P R O C E S S I N G S Y S T E M S

In technical collaboration with HRS International Ltd., UK

nnovative Technology & Processing Lines

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HRS Process Systems Limited (HRS PSL) is part of the UK based HRS Group which is a forerunner in heat transfer

technology with over a decade of expertise, providing sustainable and cutting edge heat transfer solutions to the

process industry.

Armed with ISO 9001: 2008 certification, ASME ‘U’ stamp accreditation, high rating from CRISIL and honored with the

prestigious “UK Trade and Investment India Business Awards 2007” in the “Innovation of the year” category, HRS is

dedicated to working closely with customers and helping them stay ahead with its unmatched process equipment

expertise. Our state-of-the-art facility near Pune (India) follows the best practices for manufacturing our entire range of

heat exchangers and heat exchanger based systems.

HRS product range includes ECOFLUX* Corrugated Tube Heat Exchangers (CTHE), ECOFLUX* Smooth Tube Heat ®Exchangers (STHE), HRS FUNKE Plate Heat Exchangers (PHE), UNICUS Scraped Surface Heat Exchangers and heat

exchanger based systems; and pasteurisers, aseptic steriliser and filler, evaporators, UHT systems for fruits, vegetables,

beverages, dairy and nutraceuticals.

In addition to worldwide presence, HRS Group has a

research centre in Spain, where development is carried

out on processing techniques for the food industry.

This enables HRS to offer innovative solutions

enhancing technological competitiveness. Through a

proven track record in design, manufacturing and

impeccable services support, HRS has become trusted

name in the industry!

Why Choose HRS ?

Total Integrated Solutions for Food /

Fruit / Beverage / Dairy & Nutraceuticals

Pasteurisers

HRS Monobloc*

HRS ParaDice*

Evaporator

CIP Systems

UHT Systems

Nutraceutical Processing Systems

Beverage Processing Lines

Ready-to-eat Food Processing Lines

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Our Innovative Product

Range

Hygienic

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ECOFLUX* CTHE

ECOFLUX* STHE

HRS Funke Plate Heat

Exchanger

UNICUS* Scraped

Surface Heat

Exchanger

Piston Pump

Aseptic Filler

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Global Expertise and

References

Over 9000 installed

units in a decade

Quality heat transfer

solutions ensuring

sustainability with a

competitive edge

Global manufacturing

facility for HRS Group

l Innovative

Technology

l Application

Engineering

l Customised

Solutions

l Impeccable

Services Support

HRS provides an array of innovative, hygienic heat exchangers and well automated systems for the food processing

industry. Our solutions are designed to meet the increasing demands for enhanced capacities, uninterrupted processes

and at the same time meet the stringent quality norms, regulations and safety standards of the domestic and

international markets.

Innovative Solutions for Food Industry

Food Systems Overview

BeverageProcessing

Lines

UNICUS*SSHE

HRS ParaDice*

HRS Funke PHE

ECOFLUX*CTHE

HRS Monobloc*

(Aseptic Steriliser& Filler)

UHTSystemsNutraceutical

ProcessingSystems

Hygienic Piston Pump

Pulp Pasteuriser

Evaporator

CIP Systems

ECOFLUX* Corrugated Tube Heat Exchangers (CTHE)

The development of corrugated tubes is perhaps the most exciting advancement in heat transfer technology. HRS has

mastered the making of corrugated tube to enable different flow regimes – spiral at the core and eddies at periphery.

This avoids the formation of the boundary layer, thereby boosting the heat transfer coefficient higher at low Reynolds

number with minimum increase in pressure loss in an exceptionally compact space. .

ECOFLUX* Corrugated Tube Heat Exchangers are specially designed and manufactured according to international

standards including TEMA, ASME, PED with design programs such as ChemCAD, HTRI, SolidWorks, etc.

‘MI’ Series : Multitube heat

exchanger is especially designed

for food industry. The inner

corrugated tubes carry the

process media and corrugated

shell carries service media.

‘DT’ Series : The monotube is

tube-in-tube heat exchanger.

While the inner tube carries the

process media, the outer tube

carries the service media.

‘AS’ Series : The annular space

version is a tube-in-tube-in-tube

heat exchanger. The innermost

tube and outer tube carries the

service media while the process

media passes through the

annulus between these two

tubes.

