Tetra Pak ​​​​​​​​​​​​Tetra Therm Aseptic VTIS line with Tetra Alex TA400 homogeniser

Tetra Pak ​​​​​​​​​​​​Tetra Therm Aseptic VTIS line with Tetra Alex TA400 homogeniser. Aseptic processing unit for continuous UHT treatment with direct steam injection. Mainly for heat-sensitive low-acid products such as milk, enriched milk, cream, soy milk, formulated dairy products, ice-cream mix, dairy desserts as well as ESL (extended shelf life) products. Previously used in a milk factory in Europe.

The unit is fully automated to safeguard the aseptic status while in production. The operation can be divided into four steps:

• Pre-sterilization
• Production
• Aseptic intermediate cleaning (AIC)
• Cleaning in place (CIP)

Before production can start, it is necessary to sterilize the aseptic area by circulating pressurized hot water. After sterilization, the unit is cooled down to production temperature. Finally, sterile water is circulated through the product circuit.

Production starts by filling the unit with product via the balance tank. The product displaces the water/product mix to the drain or reject tank. A specially designed balance tank and valve arrangement minimizes the amount of mixed product.

When an aseptic tank or filling machine is ready, production can start. The product is regeneratively pre-heated to about 80 °C in a Tetra Spiraflo tubular heat exchanger. Instant heating to sterilization temperature takes place in the steam injector by continuous injection of high pressure steam into the product.

The product enters a holding tube where it is held at sterilization temperature for the required period of time. The product then enters the flash vessel where the pressure and temperature drop instantly. The excess water in the form of steam is flashed off.

For optimal product stability, the product passes through an aseptic homogenizer before final cooling in the heat exchanger.

Aseptic intermediate cleaning (AIC) can be performed to prolong the production time between full CIPs. When AIC is selected, the product is displaced by sterile water before cleaning starts. During the AIC sequences, the holding tube is kept at the sterilization temperature, thus keeping the aseptic parts of the unit sterile. The AIC can be performed either with lye only or lye and acid flush. After each production run, the unit undergoes CIP with both lye and acid. If the product supply fails or a stop at a filling machine occurs, the unit goes into sterile water circulation.

Standard temperature programs for white milk: 5 - 80 - 140 - holding 4 seconds - 81 - homogenization - 20/25°C.

The current line existing out of:

High Pressure Homogeniser

Manufacturer: Tetra Pak

Model: Tetra Alex 400

Capacity: up to 15.000 ltr/h @ 400 bar

Year: 2016

Serial number: 5871116178

Motor: 400 V - 50 Hz - 340 A - 200 kW - 1.488 rpm

Parts of the homogeniser block, 2x pistons, pulley on the drivework and hydraulic system are missing, see photos.

Expansion vessel for flash cooling with built-in condenser

Manufacturer: Bujalski in the name of Tetra Pak

Model: ZBB-11-1

Year: 2016

Serial number: 160333

Capacity: 1.220 liter

Max. allowable pressure: 3,5 bar

Min. allowable pressure: -1,0 bar

Max. allowable temperature: 148 °C

Min. allowable temperature: 0 °C

Weight: 530 kg

Design code: EN-13445-3:2014

Skid 01 (CP11)

• Centrifugal pump (Alfa Laval LKH-25, 11 kW, impellor 205 mm, serial nr: 199787).
• Centrifugal pump (Alfa Laval LKH-50, 15 kW, impellor 190 mm, serial nr: 200136).
• Flowplate.
• Control panel (T5844130774, 3544-1264).

Skid 02 (CP51)

Direct heating module with:

• Steam injector for direct heating of the product.
• Centrifugal pump (Alfa Laval LKH-25, 15 kW, impellor 205 mm, serialnr 200788).
• Vacuum pump (SIHI, LEMB 161 8Z).
• Valves, pipes, fittings.
• Control panel with regulator 01 and 02 (T5844130774, 3544-1264)

Skid 03

Steam feed supply skid with 2x Samson valves and some additional piping and valves.

Plate Heat Exchanger:

Manufacturer: Tetra Pak

Model: MS10-SM

Year: 2016

Serial number: 30109-16228

Volume: 250 liter

Pressure: 0/16,0 Bar

Temperature: 0/150 °C

Number of Sections: 2x

Plate heat exchanger for cooling of recirculating water for the condenser in the expansion vessel.

Tubular Heat Exchanger 01

Manufacturer: Tetra Pak

Model: C-85

Year: 2016

Serial number: 1163426 01-21

Product: Fluid II

Design pressure PS Shell 0-16 bar and Tubes 0-40 bar

Design temperature Shell 0-180°C and Tubes 0-180°C

Volume Shell 352,4 liter and Tubes 243,4liter

Test pressure PT Shell 25,6 bar and Tubes 64 bar

Tubular Heat Exchanger 02

Manufacturer: Tetra Pak

Model: C-85

Year: 2019

Serial number: 1193240 01-11

Product: Fluid II

Design pressure PS Shell 0-20 bar and Tubes 0-40 bar

Design temperature Shell 0-180°C and Tubes 0-180°C

Volume Shell 187 liter and Tubes 126,6 liter

Test pressure PT Shell 32 bar and Tubes 64 bar

Excluded in the UHT:

• Product balance tank with level control and product bowl.
• Flow meter for water.
• Flow meter for product.
• Brazed plate heat exchanger for heating in the water circuit.
• Batch header tank CIP dosing system.
• Several pipes, bends, valves, internal signal wiring, pipes for signal wiring and fittings required for the assembly of the UHT system.
• Frequency converters.
• Main Control panel with PLC control and TPOP human-machine interface (HMI).
• Technical documentation.

Missing in the homogeniser:

Parts of the homogeniser block, 2x pistons, pulley on the drivework and hydraulic system are missing, see photos.