Tetra Pak® Pasteurizer PFEfficient pasteurization for ambient or hot filling Prepared Food production

ApplicationThe Tetra Pak® Pasteurizer for prepared foods is an invest-ment efficient and versatile continuous processing unit. It is aimed for indirect heating and cooling of desserts, fruit preparation, soups, sauces, tomato preparations and baby food as well as other low or high acid viscous products with or without particles. The unit can be equipped with different types of heat exchangers, depending on application. The pasteurizer is available as a stand-alone unit or as part of a complete line concept.

Highlights• Available with either tubular or plate heat

exchangers to optimize configuration for best design and efficiency

• Featuring consistent high food quality, enabled by full traceability with the Advanced Automation Solution Tetra PlantMaster™

• Ensures uncompromising food safety, due to high hygienic design elements according to EHEDG

• Optimizes operational efficiency, due to long running time and minimized energy consumption

• Adaptable cleaning program to secure food safety and optimized production efficiency

• Guaranteed performance, e.g. running time, product loss etc.

Maximizing versatility and efficiencyTetra Pak Pasteurizer PF, makes it possible to produce high quality products at low operation costs. Using heat generation design, when applicable on water side, it offers optimized energy consumption in a wide range of regenerative heating.

Tubular heat exchanger with floating protection system minimizes maintenance and eliminates cracks in the tube. For corrosive products, such as ketchup, corrosion-resistant material like SMO254 is used. Protection panels in stain-less steel lower the energy losses with up to 15%. Straight tubes enable visual inspection if needed. Plate heat ex-changer with optimized chevron and distribution pattern maximizes heat transfer efficiency. The plate heat exchanger is easy to open, which minimizes downtime at service. For products containing high salt content, e.g. soy sauce, titanium plates are used.

The unit offers optimal versatility with possibility to produce a wide range of products at different viscosities, smooth or with particles up to 9 mm in diameter. Option with aseptic hibernation function saves energy up to 75% during sterile water circulation. The optional pressurised internal sterili-sation loop minimizes energy consumption during start-up and water circulation. Advanced automation for reduced human error and maintained product quality. Logging of process parameters enables traceability for food safety.

Working principleThe module is fully automated using PLC control for safe operation and production. The operation can be divided into four steps:• Pre-sterilization• Production• Intermediate cleaning• CIP (Cleaning-In-Place)

Before production can start it is necessary to sterilize the aseptic area of the unit by circulating pressurized hot water. An internal sterilizing loop minimizes the energy consumption and start-up time. After sterilization the unit is cooled down step by step to production temperature. Finally, sterile water is circulated through the production unit.

When the receiving equipment is ready production starts by filling the unit with product, displacing the water to drain. The water/product mix phase can be sent to drain or reject tank. Thereafter continuous production is running.

If product supply or receiving equipment fails, sterile water displaces the product and the pasteurizer goes into sterile circulation. The product is heated in either tubular or plate heat exchangers by an indirect hot water circuit. The product passes through a holding tube for the required period of time. A temperature guard automatically monitors the product temperature after the holding tube.

If the temperature drops below the pre-set value, an alarm will be activated, production will automatically cease and the receiving equipment will close. Cooling to filling temperature takes place in additional tubular or plate heat exchangers. In order to prolong the production period between CIP, an intermediate cleaning can be performed. When intermediate cleaning is selected, the product is displaced by sterile water before cleaning starts. During the intermediate cleaning sequences, the holding tube is kept at the sterilization temperature, thus the aseptic parts in the module remain sterile. The intermediate cleaning can be performed either with lye only or lye and acid flush. This enables longer available production time on the pasteurizer before full CIP is required. After each production run, the module undergoes CIP with both lye and acid. The CIP sequences can be configured for optimized cleaning result.

Example of production parameters for ketchup

Pasteurization Sterilization

Ambient filling Hot filling Ambient filling

Product inlet temperature °C: 30 30 30

Deaeration temperature °C: 70-75 70-75 70-75

Homogenization temperature °C: 65-70 65-70 65-70

Pasteurization temperature °C: 95-98 95-98 >121

Holding time (Volumetric), seconds: 30 30 30

Product outlet temperature °C: 30 85-95 30

Pre-sterilization temperature °C: 98-110 98-110 >121

Pre-sterilization time, minutes: 30 30 30

* Temperature program for other products, please contact your local representative

CapacityThe capacity range for Tetra Pak® Pasteurizer depends on the application, see example in chart. For other capacities, please contact your Tetra Pak representative for more information.

