Example 1: Directing the finished product to different locations in the plant.
In the first example of modification, our client needed a universal device to pasteurize raw juice and to filter the concentrate in order to eliminate Alicyclobacillus (ACB) spores.
The customer placed great emphasis on the fact that the device should guarantee product safety and have a function of archiving operating parameters.
The possibility of directing the processed raw material to different places in the plant was very important.
We offered the MONA Aseptic Filtration System.
MONA is a system for pasteurization and filtration of concentrate in order to eliminate Alicyclobacillus (ACB) spores. The control program supervises the operation of the device and takes care of the procedures that guarantee the sterility of the process and the safety of the product. All operating parameters are archived and available in the form of reports.
The modification in the first example concerned the MONA system software and plant piping, which were designed to allow safe selection of product routes and directing it through the switching panel to a concentrate tank room, aseptic tank room, bottler or directly to a tanker.
Example 2: Processing different volumes of juice using the same evaporator
In this example, we have a customer who processes apples and coloured fruits. In order to optimize the investment costs, he required that the processing is carried out using one evaporator system. The customer's problem was that the single volume of the pulp batch of coloured fruits is significantly smaller than the volume of the pulp batch of apples processed at the full capacity of the evaporator. In order to meet the expectations of this customer and the whole market, we designed an evaporator station with the possibility of changing its capacity mode.
The supplied evaporator station enables the processing of apples with a capacity of up to 40,000 l/h of juice inflow. The processing of coloured fruits can be carried out with a capacity of as little as 10,000 l/h of juice inflow. This has been achieved by dividing the flow sieves in the falling film columns into three sections. Pneumatic valves installed at the top of each column direct the juice to one, two or all sections to allow operation in the following capacity modes:
- low: 10,000-22,000 l/h of juice inflow
- high: 20,000-40,000 l/h of juice inflow
Within each mode, the capacity can be continuously adjusted.
It is also important that the change of the operating mode is fully automatic without the need for mechanical intervention by the operator.
The customer has the possibility to process the raw material with different efficiency adjusted to the current possibilities and quantity of available raw material.
Example 3: Processing different types of raw materials and detergent dispenser
The third example of modifications introduced basing on the discussions with a client concerns a pasteurizer. The customer had a pasteurizer, but the device required constant supervision and control of operating parameters. He wanted to reduce the risk of operator’s errors by automating the pasteurization process. During the conversations we learned that he wants also to process vegetable purees with the pasteurizer. Finally, his additional, equally important wish was to optimise the feeding of cleaning agents in order to increase the level of work safety.
We proposed a pasteurizer with a tubular exchanger and an automatic detergent dispenser.
The software controlling the operation of the pasteurizer in combination with automation and measuring devices eliminates the need for constant supervision. All operating parameters are available in the form of reports. To enable pasteurization of various types of raw materials, we have replaced the plate heat exchanger with a tubular heat exchanger. A stirrer has been added to the buffer tank to prevent the product from settling (in the case of vegetable purées).
An additional modification was the introduction of automatic dispensing of cleaning agents, a so‑called dispenser. It consists of dispensing pumps placed in two containers filled with acid and alkali. The dispenser eliminates the need for manual measuring and adding of cleaning agents. Based on the conductivity meter readings, the system takes the appropriate cleaning agent to maintain the desired parameters during the cleaning stage.
Our customer has received a machine tailored to his needs. He is satisfied with the automation of the pasteurization process and the increased level of work safety that we have achieved
We invite you to cooperate with us!