Juice and Dairy Products: Tunnel pasteurization is extensively used to extend the shelf life of juices and dairy products like milk, yogurt, and cheese. By eliminating harmful microorganisms, it ensures these products remain safe and fresh for longer periods.

Wine and Spirits: The process is also applied to wine and spirits, such as whiskey and vodka. Tunnel pasteurization helps in preventing spoilage and extending the shelf life of these beverages, ensuring they maintain their quality over time.

Tea and Coffee: Ready-to-drink tea and coffee beverages benefit from tunnel pasteurization, which helps in preventing the growth of bacteria and other microorganisms, thereby extending their shelf life and ensuring they remain safe for consumption.

Energy Drinks and Sports Drinks: These beverages, often consumed for their nutritional benefits, are also pasteurized using tunnel pasteurization. This process helps in maintaining their quality and extending their shelf life, making them safe and appealing to consumers.

Flavored Waters and Seltzers: Tunnel pasteurization is used to pasteurize flavored waters and seltzers, ensuring they remain free from harmful microorganisms and have an extended shelf life. This is particularly important in maintaining the sensory attributes of these beverages.

Tunnel pasteurization is an essential tool in the beverage industry, offering a reliable method for ensuring product safety, maintaining quality, and extending shelf life across a wide range of beverage types.

8. Choosing the Right Tunnel Pasteurizer

Cost and ROI Considerations: Evaluating the financial aspects of investing in tunnel pasteurizers.

Investing in a tunnel pasteurizer is a significant decision for any beverage manufacturer, and it’s crucial to evaluate the financial aspects to ensure a strong return on investment (ROI). Here are some key considerations:

Initial Investment: The upfront cost of purchasing a tunnel pasteurizer can be substantial. However, it’s important to consider this as a long-term investment that will pay off through increased efficiency and product quality.

Operating Costs: Operating a tunnel pasteurizer involves ongoing expenses such as energy and maintenance costs. These should be factored into the overall cost analysis to understand the true financial impact.

Increased Productivity: One of the major benefits of tunnel pasteurization is the potential for increased productivity. The process allows for faster processing times and reduces the need for manual handling, which can lead to significant labor cost savings.

Extended Shelf Life: By extending the shelf life of beverages, tunnel pasteurization reduces waste and increases profitability. Products that last longer on the shelf are less likely to be discarded due to spoilage, leading to better inventory management and higher sales.

Improved Quality: Tunnel pasteurization helps in maintaining the quality of beverages by reducing the risk of contamination and spoilage. High-quality products are more likely to retain customer loyalty and command higher prices in the market.

By carefully considering these factors, beverage manufacturers can make an informed decision when choosing a tunnel pasteurizer. The right equipment will not only enhance operational efficiency but also ensure a strong ROI by improving product quality and extending shelf life.

Calibration and Maintenance: Ensuring long-term efficiency and reliability through regular calibration and maintenance.

9. Types of Pasteurizers

1. Tunnel Pasteurisers

System: Tunnel pasteurisers “TP-HRW” is designed to boost the biological stability of the product by thermally treating it in the packaging. Batch pasteurization, on the other hand, involves treating a specific quantity of product in a single vessel, contrasting it with the continuous process of tunnel pasteurization.

Capacity varies between 500 and 60,000 bottles or cans per hour.
Beer, kvass, juice, wine, carbonated and non-carbonated drinks, and canned foods can be pasteurized.
Temperature zones range from 7 to 10.
Pasteurization method: shower, shower-submersible
Automatic and semi-automatic modes of operation are available.
Sources of heat include steam, hot water, and electricity.
The size of the container is determined by the capacity, the desired temperature, and the container size.
The pasteurizer is shaped like a tube.
Made from Stainless Steel (AISI 304, AISI 316L, AISI 316Ti, AISI 321)
Pasteurization is a fully automated procedure.
A total of 8 pasteurisation registered parameters.
Integration of water exchange system between the heating and cooling zones.
The upper lid’s opening and locking system provides for simpler access and cleaning.
Feeding system for active containers
System to guard against overload
Condensate collecting and return system
In each zone, there is an effective and independent spraying system.
The PU is automatically monitored and adjusted.
Alarm System
Developing “recipes” for a variety of items and container sizes
Data transfer and remote access through a modem (Profibus, Internet, etc.)

Components: “HERMIS” only employs high-quality materials and components made in the European Union that complies with all quality standards.