Processing parametersTemperature program is specific for each application.

Standard equipment• Product balance tank with level control• Frequency controlled product pump• Product flow meter• Centrifugal water pump• Water flow meter• Brazed plate heat exchangers for heating in

the water circuit• Centrifugal CIP booster pump• Valves, pipes, fittings• Frequency converters, mounted on the frame• Pre-wired signal/power cables• Tubular or plate heat exchanger, depending on

application• Control panel mounted on the main module• Pneumatic, remote-controlled sanitary valves• Product piping in AISI 316• Set of pipes, bends, valves, internal signal wiring, pipes

for signal wiring and fittings required for the pre-erection of the system

• Factory pre-assembled and tested before delivery• Engineering, programming• Technical documentation in European Economic Area

(EEA) official languages

Tetra Pak Pasteurizer PF

Control panelTetra Pak® Pasteurizer PF uses a PLC based control system Type Siemens. The HMI is Type B&R. The control system is prepared for integration with Tetra PlantMaster™.

Optional equipmentFood safety• SMO254 material in tubular heat exchanger and

titanium in plate heat exchanger for corrosive products• Positive product pressure and pressure supervision

Cleaning-In-Place (CIP)• Ratio dosing of CIP detergents• Conductivity switch for supervision of CIP media change• Back-flush cleaning of heat exchanger for products

containing fibres

Product inlet

From filler orstorage tank

To filler orstorage tank

Product reject

Steam

Tower water

Tower water

Ice water

Product reject

Product inlet

From filler orstorage tank

To filler orstorage tank

Tower/Cooling water

Steam

Flow charts

THE-based

PHE-based

Operational efficiency• Automatic CIP of balance tank• Energy hibernation (EH) for reduced energy

consumption• Different levels of heat recovery

Special food treatment• High temperature program for product safety• Tetra Alrox® deaerator for product quality and long

running time• Multiple holding tubes• TetraPak® Homogenizer for product quality

Automation and control• Air cooling unit• UPS, Uninterrupted Power Supply• Relay communication• HMI 21.5’’ full HD TFT display and visualization

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Revision

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Document NoScale

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Branded Processing Unit LayoutTetra Pak® Pasteurizer PFSStandard Layout THE

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Working and service area

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Homogenizer

Modules Capacity Amax B C D E F G J*Feed Module Pasteurizer PFS 5000 l/h 3200 2400

Deaerator DD 500 3000 - 5000 l/h 1800 4800Deaerator DD 750 5000 - 10 000 l/h 1800 5200Tetra Alex 200, 200 bar 3000 - 5000 l/h 800 1310 1540 1000 1000 1530Heat Exchanger THE CHM85 5000 l/h 1650

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We reserve the rights to introduce design modifications without prior notice, Tetra Pak, ,PROTECTS WHAT’S GOOD, Tetra PlantMaster are trademarks belonging to the Tetra Pak Group.

www.tetrapak.com

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Consumption data (For ambient filling of ketchup 5,000 kg/h)

Media Design temperature

Design pressure

Consumption Pre-sterilization

Consumption Production

Consumption CIP

Steam – 6 bar 1,065 kg/h * 762 kg/h 593 kg/h *

Instrument air – 6 bar 50 Nl/min 50 Nl/min 200 Nl/min *

Potable water 15°C 3 bar 5,000 l/h * 600 l/h 11,290 l/h *

Ice water 2°C 3 bar 30,000 l/h ** 30,000 l/h –

Tower water 30°C 3 bar – 30,000 l/h –

* No or low consumption during circulation. ** During pre-sterilization above 100°C.

Media Voltage Consumption Note

3-phase power 380V/50Hz 25 kWHomogenizer not

included

1-phase power 220V/50Hz 1 kW

Dimensions (Example for 5,000 kg/h ketchup)