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Particulate Filling

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What impacts particulates filling capability
Key elements for particulates filling

Product Processing Filling machine Package


characteristics & settings

Quality Control
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Product characteristics

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Wide varieties of particulates in the market
Hardness and dimension are crucial for the characterization

CITRUS VESICLES / SACS FIBERS


Collapsed / whole vesicles Tomato peels
fruit wires

SOFT / GELATINOUS PARTICLES HARD PARTICLES


Nata de Coco Seeds
Aloe cereal / nuts / grains
stone cells

SOFT / HARD FRUIT PIECES


Peach cubes
Pineapple pieces

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Note: Definition may differ from country to country or from customer to customer MM/2015-03-16
How do particulates impact filling capability?

It is critical to understand the following:


Size, content and physical properties of particulates
Property of carrier

Before performing filling trials it is very important


to characterize products to be able to execute
filling process in the best possible way.

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Processing for
Particulates Filling

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Processing line critical process parameters

HEAT / HOLD TIME PARTICULATES PARTICULATES


DISTRIBUTION INTEGRITY

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Heat/Hold time depends on particulate types
particulates might need different heat/hold profile

120 C Liquid
Particulates
100 C

80 C

60 C

40 C

20 C

0 C
0 SEC 50 SEC 100 SEC 150 SEC 200 SEC 250 SEC 300 SEC 350 SEC 400 SEC

6.000 lph, 95C / 15s, 15% particulates 6x6x6 mm


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Particulates distribution

Aseptic tank and agitator design are crucial to control


particulates distribution and ensure particulates integrity

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Particulates integrity

Pumps need to be designed for gentle


handling of sensitive products
Heat exchanger to be selected
according to the product type
Pipe diameter in the heat exchanger
needs to be matched to the size of
particulates

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3 typical particulates processing layout design

Aseptic single line single stream


Aseptic single line with in-line dosing of particulates
Aseptic dual line double stream

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Aseptic single line single stream

Pulp
particulates

Mixing Aseptic
Sterilizer Filling
tanks storage

ADVANTAGES LIMITATIONS
Carrier
Traditional design Particulate size
Simple operation Long holding time for juice
Lower investment level

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Aseptic single line with in-line dosing of particulates

Pulp Mixing
particulates tanks

Mixing Aseptic
Juice Steriliser Filling
tanks storage

ADVANTAGES LIMITATIONS
Effective deaeration of juice Extended holding time
Improved particulate integrity for juice
Cost efficient line Medium investment level

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Aseptic dual line dual stream line
For superior product quality

Pulp Mixing Aseptic


Steriliser
particulates tanks storage

Aseptic
Filling
mix/storage

Mixing Aseptic
Juice Steriliser
tanks storage

ADVANTAGES LIMITATIONS
Good particulate integrity Higher investment level
Effective deaeration of juice
Optimal holding time for juice
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Processing investment level

ASEPTIC SINGLE LINE FOR HOMOGENEOUS


NON PARTICULATES PRODUCT: 100%
ASEPTIC SINGLE LINE SINGLE
STREAM FOR PARTICULATES: 150%
ASEPTIC SINGLE LINE WITH IN-LINE
DOSING FOR PARTICULATES: 175%
ASEPTIC DUAL LINE DUAL STREAM
FOR PARTICULATES: 300%

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Tetra Vertenso is the integrated solution for particulates
Tetra Pak design for optimal processing solution

Pre mix tanks Tetra Therm Aseptic Drink Tetra Alsafe

Tetra VertensoTM
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Roll fed filling equipment
for particulates filling

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What enables particulates filling on roll fed machines?
Two elements are crucial for particulates filling

1 PARTICULATES SEALING KIT


2
Transversal sealing

2
1 2 PARTICULATES FILLING KIT
Regulating valve
Counter pressure flange in the filling pipe
assembly

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* Please note that once the kit is installed, the equipment can work with homogenous product. MM/2015-03-16
Particulates sealing kit
Mandatory for all particulates products

PAPER TUBE WITH PRODUCT


Dollies Radius 15 Mushroom
TRANSVERSAL SEALING PART
Installation of Radius 15 dolly to apply
effective pressure and push the product out
from the sealing area

Flat Dolly Mushroom dollies*


*Not needed for homogeneous products

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Particulates filling kit
Required for specific particulate dimensions

PRODUCT REGULATING VALVE


Servo valve
Shutter

wider opening section

COUNTER PRESSURE FLANGE

wider longitudinal section

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Tetra Pak
Particulates packing capability

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Package portfolio with particulates
Wide range of packages

Particulates sealing and filling kits are available for all packages*

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*Except: Tetra Brik Aseptic 80 S, 100 B and 125 S MM/2015-03-16
Equipment portfolio for particulates
Filling and sealing kits can be installed on:

TBA/19
0100*, 0200, 0300, 0400, 0500

Tetra Pak A3/CompactFlex


0100, 0200, 0300
Tetra Pak E3/CompactFlex**
0100

Tetra Pak A3/Flex


0200, 0300, 0400

*TBA/19 0100: ready for Q3 2015 External


** TP E3/CF pasteurised & ESL MM/2015-03-16
Equipment portfolio for particulates
No kits needed on:

TT/3 XH Ambient

TR/27 XH

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Importance of package functionality
Selection of the right material and opening for each product

The package material should be selected according to


the product content

Straws, caps should be selected according to the


particulate dimensions

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Tetra Pak filling capability

