Nestle Binh An

GROWTH
Aseptic system
Training
August 25th 28th, 2014

TM-TPVN/HT
7/23/16

Day 1:
Milk & Aseptic technology

TM-TPVN/HT
7/23/16

Aseptic processing systems

Absolute sterility not possible

Bacteria

N
Logarithmic destruction
Time/temperature would be
too drastic
Not possible to prove
by random testing
Not possible to prove sterility
(prove absence)

t Time
PSD.TPD&B.TH.3.02, AA05

Aseptic processing systems

Sterilization of food requires that all living

microorganisms be inactivated, including the
pathogens.
Product remains fresh for months without
refrigeration and preservatives.
Product:
Low acid (food pH > 4.5, milk pH > 6.5)
High acid (food pH < 4.5, milk pH < 6.5)

Product

Temp(C)

Time

Low acid

135-140

A few seconds

High acid

90-95

15-30 seconds

TM-TPVN/HT
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Aseptic processing systems

UHT - Ultra High Temperature

Vegetative cells

Yeast

Spores

Pathogenes

Mould

Virus

Aseptic processing systems

UHT - Ultra High Temperature

Vegetative
cells

Pathogenes

Spores
Yeast

Mould

Virus

Aseptic processing systems

Ultra High Temperature processes

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Machine Introduction General

Product lifetime

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Aseptic processing systems

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Aseptic processing systems

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Aseptic processing systems

Pre-processing

Deaeration
Separation
Standardization
Homogenization
Pasteurization

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Aseptic processing systems

Deaeration with Tetra Alrox

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Aseptic processing systems

Homogenization

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Aseptic processing systems

Homogenization of dairy products

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Thermal treatment definitions

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Thermal treatment definitions

Sterilization

A process applied to a product with the object of

destroying all micro-organisms (by heat treatment
exceeding 100C)

Sterile

Condition in which living cells are absent or killed.

Sterilizer

Equipment used for sterilization: autoclave, hydrostatic

sterilizer or aseptic processing plant

Commercially sterile product

Product which is free from micro-organisms that can

grow and contribute to its deterioration under the
intended storage conditions

Aseptic

Condition to prevent bacteriological contamination

Thermal treatment definitions

The commercially sterile product must

Keep without deterioration

Remain stable and good commercial

value during storage

Free from micro-organisms and toxins

harmful to the health of consumers

Absolute sterility not possible

Thermal destruction is logarithmic

Not possible to prove by

random testing

Thermal treatment definitions

D-Value
The express D65 = 1 min
means that the number of organisms is
reduced with 1 D when treated one minute
at a processing temperature of 65 C.
2 minutes exposure results in 2D
1D = 90% reduction = 1 LCR
2D = 99% reduction = 2 LCR
3D = 99,9% reduction = 3 LCR
4D = 99,99% reduction = 4 LCR
LCR: Logarithmic Reduction

Thermal treatment definitions

Sterilization Efficiency
The Sterilization Efficiency of a
process is the number of LCR that
it gives on the most resistant
microorganism.

Thermal treatment definitions

z-Value
Is the change in temperature in C required
to cause 10 fold change in D-value
z = (T1-T2)/(logD1-LogD2)
A certain micro-organism is
characterized by a z-value of 10 C

Thermal treatment definitions

Most heat resistant of spores
Bacteria

D90-value (hrs)

B. Stearothermophilus
B. Subtilis
B. Cereus

> 100

30

C. Botulinum, strains A

D121-value (sec)
300

60
3

C. Botulinum, strains B/E <0,02

12
1,4
< 0,05

Thermal treatment definitions

Typical killing data for some micro-organisms
Group of Orgsm

D-value (min)

Vegetative Bacteria
(heat sensitive)

65

Vegetative bacteria
(heat resistant)

10

65

Bateria spores

0,2

121

Yeast and Mould

65

Mould
3
(heat resistant ascospores)

90

Temp (C)

Thermal treatment definitions

Definition of F0-value
The F0 makes it possible to compare the effect
of different time/temperature combinations
t

= sterilization time (s)