Gear reducers: LENZE, SEW-EURODRIVE
Pumps: LOWARA, GRUNDFOS, KSB
Steam valves: BURKERT, SAMSON
Temperature register: ENDRESS+HAUSER
Heat exchangers: FUNKE, KELVION
Active bottles transfer system: REXNORD
Electrical control system: SIEMENS, MOELLER, OMRON
Automatic control system: SIEMENS
Plastic modular belt: REXNORD, MOVEX

Conveyor belt system: Essential for transporting beverages through the heated tunnel-like chamber during pasteurization, ensuring quality and longevity by eliminating spoilage microorganisms.

Stainless steel conveyor belt: HERMIS, TWENTEBELT
Air supply system: SMC, FESTO
Spray nozzles: LECHLER

Additional: The following models and settings are available from HERMIS for tunnel pasteurizers:

The “TP-HRW-R” is a reversible tunnel pasteurizer for small beverage plants with a capacity of 500 to 4000 bph.
Tunnel pasteurizer “TP-HRW 5” for small beverage facilities with production rates ranging from 800 to 6000 bph
Tunnel pasteurizer “TP-HRW 10/15” for beverage facilities with a capacity of 5000 to 15000 bph.
Tunnel pasteurizer “TP-HRW 20/60” for large beverage facilities with production rates ranging from 15000 to 60000 bph
“TP-HRW-D” double-deck tunnel pasteurizer for big beverage plants with a capacity of 24000 – 60000 bph.

These models utilize gradual heating, ensuring effective pasteurization while preserving the quality and taste of the beverages.

2. Reverse Tunnel Pasteurisers

Reverse Tunnel Pasteurisers “TP-HRW-RR” are designed to increase the biological stability of a product by thermally treating it in its container (glass bottles or cans).

500 to 1500 bottles or cans per hour capacity
Beer, kvass, juice, wine, carbonated and non-carbonated, beverages that aren’t carbonated, vegetables and tinned meals can be pasteurized
Sources of heat include steam, electricity and hot water.
Stainless steel (AISI 304, AISI 316L, AISI 316Ti, AISI 321)
The entrance and exit of bottles or cans into the pasteurizer on the same side
LOW WATER AND ENERGY REQUIREMENTS
Pasteurisation process regulation, manual and automatic
Easy adjustment of pasteurisation temperature
Manageable operation
An automatic emergency system shuts down in a crisis.
Space-saving

3. Flow Pasteurisers

System: Pasteurisers “H&G” is meant to pasteurise beverages by rapidly heating them to a specific degree, keeping them at that temperature for a predetermined duration, and then cooling them. As a result of the thermal process, the quantity of microorganisms is reduced and the shelf life is extended, thereby extending shelf life.

Capacity ranges from 800 to 50,000 liters per hour.
Beer, wine, kombucha, juices, juice drinks, sugar syrup, carbonated and juice-containing drinks can be pasteurized. Flow pasteurizers use a thermal process to help in prolonging shelf life by reducing microorganisms and extending the freshness of beverages.
Automatic and semi-automatic modes of operation are available.
Sources of heat include steam, electricity, and hot water.
Water and propylene glycol are used as cooling agents.
AISI 304, AISI 316L, AISI 316Ti, AISI 321 stainless steel
Automatic temperature regulation
Temperature monitor
Pasteurization on pre-determined PU units
Automatic system shut down in an emergency
Storage and configuration of previously defined parameters
Data transmission and remote access via modem are both possible.

Components: Flow pasteurizers are equipped with –

Heat exchangers: KELVION, ALFA LAVAL
Controlling devices: BURKERT, SAMSON, NEGELE
Pumps: PACKO, LOWARA, HILGE, GRUNDFOS, ALFA LAVAL
PLC control system: SIEMENS
Air supply system: SMC, FESTO

Additional: Pasteurizers can include a buffer tank.

4. Chamber Pasteurisers

System: The chamber pasteurisers are used to pasteurise bottles of goods. Small beverage plants in the beverage industry will benefit from this.

400-600 bottles per hour capacity
Beer, kvass, juice, wine, carbonated and non-carbonated drinks can be pasteurized. Tunnel pasteurization is a gentler alternative compared to aggressive sterilization methods, which can compromise the sensory attributes of beverages.
Heating, pasteurisation and cooling are the steps in the pasteurization process. Unlike more aggressive sterilization methods that may negatively impact flavor, color, and nutritional content, tunnel pasteurization balances safety with the preservation of these sensory attributes.
Semi-automatic method of operation
AISI 304, AISI 316L, AISI 316Ti, AISI 321 stainless steel
The manually controlled pasteurization process
Automatic pasteurization temperature maintenance
Manageable operation