UHT PLANT/ASEPTIC STERILIZER/ASEPTIC HOMOGENIZER/DEGASER/ASEPTIC TANK/CIP/SIP/HOW/WHAT/variable capacity/ASEPTIC PROCESS/ASEPTIC FILLING

The UHT treatment (Ultra High Temperature) is a modern and innovative technological process that consists in carrying a foodstuff fluid to a high temperature and after a short holding time cooled quickly up to room temperature.The product, sterilized, is then filled in aseptic conditions with use of Aseptic pouch filling machines
So treated products keep freshness, taste, and nutritional value similar to the fresh products but with the very great advantage that can be kept at room temperature forconservancies. 

A UHT LINE CONSIST OF 

1.RAW MILK RECEPTION DOCK

2.RAM MILK STANDARDIZATION UNIT

3.ASEPTIC STERILIZER

4. ASEPTIC/NON ASEPTIC HOMOGENIZER

6.DEGASER WITH AROMA RECOVERY SET UP

7.ASEPTIC TANK

8.ASEPTIC FILLING MACHINE

RAW MATERIALS/UTILITY REQUERD 

1. FILM FOR FILLING MACHINE(MATERIAL&TYPE SUITABLE FOR SHELF LIFE OF PRODUCT REQUIRED),

2.SATURATED STEAM,

3.COOLING TOWER WATER,

4.CHILLED WATER,

5.COMPRESSED AIR

6.RO WATER,

7.HYDROGEN PEROXIDE

8.ELECTRIC CITY

A.WHAT IS ASEPTIC STERILIZER

(Example of a Indirect heating uht sterilizer for Milk)

Sterilization Temperature :140Deg.C
Holding Time :4s
Capacity of sterilizer can be variable but the maximum and minimum should be fixed and pre designed,
advanced sterilizers are multy product treatment ,with fully automated instrumentation included holding time and capacity variation & Positive pressure measurement and control.

• Milk
• Cream
• Vla
• Custard
• Pudding
• Soft ice mix
• I ce cream mix
• Condensed milk
• Baby food
• Processed cheese

• Sauces

The thermal treatment in corrugated tubular steriliser is very quick and effective, since

the corrugated tube heat exchangers increase the thermal transference coefficient reducing

the required time for the thermal process.

This process make easier the elaboration of a much more natural product, avoiding the thermal

degradation and keeping the properties of the product.

Advantages

• Less vulnerable to fouling giving long production runs

• High operating pressures are acceptable

• Processes products with fibres and particulates

• Processes high viscosity products

• Low shear characteristics for cream

• Low requirement for gasket material and easy gasket exchange

• Very robust design

• Low maintenance costs

• Can be designed as a multi-purpose plant

B.ASEPTIC HOMOGENIZER

  LOCATION OF HOMOGENIZER VARIES WITH EACH SYSTEM, BUT IN UHT PROCESS THERE ARE MAY BE AN ADVANTAGE AFTER HEATING.

  HOMOGENIZATION CAN BE CARRIED OUT BEFORE AND AFTER THE UHT HEATING.

 IF AFTER ARRANGEMENT IS ADOPTED, HOMOGENIZATION WILL COST MORE SINCE THE PROCESS CARRIED OUT ASEPTICALLY.

IT PREVENTS OR REVERS PROTIEN –PROTIEN AND FAT GLOBULE –PROTIEN AGGREGATION.IT ALSO RETRAVES THE FORAMATION OF SEDEMENTS OF HEAT PRECIPITATED PROTIEN.

 ALSO IT IS ADVANTAGEOUS TO HOMOGENIZE THE PRODUCT AFTER STERLIZATION SINCE THIS ORDER PROVIDES ADDED HEAT STABILIT Y TO THE PROTIEN SYSTEM.