ASEPTIC ROLL FED CHILLED & *HAAD


SYSTEMS BLANK FED SYSTEM

Tetra Brik Aseptic / Tetra Prisma Aseptic /


Tetra Rex & Tetra Top
Tetra Gemina Aseptic

Continuous Intermittent
filling filling

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*High acid ambient distribution MM/2015-03-16
Tetra Pak particulates capability
Roll fed filling

78% of products in the market


Package Integrity risk

Hard particles
< 0.2 mm
up to 3% Soft cereals Orange vesicles
2x2x2 mm >8%
Nata de Coco Orange
& Grass jelly vesicles
3x3x5 mm up to 20 mm
up to 8% ww up to 8% ww
Tomato Sauce with
garlic/basil
Peach (small particles)
4x4x4 mm
Passata / Tomato Frito up to 5% ww
(no or small particles, no seeds)

Light Green / Green Orange


Feasible To be assessed

Particles Size & High % WW


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Light green zone: what Tetra Pak can pack
With particulates sealing kit

Maximum Particulate
Element Wet weight
Dimension Hardness

Hard particles 0.2mm Hard Up to 3%

Nata de coco &


3x3x5mm Gummy and slippery Up to 8%
Grass Jelly

Seeds: 0.2mm
Tomato Passata Hard Up to 3%
Skins: 3x3mm

Tomato Frito
Basil: 3x3mm Up to 3%
(Passata & basil, garlic, Low
Garlic, Carrot: 3x3x3mm (total amount of particles)
carrot) *

Orange Vesicles 20 mm (length)


Low Up to 8%
(collapsed) randomly distributed

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* No onion nor oregano MM/2015-03-16
Light green zone applications

Filling Machine availability:


TBA/19 all dev steps (note: 0100 Q3 2015)
Tetra Pak A3/Flex 0200, 0300, 0400
Tetra Pak A3/CompactFlex 0100, 0200, 0300
Tetra Pak E3/CompactFlex 0100 (Pasteurised & ESL)

Assumptions in order to successfully pack particulates:


Homogeneous distribution inside the product
Installation of sealing kit

Packages:
Almost all packages can be fulfilled with particulates except for:
TBA 80S/ TBA 100base/TBA 125S (due to TS 6mm fin height
too narrow geometrical design constrain)

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Green zone: what Tetra Pak can pack
With particulates sealing & filling kits

Maximum Particulate
Element Wet weight
Dimension Hardness

Peach 4x4x4 mm Gummy and slippery Up to 5 %

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Green zone applications

Filling Machine availability:


TBA/19 all dev steps (note: 0100 Q3 2015)
Tetra Pak A3/Flex 0200, 0300, 0400
Tetra Pak A3/CompactFlex 0100, 0200, 0300
Tetra Pak E3/CompactFlex 0100 (Pasteurised & ESL)

Assumptions in order to successfully pack particulates:


Homogeneous distribution inside the product
Installation of sealing kit & particulates kit

Packages:
Almost all packages can be fulfilled with particulates except for:
TBA 80S/ TBA 100base/TBA 125S (due to TS 6mm fin height
too narrow geometrical design constrain)

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Example of particulates kit capability
Installation time required - Carton Value - Continuous filling

Down time

Machine Filling kit Sealing kit Total


TBA/19 30 mins 30 mins
Light Green

Tetra Pak A3/CompactFlex Not required 10 mins 10 mins

Tetra Pak A3/Flex 10 mins 10 mins


TBA/19 20 hours 30 mins 20h 30 mins
Green

Tetra Pak A3/CompactFlex 16 hours 10 mins 16h 10 mins

Tetra Pak A3/Flex 0200 and above 1 hour 10 mins 01h 10 mins

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Orange zone: case by case evaluation

Element Dimension Hardness Wet weight

Soft cereals
2x2x2 mm Not applicable 4%
(flakes)

Tomato frito
(onion, garlic, Between 2x2x2 and
Not applicable 3%
3x3x3 mm
no oreganon)

Tomato sauce with Between 1mm and 2


Between
small particles mm lenght Not applicable
1 and 2 %
(skins and seeds) <0.2 mm

Orange vesicles No length limit Not applicable >8% ww

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Samples of particulate filling capability
with Tetra Top & Tetra Rex systems
Intermittent filling
99% of products in the market
Hard

Nuts, grains, Pineapple


seed cereals
Nata de Coco
& grass jelly Pineapple

Kiwi
Strawberry Strawberry
Passata / Tomato Frito
(no or small particles, no seeds)
Soft

Orange Peach Peach

Light Green / Green Orange


Feasible To be assessed

Fibre & Pulp Particle Size 10x10x10 mm 15x15x15 mm


0 mpas Viscosity <1000 mpas External
(JNSD) (yoghurt) MM/2015-03-16
How can we support you in
developing new product
recipes

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Customer Innovation Centers (CIC): global support in
processing and packaging of particulate products
LUND
Capability to process particulate
products up to 20mm.
Particulate filling kit TBA/19 GOTEMBA
(TBA250B) Capability to process
Tetra Top particulate products
up to 4mm.
Particulate filling kit
AARHUS TBA/19 (TBA200S)
GORREDIJK
LE MAY
DENTON SHANGHAI
Capability to process particulate Capability to process
products up to10mm. particulate products
Particulate filling kit for: up to 4mm.
Tetra Pak A3/CompactFlex 330ml PUNE Particulate filling kit
DreamCap (April 2015) TBA/19 (TBA250B)
Tetra Pak A3/
CompactFlex
(TPA200Sq)
CAMPINAS

SINGAPORE
Capability to process particulate
PACKAGING & PROCESSING products up to 5mm.
POWDER APPLICATIONS Particulate filling kit TBA/19 (TBA250S)
ICE-CREAM External
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