The perfect combination of linking process and filling technology in milk processing

Ideal for not only a variety of beverages, but also other related industries. Traditional market products, such as fresh milk processing plants, not only produce and mix milk mixed drinks, yogurt drinks and whey drinks with added fruit and flavor, but also produce coffee milk and other coffee drinks. In the traditional beverage manufacturing industry, which only produces juices or soft drinks, it has been popular in all product fields a few years ago. The infinite possibilities offered by the product mix are extremely attractive, and Krones is the expert in this type of blending, and its advantages are reflected in the perfect combination of filling technology and advanced process technology. Of course, according to actual needs, it can also combine packaging technology, task management, logistics technology, upstream automation and IT technology.

Milk diversification

In order to achieve the best processing results, Krones uses the filling technology of different filling systems to develop the corresponding process technology. The technology fully meets all aspects of hygiene, shelf life and product type. For fresh milk processing plants, milk and milk-based beverages are of course the most important products, such as yogurt, milk mixed drinks, whey drinks, milk products containing probiotics, acidified milk drinks, and coffee drinks. In addition, there are common milk such as pasteurized milk, ESL milk or UHT high temperature disinfected milk. Krones is able to design solutions according to the specific application, complementing process technology and filling technology, and effectively becoming the overall operating system. In terms of energy saving, reducing water consumption, reducing wastewater discharge, introducing upstream automation and IT technology, and reducing production costs, it can also be more easily demonstrated in a complete solution. Another advantage of the full solution is that the user has only one contact, so communication is more convenient.

Special sterilization requirements for fresh milk, ESL milk and UHT milk

In the fresh milk processing industry, the production process begins with the collection of fresh milk, which is then refrigerated and stored in a raw milk tank. The first heating can be achieved by low temperature heating or pasteurization, and the processing period or shelf life can be extended to 2 days to 10 days. At the same time as pasteurization, it can be degreased in a centrifuge to standardize the milk fat content to a predetermined level and, if necessary, homogenized. This “normal” pasteurized fresh milk is always of high value in the market and is usually filled in glass bottles or cartons for a shelf life of ten days.

ESL30 (extended shelf life) Milk is also of high value in the market. It must be transported in cold chain as well as fresh milk, but the shelf life is longer, ranging from 22 days to 30 days. The pasteurization process technology used is basically the same, but after a low temperature pasteurization treatment of 72 ° C ~ 74 ° C, it must also pass a second 127 ° C high temperature pasteurization.

Slightly different is the use of a third high temperature pasteurized UHT (Ultra High Temperature) milk. The treatment method is sterilized at a high temperature of 138 ° C to 142 ° C in a few seconds, and the technical requirements are high. For example, sterile storage tanks and anti-vapor evaporation devices are required to ensure that the equipment is completely free of secondary contamination. This process must be monitored throughout the process so that it can react in a timely manner in the event of a failure. The shelf life of UHT milk is about 6 months.

Special instantaneous heating to complete each task

The perfect instantaneous heating program set is suitable for a wide range of products and tasks. The VarioFlash Instantaneous Heater with tubular heat exchangers handles high viscosity and fiber-containing beverages. Others can use plate heat exchangers.

The instantaneous heating device is based on a reliable heat exchanger and heating section heating principle. In the equipment, the unheated product is heated in the first zone by the product that has been heated over. In the second zone, the hot water temperature is precisely adjusted and the product is heated to the desired temperature. In this indirect heating mode, the temperature of the exchanger surface is slightly higher than the temperature of the product therein. After that, the product is kept at the pasteurization temperature for a set period of time, and finally cooled by the unheated product. In this way, almost all of the used thermal energy can be reused.

Fully automatic operation visualization

The sophisticated control system is the heart of a fully automated instantaneous heating unit. The system consists of the Krones automation system Zenon. If it is necessary to automatically coordinate and control multiple heating devices and buffer tanks at the same time, the Krones Botec F1 system is required.

In the practical application of fresh milk processing plants, it is necessary to maintain a certain heating temperature and strictly adhere to extremely compact placement time. The buffer tank can hold the quantity of the product constantly and continuously or intermittently deliver the product to the filling machine. The level of the buffer tank is monitored by a reliable differential pressure gauge for a long time.

When the production interval is long, it is ensured that the necessary heating temperature is maintained. When the efficiency of the instantaneous heating device is reduced and the buffer tank reaches its maximum, the control system reacts. The products in the equipment are pushed out of the water in the buffer tank, and all steps are automated and secured. After that, the water circulates continuously in the instantaneous heating device. When started again, the instantaneous heating device automatically matches the filling efficiency. These systems all use a certain degree of energy recovery design, which can achieve 94% for plate heat exchangers and 85% for tubular heat exchangers depending on the heat exchanger surface area.