‘K’ Series : Corrugated tubes are

bundled into smooth profile

shell. This heat exchanger is

designed for various industrial

applications.

Applications

Pre-heating, Heating, Cooling,

Chilling, Pasteurisation,

Sterilisation, Evaporation

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ECOFLUX* Models

Advantages

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Turbulence is created at low fluid

velocities to enhance heat transfer

Fouling on tube surface is

minimized

Smooth indented inner profile

ensures easy cleaning

High response to CIP enables heat

transfer in viscous products

Uniform thermal processing

These equipments for the food processing sector are

made to the guidelines of European Pressure

Equipment Directive and also for Food and Drugs

Administration (FDA & EHDGE).

HRS Funke Plate Heat Exchanger (PHE)

HRS has acquired exclusive rights by the way of license

manufacturing agreement for design, manufacture,

supply and service of Plate Heat Exchangers, with

FUNKE Warmeaustauscher GmbH! HRS Funke Plate

Heat Exchangers are used for specialized applications

in food and dairy industry. The range incorporates

pressed, herringbone patterned heat transfer plates,

mounted in an alternate inverse formation to create

two channels, one for each fluid. A large number of

points of support are created where the pressings

intersect, which leads to a high level of turbulence and

subsequently excellent heat transfer properties.

Features

Well-researched in-house design

Variations in plate embossing for highest

efficiency

Available in a range of SS, exotic materials to

suit the process needs

Multi section units consisting two or more plate

packs separated by intermediate plate or

C-Plates

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Innovative Solutions for Food Industry

Advantages

Reduction in operational downtime due to

glueless clip type gaskets

Secured seal with number of two-pronged clips

that slide beneath the plate to hold the gasket

Avoid cross contamination of two fluids by

double seal arrangement

Ideal for Heating, Cooling, Chilling,

Pasteurisation, Sterilisation

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®UNICUS Scraped Surface Heat Exchangers

®UNICUS Scraped Surface Heat Exchanger is a

specially developed patented product with a unique

scraping mechanism which optimizes the heat

exchange area thereby enhancing the heat transfer

coefficient for high viscosity / fouling applications. This

is specially advantageous for processing viscous,

particulate products.

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Patented non-fouling scrapping mechanism

reduces production loss

Lower induced shear stress in the product,

Product particle integrity is maintained

Hygienic design to global food processing

equipment norms, including certifications

High heat transfer coefficient, increase in

turbulence, even at low velocity for viscous

products

Low maintenance cost as no rotating parts

Features & Advantages

Heating, Cooling, Chilling, Pasteurisation,

Evaporation and Aseptic Processing of high

viscosity, Fibrous and particulate products like fruit

juices / fibers / dices, fruit pulp, purees, food

paste, yoghurt, pudding, vegetable pieces, soups

Applications

HRS piston pump is hydraulically

operated positive displacement pump

that has been designed for pumping

delicate and particulate foods. HRS

Piston Pump is of a completely

hygienic design, and incorporates a

separator fitted between the pump

and the hydraulic chamber to ensure

that there is no contact between the

product and hydraulic oil.

The hygienic design combined with a

perfect response to CIP cleaning

makes this pump suited to food

processing applications where product

integrity and shape must be

guaranteed, to maintain both

appearance and nutritional quality.

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Handle particulate products

delicately

No product breakage; maintains

product integrity\

Hygienic design, perfect

response to CIP

No seals in contact with product

Self priming and will draw the

product from the storage vessel

Can work under vacuum

Variants in a range of diameters

to suit the process

Features

Piston Pump Clean-in-Place (CIP) Systems

The technology of Clean-in-Place (CIP) is vital in food industry to have

hygienic and aseptic process environment to meet food safety

standards like HACCP and ISO. CIP allows cleaning of the interior

surfaces of pipes, vessels, process equipment and other associated

fittings without disassembly. Usually, CIP is carried out with chemical

solutions with caustic soda or similar bases and acids like nitric acid, to

clean the organic and inorganic solid deposits on the tube surfaces,

thereby eliminating product contamination

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Single skid mounted equipment for easy installation and mobility

Suitable velocities can be maintained for effective cleaning

Highly automated with sensors, pneumatic valves and PLC based

controls

CIP by single user operation of whole plant from one location

Data acquisition with SCADA

Design conformation with 3A, USDA, FDA and PMO standards

Features

Integrated Automated CIP Station

HRS excels in design and supply of built-in sophisticated CIP systems

advantageous over the conventional system which enable optimum

consumption of water, chemicals, steam and power, thereby

decreasing effluent discharge.