T = sterilization temperature, (C)

z = the increase in temperature
necessary to obtain the same
effect in one tenth of the time
F0 = 1 when heated one minute at 121.1C
F0 3 to achieve a commercially sterile product

Thermal treatment definitions

Definition of C*-value
C*-value is an indicator of chemical
changes in the product associated
with heat treatment
C* = 1
= heat treatment at 135C for 30.5 s.
and z = 31.4C
= 3% destruction of thiamine

Thermal treatment definitions

Lactulose value

Indirect measurement of chemical changes

Lactulose is a type of milk sugar formed at

elevated temperatures and indicates the
extent of chemical changes to the product
e.g. the heat load

Lactulose is the way of measuring the

heat load on UHT milk, and also has
the advantage that its formation is
possible to calculate theoretically,
given the time-temperature curve

UHT treatment

Finding the optimal combination

of temperature and time
Sterilization effect
Chemical changes

Break

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Basic microbiology

Bacteria

Yeasts

Moulds

Basic microbiology
Multiplication of bacteria

1024
10 000 000
bacteria bacteria

30 min.
Generation time

30 min

11,5
hours

Basic microbiology

Temperature
conditions for

Maximum
Optimum

bacterial
growth

Minimum

Basic microbiology

Classification
of bacteria
by temperature
preference

Thermophilic

45 C

Mesophilic
20 C
Psychrophilic
7 C

Psychrotrophic

Basic microbiology
The influence of Temperature
Bacterial development in raw milk
Mio Bact/ml

Hours

Time-temperature combinations

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Time-temperature
Lethal effect on bacteria

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Time-temperature
Destruction of enzymes and micro-organisms

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Time-temperature
Combinations needed for destruction of spores

Lunch

Milk properties
Analyse of milk
The common tests carried out
on milk supplies are:

taste and smell

cleaning
sediment
somatic cell count
bacteria count
protein content
fat content
freezing point

Milk properties
Composition of Cow's Milk
Fat 4.1%
Protein 3.4%
Lactose 4.8% MSNF
Salt 0.7%

Water 87%

Total solid
=
Dry matter

Milk properties
Size of Cow's Milk Constituents

Whey Proteins

Bacteria

Lactose

Casein

Fat

Salts

0,0001

0,001

0,01

0,1

1,0

10,0

Particle size
100,0

Milk properties
Structure of milk

Fat globule

Skim milk

Milk properties
Raw milk quality

for processability:
pH
alcohol stability

6.65-6.80
>75%

for sterility level:

limit of heat resistant spores

Milk properties
Comparison of processability of Buffalo milk and Cows milk

Quality

Cows milk

Buffalo milk

Fat content (%)

3,2 - 4,8

6-7

Protein content (%)

3,2 - 3,4

4,3 - 4,5

Casein content (%)

2,6 - 2,8

3,51 - 4,36

Whey proteins (%)

0,6 - 0,8

0,53

75

142,2

6,65 - 6,80

6,9

80

72

Colloidal Ca (mg/100ml)
pH
Alcohol stability (%)

Milk properties
Quality paameters for raw material UHT products
Improvement of
hygienic
conditions in raw
material
production
Total Count
Flavour
Adulteration
Somatic Cell Count
Etc.

Factors pertaining to
the suitablity of
production
Spore Count
Protein Stability
pH
Dirt particles
Thermoresistant
enzymes
Etc.

Types of milk

UHT systems

UHT systems
Full range of solutions
Direct heating

Injection
Infusion

Indirect heating

PHE
THE

UHT systems Selection guide

Objective advice!

Premium
quality

4 UHT technologies
Tetra Pak masters
them all
Your demands
decide!

DIRECT
DIRECT
UHT UHT Product
properties
injection
infusion UHT
INDIRECT
INDIRECT
UHT
PHE
THE
Outstanding
efficiency

Types of UHT
Direct or indirect?