The entire process can be seen on the operator panel, and the valve status or floor position can be adjusted. When the product is replaced, simply enter a small amount of information to match the defined process parameters to the new given conditions. Any changes will only be made to the appropriate program level by the operator with the execution permission. All equipment consists of high quality components with CIP functionality and installed in accordance with hygienic design rules.

VarioAsept Instantaneous Heating Unit for UHT

The VarioAsept instant heating unit is specially developed for production areas where the requirements for aseptic filling and UHT filling of beverages are high. All the workflows and components of the instantaneous heating device are very cumbersome, so in the aseptic area of ​​the instantaneous heating device, only the parts that meet the highest hygiene requirements are used. The media is reliably separated by an anti-leakage fuse. In addition, the anti-vapor evaporation device ensures a sterile environment for the problematic parts. The buffer tanks are also manufactured according to hygienic design and are sterilized by flow steam. The entire unit is sterilized by hot water circulation at 125 °C. Whether in terms of efficiency, design or process technology, the VarioAsept instant heating unit is perfectly coordinated with the Krones PET Asept line. The Krones Group presents its advantages to its customers with its overall design.

CIP equipment is essential

CIP equipment is essential in the fresh milk industry. No milk processing plant does not need it. All of the recycled water containers of the VarioClean CIP are made of high quality chrome-nickel stainless steel. The container containing the hot cleaning medium is covered with stainless steel. Standard equipment has 1 to 4 containers, and the greater the number of tanks, the greater the flexibility of the equipment. Different cleaning media such as hot water, lye, acid and recycled water are stored in CIP equipment. Starting with equipment with two tanks, it can be cleaned with recycled water. Accurate measurement technology ensures that the media is completely separated, significantly reducing the waste water treatment burden.

Typically, the filler is connected to the CIP device via a panel. Here you can use a curved tube to select the connection product or the cleaning device. The sensor monitors the position of the curved tube correctly. If the position is wrong, the device remains closed. Also, a double seat valve can be used. Product and cleaning path conversions are fully automated and cleaning time is free to choose.

The functionality of any special system required for the filling of sterile beverages can be provided by CIP equipment. They meet the high standards for aseptic filling of beverages. These devices are cleaned at a higher temperature and the entire heating device is heated to around 125 °C. Pressure balanced vessels monitor the inevitable overpressure in the system.

Mix more ingredients

In addition to processing pure milk, you need to add more ingredients to the flavored milk or milk blend. In order to avoid diluting the milk with water, liquid milk cannot be used, and solid milk powder must be used. In this process, batch processing must be used instead of continuous processing. Typically, the mixing process is completed between the first pasteurization and the second heat. A suitable method for adding the milk powder is to mix the crystal sugar or the powder flavor into the milk through a vacuum mixing tank in a funnel or a multi-can system, and the method can be carried out by artificial bagging or by fully automatic weighing. When producing fruit whey drinks or milk mixed drinks, it may also be necessary to add concentrated juice, whey powder, fruit, concentrated essence, vitamins and other ingredients.

Since oxygen must be added to the product while using the powdered ingredients, there must be a deoxygenation step after the ingredients. Otherwise, the milk is difficult to heat and will quickly form a film on the heating device. The vacuum deoxidation equipment developed by Krones has been able to effectively reduce the oxygen content to less than one part per million and to increase the service life of the equipment. When processing juice, it also has a set of flavor recovery equipment.

High flexibility

The equipment designed and supplied by Krones is highly flexible, an open system and can be used in fresh milk processing plants, juice production plants and beverage production plants, with a wide range of products to meet the wishes of manufacturers. This flexibility is further reflected in Krones' filling technology, which can be used to fill pure milk, flavored milk, whey drinks, yogurt drinks, milk mixed drinks and ready-to-drink coffee. The filling machine uses a rotary rotary conveyor, which is extremely efficient in filling glass bottles, HDPE bottles and PET bottles, and can quickly convert containers and product types.

The above is a multi-functional device that combines various elements of the juice industry and the milk industry. Therefore, the composition of beverages from those ingredients is no longer the focus. In the case of a milk processing plant, milk can be mixed as an intermediate product with a concentrate. If it is a juice production plant, you can use the milk powder to redraw the milk. In the case of ready-to-drink coffee producers, milk can be used as a base product, mixed with a certain proportion of coffee and sugar, and milk powder and coffee can be added as a basis. Krones is able to complement all the products used in the production of fresh milk and beverages, and has contracted various projects in Germany, Italy, France, the United Kingdom, the United States, Asia and Africa, and even successfully demonstrated in some extremely complex projects. A strong strength.