The CIP solution is heated in heat exchangers using steam and

condensate setup. Multiple tanks are provided each for water, caustic

and acid solutions. Selection of centrifugal pumps, CIP circuit design

and tank sizing is done on the basis of plant requirements. In large

systems, mix proof valves are provided to carry production and CIP in

the same processing area.

CIP Systems find applications across all types

of food, fruits, dairy, confectionary and many more industries to

ensure efficient, easy maintenance and hygienic process

environment.

Applications

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Processing of dices/ particulate and viscous

foods for end use in:

- Fruit bases, dices, extracts and toppings,

custards and puddings, soups, sauces, ice

cream with particles, salad dressing and

spreads, fillings and coatings

Processing of Ready-to-eat convenience foods,

Indian curries, mixes, mash, purees

Blanching and chilling of vegetables

Continuous rice cooking

Applications

Innovative Solutions for Food Industry

HRS ParaDice* is a unique offering from HRS Process

Systems for dices and ready-to-eat food processing

industry. This system is capable of processing fruit

dices / vegetable dices/ particulate foods without any

damage!

The dices are pumped using HRS Hygienic Piston

Pump and treated in the highly efficient ECOFLUX*

‘DT’ Series Heat Exchangers. These particulate foods

are pasteurised for hot fill or aseptically processed for

filling in aseptic containers.

This unique technology opens up a huge potential of

applications for food processing, to ensure better shelf

life, natural taste and structure for a range of foods.

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ECOFLUX* CTHE 'DT' series with specially

designed 'dimpled’ pattern tubes for rapid,

homogeneous heat transfer

HRS Hygienic Piston Pump – ‘BP’Series is the

core of the system for handling particulates

Closed loop hot water system with ECOFLUX*

CTHE for steam economy

Sanitary type valves, feed/ balance tank

Integrated CIP system

PLC based control panel with SCADA

Features

ParaDice*

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Retention of natural colour and flavour of

product

Processing of whole dices, leaves without

breakage

Hygienic design

Gives better product shelf life

Controlled process automation for easy

operation

Energy efficient CIP for hassle free

maintenance

Advantages

Pulp Preheater & Pasteuriser

Pulp or puree typically has a higher fiber content and

considerable plant cellular material in the suspension

compared with juice. Concentrated pulp has more

fibres and sugar per volume compared to single

strength pulp.

HRS PSL has revolutionized the fruit pulp, especially

mango pulp industry with advanced systems for pre-

heating and pasteurisation of fruit pulp. HRS

ECOFLUX* based pasteuriser heats the product upto

desired temperature and holding it for few seconds for

inactivation of microbes, followed by filling in cans to

ensure high product shelf life. The automatic control

panel provided with the pasteuriser allows minimum

intervention of operator thereby reducing human

errors.

HRS PSL also offers systems for chilling pulp using

tower water and chilled glycol for frozen pulp filling

and storage.

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Customized designs to suit varied capacities

Indirect, fast and uniform product heating using

pressurized water

Long productive hours due to unique designing

of heat exchangers

Branded system components and process

control instruments

De-aerator eliminates weight variation in filling

Fast CIP and nearly zero maintenance

Retention of natural colour, flavour and aroma

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Fruit purees, concentrates, confectionary bases

Tomato ketchup, Pulp of mango, orange, guava

and many more fruits

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ECOFLUX* MI series heat exchangers, skid and

skid-mounted balance tank

Hygienic, screw type positive displacement

pump and sanitary type flow diversion valves

CIP pump for faster cleaning of entire system

Closed loop hot water system consisting of

ECOFLUX* CTHE 'K' series

Integration with automatic can filling station

for uninterrupted production

PLC based instrument control panel including

SCADA provision

Features

Advantages

Applications

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Evaporator calendria

Vapour Separator

Surface Condenser

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Optimum utilization of thermal energy (Steam)

can be achieved in multiple effects with live

steam

Controlled operating condition for product

levels and retention time

Scaling retardation due to optimum velocity of

liquid in tubes

Easy to clean CIP system

Operator friendly PLC based system

Stability of operation and capacity of longer run

period giving better payback on investment

Evaporator

Handling of large volumes of liquid products has

always been a challenge in food applications.