 WHEATHER OR NOT HOMOGENIZER IS BEFORE OR AFTER THE HEATING SECTION THE MILK IS HOMOGENIZED IN THE SAME TEMPERATURE RANGE 70-80deg.C (158-185F)

http://milkyworlds.blogspot.in/2014/08/aseptic-and-non-aseptic-homogenizer.html

(Example:UHT PLANT BY REDA.S.p.A Itali,Including Sterlizer,Homogenizer,Degaser & Aseptic Tank,M/S Repute India is the Indian agent)

C.DEGASER

Vacuum Degasser
The vacuum degasser is an indispensable device in juice, milk and tea drink production line. It’s mainly used to degas for products after homogenizing in vacuum state. Thus can prevent fruit juice oxidization and extend fruit juice storage life 

Vacuum Degasser Features
• Vacuum degasser working hours and period can be adjusted as required

• Several vacuum degassers can operate together in parallel
• Convenient installation, full-automatic working
• High corrosion resistance and security
• Minimal moving parts for reliable operation
• Unique design assures reliable continuous operation
• Easy maintenance and service

Effects of Vacuum Degasser
1. The vacuum degasser can remove the air (mainly oxygen) from the feed liquid, to restrain oxidization of pigment, vitamin, flavoring component and other materials, keep the product quality; 
2. To dislodge particle gas that adhere to feed liquid, stop the float of fine particles, keep the good appearance; 
3. To decrease foaming influence to sterilization in filling or high temperature sterilization process; 
4. To reduce corrosion of container internal surface.
C.ASEPTIC TANK

As an asecptic tank unit, the sterile tank is the link between process and packaging. The sterile tank guarantees a consistent product quality over the entire production time, since multiple heating of the product due to production stop or capacity failure on the filler lines can be avoided. Another advantage is, that the sterile intermediate storage of the aseptic product ensures the non-stop production of the filler lines even during CIP operations carried out on the process equipment. 
Depending on the production volume, tank capacities are available from 500 l to 100.000 l. Sterile tank units allow for aseptic, flexible connections of one or more process lines and packaging lines, so that different products can be filled at the same time without manual coupling

C.ASEPTIC PROCESS AND ASEPTIC FILLING

Aseptic packaging systems fill sterile product into sterile packages within the confines of

the sterile zone of the filler. The aseptic zone/sterile zone extends from the point where sterilized

packaging enters the sterile zone to where the sealed package is evacuated. Common attributes to

all aseptic packaging systems include:

1. The sterile product, sterile package, and sterile zone prevent post-processing

contamination.

2. The food contact surfaces of the package are sterile.

3. Product is filled aseptically into the package.

4. Packages are sealed hermetically.

5. Automation exists in monitoring and controlling the critical points

RELEVANCE OF ASEPTIC PROCESS?

 The demand for ultra high temperature processed and aseptically packaged dairy foods is growing throughout the U.S. The technology provides value-added food preservation for many foods including flavored milks, puddings, custards, creams, ice-cream mixes, whey-based drinks, sports drinks, and yogurt. Ultra high temperature nonfat milk, milk, light cream, and 18% cream are used throughout the U.S. by the restaurant and food service industries. There are several advantages to aseptic processing and packaging over traditional pasteurization. Advantages include extended shelf life, lower energy costs, and the elimination of required refrigeration during storage and distribution. Challenges are present in all aspects of dairy

processing. Major challenges associated with ultra high temperature processing and aseptic packaging of dairy foods include product quality loss, such as age gelation, fat separation, and flavor loss, as well as manufacturing issues such as limited production capacity, potential contamination, slow packaging speeds, and limited shelf life knowledge.

EFFECT ON FLAVOR AND AROMA!!

Less severe

Natural flavors and aromas of mlk, juices and vegetables are better maintained

EFFECT ON NUTRITION!!

Minimal nutritional losses

Heat and vegetables lose thiamin and pyridoxide(other vitamins are not really affected)

There are several advantages to aseptic processing and packaging over traditional

pasteurization. Advantages include extended shelf life, lower energy costs, and the elimination of

required refrigeration during storage and distribution. Challenges are present in all aspects of

dairy processing. Major challenges associated with ultra high temperature processing and aseptic

packaging of dairy foods include product quality loss, such as age gelation, fat separation, and

flavor loss, as well as manufacturing issues such as limited production capacity, potential

contamination, slow packaging speeds, and limited shelf life knowledge.