Direct steam injection sterilizer

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1 Stematic Long Run Stematic Long Run Direct steam injection sterilizer

STEMATIC LONG RUN - Direct steam injection sterilizer Stematic long run

potential and know how in the UHT sterilization fi eld, Stematic Long Run

that can be adopted for the UHT treatment of foodstuff to be aseptically fi

problems related to milk sterilization; strict process tests on pilot

performance, premium quality of the fi nished product and remarkable

Stematic Long Run is covered by international patents and offers the

2 STEMATIC LONG RUN - Direct steam injection sterilizer Stematic long run Direct steam injection sterilizer Expression of Rossi & Catelli s innovatory potential and know how in the UHT sterilization fi eld, Stematic Long Run is, from a technologic point of view, the most advanced and reliable plant that can be adopted for the UHT treatment of foodstuff to be aseptically fi lled. It is the result of systematic studies carried out on all aspects and problems related to milk sterilization; strict process tests on pilot plants, research of the most effective solution to ensure excellent performance, premium quality of the fi nished product and remarkable economic advantages. Stematic Long Run is covered by international patents and offers the additional advantage of a fully automated control and supervision system. Overall view of a Stematic Long Run A-M plant for milk production having l/h working capacity 2

Range of products: Milk. Flavoured milk.

Base product for ice-cream. Soy milk. Flavoured soy milk.

Construction features The plant includes: surge tank for product collection,

product filter, multitube heat exchanger for product preheating by fl ash-cooler

raising/stabilizing up to about 80 C, by means of indirect steam, steam

The vessel is externally manufactured in stainless steel and the internal

3 Range of products: Milk. Flavoured milk. Cream for coffee, whipping cream, cooking cream. Bechamel. Base product for ice-cream. Soy milk. Flavoured soy milk. Milk-based puddings and desserts. Soy-based puddings and desserts. Construction features The plant includes: surge tank for product collection, high-pressure centrifugal pump for product feeding to the heat exchanger, product filter, multitube heat exchanger for product preheating by fl ash-cooler recovered vapours, multitube heat exchanger for product temperature raising/stabilizing up to about 80 C, by means of indirect steam, steam injection sterilizer (patented), for product temperature increasing up to about 150 C (adjustable value). The sterilizer is properly designed to ensure perfect steam distribution. The vessel is externally manufactured in stainless steel and the internal surfaces in contact with the product are made of a non-stick material to prevent the product from burning, tubular holding section suitable to keep sterilizing temperature steady, Top: Side view of the product feeding unit. Down: Side view of multitube heat exchangers. 3

STEMATIC LONG RUN - Direct steam injection sterilizer vacuum flash-cooler for the instantaneous cooling down of the product to about 80 C, while released

The machine, manufactured according to EC Directive 89/392/CEE and subsequent ones, includes: - compression head fi tted with compression block made of

diaphragm analog pressure gauge, homogenization chamber, - overpressure valve, spring-loaded type, placed on the compression head, - homogenizing valve,

electric panel including control instruments and a frequency converter for variable product capacity, multitube cooling section for product temperature

pumping pistons, valves, temperature detectors, thermometers, pressure gauges, piping and fittings, control system including: - power board, - control

4 STEMATIC LONG RUN - Direct steam injection sterilizer vacuum flash-cooler for the instantaneous cooling down of the product to about 80 C, while released vapours are conveyed to the condenser/recovery unit, aseptic centrifugal pump for product feeding to the homogenizer, high-pressure aseptic homogenizer. The machine, manufactured according to EC Directive 89/392/CEE and subsequent ones, includes: - compression head fi tted with compression block made of forged nickel-chrome-molybdenum steel, self-aligned pumping pistons made of chrome coated stainless steel, double-guide suction and delivery valves, diaphragm analog pressure gauge, homogenization chamber, - overpressure valve, spring-loaded type, placed on the compression head, - homogenizing valve, - cast iron body containing all the driving components, - driving system with AC motor, - stainless steel casing, - lubricating system, - stainless steel electric panel including control instruments and a frequency converter for variable product capacity, multitube cooling section for product temperature cooling, washing solutions preparation system, condensate preparation system to lubricate the aseptic pump mechanical seal and the aseptic homogenizer pumping pistons, valves, temperature detectors, thermometers, pressure gauges, piping and fittings, control system including: - power board, - control board, - pneumatic boards, circuit connections protected by temperature-controlled steam barriers. Left: injection head detail Right: Side view of fl ash-cooler 4

Supervision system The supervision system allows the display of all fi eld variables, recording all historical processing data and carrying out all operations required to attain the best possible