Concentrating fruit pulps for reduction of volume by

reduction in water content gives longer shelf life to the

product and makes it easy for bulk transportation. The

concept of evaporation has evolved from these

requirements. Evaporation is the process of vaporizing

the water from a solution to generate concentrated

product.

HRS provides well engineered Evaporation Systems

incorporating our specialized range of heat exchangers

to suit the product thermal stability, with capacities

ranging upto 16 tons/ hr.

Advantages

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Deaeration/ Vacuum

System

Product Pump /

Condensate Pump

CIP Cleaning

System

Condensate

Recovery

PLC based

Automation

Key Components

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and concentrates

Applications

Innovative Solutions for Food Industry

Aseptic Filler

Aseptic packaging allows storing product processed in steriliser with excellent microbiological quality at ambient

temperature. This facilitates storage and transportation.

The aseptic filler series from HRS Aseptic Filler – 200 and HRS Aseptic Filler - 1000, designed and manufactured by

HRS, provides solution for filling liquid food in aseptic bags for the food processing industry.

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Automatic filling heads, complete structure with

stainless steel pallet conveying system

Designed to fill high and low acid fluids,

concentrates and particulate products

The automatic head design provides high filling

speed, No rotating platform is required

Flexible to fill aseptic bags (capacity ranging

from 10 to 1000 L) through 1” or 2 “ spouts

Weighing conveyor platform with control on

the filling process by load cell based system

Pressured hot water/ sanitary steam responsible

for sterilising the product lines (SIP), filling

chamber and seals

System of clamping bag edges to the filling

heads to avoid tension between spout and bag

Completely hygienic operations by automatic

CIP cleaning system

Aseptic 3 way valve that allows only the sterile

product into the filler

High pressure sanitary steam is used for

sterilisation of the fitment, cap and exposed

parts before each filling cycle

Precise weight control and labeling of drums.

Includes mass flow meter and load cells in the

filling and weighing platform

Pneumatic system allowing condensates

discharge during filling process

PLC self control system to continuously check

the conditions that provides high reliability in

the filling process

Aseptic filling for a range of foods such as fruit and

vegetable pulps, purees, particulates and concentrates

For mango, tomato, orange, guava and many more …

Features and Advantages

Applications

Innovative Solutions for Food Industry

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Compact unit of Aseptic Steriliser and Aseptic

Filler

Designed with ECOFLUX* CTHE for maximum

energy efficiency

Optimal velocities and turbulence for consistent

processing

De-aeration tank for air bubble removal

Homogenizer for uniform particulates

Bag-in-drum filling mechanism

Integrated CIP dosing system

Complete PLC based automation

HRS Monobloc Steriliser

HRS Monobloc Steriliser is an integration of the

Aseptic Steriliser and Aseptic Filler on a single skid fully

automated with PLC based controls.

This system is one of the latest advancements in our

product range to further offer innovative and hygienic

solutions thereby bringing global technology

advantage to our customers. Designed to process upto

7000 kg per hour of fruit pulp / puree concentrate of

high viscosity, the HRS Monobloc Steriliser comes with

aseptic filler for bag-in-drum filling mechanism.

The heart of the Aseptic Steriliser are the ECOFLUX*

‘AS’ series Corrugated Tube Heat Exchangers which

enable processing of the product at desired

temperature range, a piston pump for homogenizing

and de-aerator with automatic vacuum control system

supported with CIP pump and peripherals.

The filling section of the HRS Monobloc Steriliser is

with the Aseptic Filler which has fully automated,

double filler heads with bag clamping system,

conveyor to support the drums and a sanitary steam

line for sterilisation of the filling chambers.