Direct UHT
Steam injection or steam infusion
Almost instantaneous heating & cooling
Low impact on quality
Higher operating cost

160C
Direct

Indirect

140C
120C
100C

Indirect UHT

80C

Tubular or plate heat exchanger

Somewhat slower heating and cooling
Somewhat higher impact on quality
Lower operating cost

60C
40C
20C
Pasteurization

20

40

60

80

100

120

SEC

Available TP Portfolios

Indirect systems

Tetra Therm Aseptic Flex

Direct systems

Tetra Therm Aseptic VTIS

Available TP Portfolios
Aseptic tank system

Tetra Alsafe LA

Available TP Portfolios
Aseptic dosing

Tetra Aldose

Aseptic dosing

Tetra FlexDos

Available TP Portfolios
Tetra Therm Aseptic Flex

Cost-effective

Efficient operation by indirect

heating in tubular heat exchanger
Applications from white milk to
high viscous ice cream mix
Capacities from 2,000 - 40,000l/h

Available TP Portfolios
TA Flex Simplified flowchart

Available TP Portfolios
Tetra Therm Aseptic Flex

Tetra Spiraflo

Tubular heat exchanger (THE)

Floating ends for thermal expansion

Available TP Portfolios
Tetra Therm Aseptic Flex

Tetra Alex homogenizers

Improved efficiency
with counter-pressure
Efficient break-up of
clusters
Minimal number of
spare parts

Available TP Portfolios
Tetra Therm Aseptic VTIS

Premium product quality

Direct heating by steam injection or

steam infusion
Applications from white milk to high
viscous ice cream mix
Capacities from 2,000 - 30,000l/h

Available TP Portfolios
TA VTIS
Simplified flowchart

Available TP Portfolios
Tetra Therm Aseptic VTIS

Direct steam injection

Instant heating, temperature equilibrium and condensation

Very low fouling outstanding cleanability
Unique verified performance

Available TP Portfolios
Tetra Therm Aseptic VTIS

Steam infusion

Patented air
insulation design
reduces fouling
Patented, even
steam distribution

Available TP Portfolios
Tetra Therm Aseptic VTIS

Flash cooling

High-precision temp. control

Large product surface gives

instant cooling

Low carry-over

Unique, built-in condenser

gives short pre-sterilization
and cleaning times

Extremely low hold-up

volume

Easy access for inspection,

service and maintenance

Processing principles

UHT milk manufacturing process

Pre-sterilization

Production

(Aseptic Intermediate CIP AIC)

CIP

Day 2:
UHT

TM-TPVN/HT
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UHT Operation

Tetra Therm Aseptic Flex - NG CM

Ser. No.: T5844151227
Indirect UHT
Continuous aseptic processing module
Using Tubular Heat Exchanger (THE)
Product: Milo

TM-TPVN/HT
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Technical data

Tetra Therm Aseptic Flex - NG CM

Ser. No.: T5844151227
Indirect UHT
Continuous aseptic processing module
Using Tubular Heat Exchanger (THE)
Product: Milo

TM-TPVN/HT
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Technical data

Noise Emission
Product configuration
Connection data
Specification, heat exchanger

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Main components and functions

Feed module
Booster module
THE
Homogenizer
Local control panels (FCP)
Motor panels (MCC)
Homogenizer panel (MCC)

TM-TPVN/HT
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Main components and functions

TM-TPVN/HT
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P&ID detailed tracing - Use colored P&ID

Main sides
Pre-heating

Holding cell
Aseptic side

Cooling

Balance Tank

Hot water side

TM-TPVN/HT
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P&ID detailed tracing - Use colored P&ID

Measuring points
TC44

TSL42
PT05

PC78
TC67

TT08

PC74

PC68

TM-TPVN/HT
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P&ID detailed tracing - Use colored P&ID

Hot water circuit

M10

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P&ID detailed tracing - Use colored P&ID

Hot water circuit

M9

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Machine Introduction Main steps

Sterilizing
Production
AIC
CIP

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Activations diagram
Sterile water Production AIC Shutdown EM Emptying

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Activations diagram
Full CIP

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Activations diagram
Adapted Cleaning

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Activations diagram
Header batch sub-program

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Machine steps
Process cycle: Phases and Steps
Step 1 17: Sterile water
Step 21 45: Production
Step 51 55: AIC
Step 70 71: Shutdown
Step 80 85: Emergency emptying
Step 101 149: CIP (Full cleaning)

TM-TPVN/HT
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