5 Supervision system The supervision system allows the display of all fi eld variables, recording all historical processing data and carrying out all operations required to attain the best possible performance of the plant. Line management takes place by means of a personal computer, fi tted with touch screen color video and connected to the PLC; while the supervision system is a 32 bit application software based on an open structure running in a Windows NT or 2000 environment. Characteristics of the supervision program: Dynamic block diagram of the unit with display of each motor status (run, shut-down, alarm, stop and rpm) and of each valve (open, closed) with piping color depending on the fl uid contained in each operational phase. Indication of all operational phases of the unit (washing, production, rinsing, etc.) and relevant sub-phases. Dynamic display of all PID controller operations with real-time trend of the last 10 minutes of work (setpoint, controlled variables and controller output graphs). Possibility of controlling each valve or motor automatically or manually (in the latter case there is a password protection). Operational parameters input. Product parameters input. Recording of all process variables and graphic display. Recording and display of all alarms. Recording and display of production data. This data can be downloaded directly from the Ethernet network or through fl oppy disk and processed on other stations (optional). Options SOFTWARE for PC data download and historical file printing A program for printing historical data from the remote station is available. Data can be moved to said station by fl oppy disk or local network, if present. All temperature values can be printed, with selection of the day and of three contemporaneous curves on each graph. An alarm print-out is also provided, by selecting the day as well. Suitable functions allow to sequence print, at the end of each day, a series of temperatures and alarms by means of one single control. Une page-écran du système de supervision. 5

STEMATIC LONG RUN - Direct steam injection sterilizer Running features Once thermal conditions for the production is achieved, the product is fed to a surge tank and, by means of the fi rst

The product is then transferred to a second multitube heat exchanger and subsequently fed to the injection head where it is instantaneously heated up to the sterilization temperature by means of

6 STEMATIC LONG RUN - Direct steam injection sterilizer Running features Once thermal conditions for the production is achieved, the product is fed to a surge tank and, by means of the fi rst centrifugal pump, is transferred to a multitube heat exchanger where it is heated-up to about 80 C by means of heat recovery obtained from vapours extracted from fl ash cooler. The product is then transferred to a second multitube heat exchanger and subsequently fed to the injection head where it is instantaneously heated up to the sterilization temperature by means of direct steam injection. Product is maintained at a steady sterilizing temperature in the tubular holding section; then it passes through the fl ash-cooler that provides, under vacuum conditions, the instantaneous expansion cooling the vapour extraction so to restore the initial solid content, the undesirable smell stripping (off fl avours). At this point, a second centrifugal pump, properly equipped to safeguard the sterility, transfers the product to the homogenizer conceived in order to avoid the phase separation during the product shelf-life. The product is fi nally water-cooled in a multitube heat exchanger and can be conveyed to intermediate aseptic tanks or directly to aseptic fi llers. HOLDING HOLDING 6

7 Overall view of a Stematic Long Run A-XXL plant for milk production having l/h working capacity. MILK STEAM WATER STERILE AIR 7

8 STEMATIC LONG RUN - Direct steam injection sterilizer Cream preparation Stematic Long Run is particularly recommended for UHT treatment of cooking cream with any fat content. Pumps are fi tted with special propellers duly designed to gently handle the cream and avoid possible whipping or foaming. The plant can be equipped with mono or lobe pumps on request. Front-view of a Stematic Long Run A-L plant for soy milk production having l/h working capacity. 8

Stematic Long Run Pilot Plant The pilot plant,

to laboratory tests and small productions.

products to 100 l/h for thick and viscous

The plant has the same structural features that

and the possibility to manage the processing

9 Stematic Long Run Pilot Plant The pilot plant, monoblock execution assembled on skid, is devoted to laboratory tests and small productions. The output ranges from 200 l/h for liquid products to 100 l/h for thick and viscous products. The plant has the same structural features that can be found on the industrial production plants and the possibility to manage the processing variables (capacity, pressure, temperature, level). Therefore it is possible to carry out any test focused to optimize the production and to develop new product research. Lateral view of a Stematic Long Run Pilot Plant 9

10 STEMATIC LONG RUN - Direct steam injection sterilizer Advantages and strong points Time-temperature chart high capacity (up to 40 m3/h) short depreciation period, continuous production cycles of up to 48 hours, without intermediate washing; low incidence of times and costs connected to washing cycles, reduced product losses, short product residence time at the sterilization temperature, instantaneous product heating and cooling, preservation of the organoleptic and nutritional characteristics of the fi nished product, temperature-controlled steam barriers in all critical points: aseptic conditions assured, reduced overall dimensions and fl exibility thanks to modular execution. fully independent CIP system for plant washing and calcium deposit removal, supervision on WINDOWS operating system: fully accessible and rearrangeable system C 83 STEAM INJECTION FLASH COOLING PREHEATING 18" PASTEURIZING HOLDING OF STERILIZATION HOMOGENEIZATION COOLING 4" 6" 15" 40" sec. 0 10" 20" 30" 40" 50" 60" 70" 80" 90" 10

11 Technical characteristics STEMATIC A-SS* A-S A-M A-L A-LL A-XL A-XXL A-XXLL Capacity Dimensions A width B depth C heigth Installed electric power** Steam Well water l/h mm mm mm kw kg/h l/h STEMATIC CREAM A-SS*/P A-S/P A-M/P A-L/P Capacity Dimensions A width B depth C heigth Installed electric power** Steam Chilled water l/h mm mm mm kw kg/h l/h * Model integrated and assembled on skid ** Aseptic homogenizer included 11

12 10/2005 cgp.it Rossi & Catelli S.p.A. - Via Traversetolo, 2/A Parma - Italia - ph fax info@rossicatelli.com

Programme area 4a. Fluid Energy Machines

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