Features

For processing of fruit pulps such as Mango, Guava,

Papaya, Banana, Tomato and many more for

Aseptic Sterilisation, Filling of purees & pastes

Concentration of fruit pulp, purees

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Applications

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Hygienic end product with better shelf life at

ambient storage temperature

Better aroma retention due to HTST technology

Continuous processing for consistent quality

Easy-to-operate with PLC controls

Integrated CIP to enhance equipment life

Lower maintenance

Advantages

Beverage Processing and HRS

There is a tremendous demand for ready-to-drink beverages in the market. Consumers are increasingly looking for

convenience foods and drinks, and at the same time have an eye for health consciousness in a busy routine.

Consequently, the concept of packed fruit juices has evolved. Primarily, this process involves pasteurisation of juices to

ensure the desired shelf life of the beverage.

HRS is the major supplier of pasteurisers for fruit based beverage industry. HRS designs turnkey beverage processing

lines using hygienic corrugated shell and tube heat exchanger for pasteurisation of fruit juices to inactivate micro-

organisms and to ensure the desired shelf life of the beverages. Parle Agro, PepsiCo India, Coca Cola, Nestle, ITC have

been our esteemed clients to name a few.

HRS India has supplied beverage pasteurisers incorporating ECOFLUX* MI Series heat exchangers ranging in capacity

from 1,000 to 30,000 l/h. HRS offers pasteurisers for filling in glass bottles, PET bottles and Aseptic packages. Products

being processed include pulpy beverages i.e. mango, orange and lemon, and also isotonic juices.

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Compact size, aesthetic design and low floor

space requirement

Prolonged production cycles due to self cleaning

nature of corrugated tubes

Close approach temperature that retains the

natural product flavor and nutrients

Steady product temperature control within

+ 0.5 degree

Indirect heating by low temp hot water

Heat enclosure to prevent radiation heat loss

Fully automated system avoiding manual

intervention

Positive pressure on product side over utilities

for extra safety

Precise flow control maintains constant holding

time throughout production

Energy recovery upto 90% depending upon

filling temperature in PET bottling / aseptic

packaging

Minimal product losses due to precisely

programmed product startup and end up

sequences

Faster and efficient cleaning due to forward and

reverse CIP cycles

Low water consumption due to accurately

automated CIP system

Features & Advantages

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ECOFLUX* Corrugated shell and tube heat

exchangers

System material of construction in SS316,

SS316L, SMO254, SAF2205, AL6XN, Titanium

Sanitary Centrifugal Pumps, Lobe pumps

Imported sanitary pneumatic actuated valves

Imported instruments and sensors for flow,

pressure, temperature and conductivity

measurement

PLC based control panel with touch screen HMI

and SCADA for centralized control

Key Components

Complete Beverage Processing Line

HRS is proficient in design and engineering complete

beverage processing plant starting from preparation to

pasteurisation.

An integrated fruit based beverage processing line

with multiple sections includes sugar syrup

preparation, pulp unloading, ingredient dosing

sections, beverage blending section, ready beverage

storage section, beverage pasteuriser and a centralized

CIP station.

HRS designed sugar syrup preparation section includes

insulated sugar dissolving tank with sugar dumping,

tubular heat exchanger for heating water and a jet

mixing system to dissolve sugar into the hot water. The

sugar syrup is filtered through a plate and frame filter

press, cooled and stored in holding tank. In the

beverage blending section, fruit pulp, flavours, sugar

syrup and other ingredients are blended together and

homogenized to be ready for transfer to beverage

tanks prioir to pasteurisation. The ready beverage is

processed in HRS pasteurisers manufactured with

energy efficient ECOFLUX* tubular heat exchangers.

Compact blending systems for dissolving essential ingredients

Innovative Solutions for Food Industry

Steriliser / Pasteuriser

Sugar Syrup Pulp Essential Ingredients

Blending Section

Beverage Tank

Aseptic FillingPET FillingRGB Filling

Advanced Solutions for Dairy, Nutraceuticals, Infant Food and Probiotic

The heat transfer technology from HRS has revolutionized thermal processing solutions right from basic heating,

cooling, chilling and condensation to more complex solutions like pasteurization, sterilization, evaporation and many

more such processes. This has been particularly very advantageous for the food, fruit and dairy processing industry.

The UHT Sterilizer by HRS has a complete hygienic design to give the final output at the desired temperatures. It can be

customized to suit varied capacity ranges from 1800 LPH to 18000 LPH (litres per hour) and comes with a special

provision for future capacity expansion.

The UHT Sterilizer is based on the principle of sterilization through hot water generated from steam. This process allows

heating milk at ultra high temperature to sterilize and then cool it to ambient temperature for further input to desired

aseptic packaging line. Milk is intermediately directed to deaerator for removal of dissolved oxygen and homogenizer

for product uniformity.

To ensure correct quality end product, this system is provided with special features and PLC automation controls to

enable for flawless operation with minimal manual interference.

The UHT sterilizer is programmed to perform CIP automatically and efficiently. High CIP flow velocities ensure proper

and effective cleaning of the equipment, thereby ensuring minimal downtime and ease of maintenance.

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Specially designed ECOFLUX* Corrugated Tube

Heat Exchanger based Aseptic Sterilizer

Uniform thermal processing

Suitable for working in high temperatures and

pressures

Longer production cycles

HTST & UHT technology for better product

shelf life

Provision to direct intermediate milk to

deaerator & homogenizer

Integrated automated CIP for easy maintenance

High response to Cleaning in Place (CIP)

Automated with PLC control and using mix

proof valves / seat valves

Minimal spares requirement

Integration with desired packaging system

Features and Advantages

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Regenerations efficiencies upto 90%

Compact designs, customized solutions

Low Maintenance cost

Higher shelf life & product uniformity

Improved product quality with hygienic

designs

End product cold storage not mandatory

thereby saving investment on infrastructure

Final product safety

Benefits

UHT Steriliser

Applications

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Milk

Flavoured Milk

Cream

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Yoghurt &

Fermented

milk products

Dairy

Formulations

Infant Food

HRS advantage is extended to the dairy industry

through state-of-art systems such as PHE based

pasteurisers, chillers, inoculation tanks and many

more solutions for milk, cream, whey, whey

cream, yoghurt, curd milk and allied products.

Demand for high quality Nutraceuticals is on the rise mainly because of the changing consumer lifestyle, need for

building immunity through right nutrition and increasing awareness about nutritional supplements.

With its trusted process and engineering know-how, HRS provides Nutraceutical processing systems for the food and

healthcare industries. The system is integrated with ECOFLUX* DT series based pasteurizer and ECOFLUX* MI series

water heater to form the powder mixing section, powder solution processing section and oil storage and dosing section.

The powder mix section includes a tri-blender, mixing cum storage tank and tubular heat exchangers for water RO

heating. Superior quality pumps are used for powder and essential nutrient mixing and dosing. This primary mix is

processed further for getting uniform particulates and finally pasteurised and cooled for sending it to next section.

For large plants, an independent multiple circuit CIP system is engineered with the nutraceutical processing system.

This consists of pumps and steam set-up to circulate CIP liquid at desired temperatures. The entire integration can be

done with separate control panels for main unit & CIP system.

Nutraceutical Processing

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Sanitary design for aseptic processing

environment to ensure final product safety

Uniform processing, longer production cycles

Custom-built system to suit varied capacities

Tri-blender for effective mixing

Complete with SS tanks for batches and

collection of diverted product

High end PLC automation using mix proof

valves and seat valves

Suitable for high temperature and pressure

conditions

Engineered with HRS’ process expertise to

ensure higher shelf life

High response to integrated closed loop CIP

Features and Advantages

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Probiotic Health Supplements

Dietary and vitamin supplements

Infant Food Substitutes

UHT/ HTST Milk sterilization

Dairy formulations

Applications

Substitutes

Innovative Solutions for Food Industry

HRS PROCESS SYSTEMS LIMITED

201/202, Karan Selene, 851, Bhandarkar Institute Road, Pune - 411 004. IndiaTel. : +91 20 2566 3581 / 82 / 6604 7894 / 95Fax : +91 20 2566 3583E-mail : info@hrsasia.co.inWeb : www.hrsasia.co.in

®UNICUS

SSHEECOFLUX*

CTHEHot Water Systems

Plate Heat Exchangers

ECOFLUX* STHE

CIP Systems EvaporatorHygienic Piston Pump

Food Systems