Juice tunnel pasteurizer

Types of juice tunnel pasteurizers

A juice tunnel pasteurizer is a continuous pasteurization system for various liquids, including fruit juice. Juice tunnel pasteurizers are also known as UHT (Ultra-High Temperature) processing systems. They are vital in the food and beverage industry because they can kill harmful microorganisms in liquid products without significantly affecting their nutritional value or taste.

Hotels, restaurants, hospitals, schools, and beverage production plants are some of the applications where juice tunnel pasteurizers are used. They are preferred in these settings because they allow for rapid pasteurization and cooling of large quantities of juice. The efficiency of these machines makes it easy to produce juice that can be stored for long periods without refrigeration.

There are three main types of juice tunnel pasteurizers, including:

• Thermal Spiral Pasteurizers: These pasteurizers use a spiral configuration to create a compact footprint while ensuring efficient heat transfer. The juice is pumped through a helical pathway, exposing it to heating and cooling mediums in different sections of the spiral.
• Thermal Tunnels Pasteurizers: This is the most common type of pasteurizer. The beverage is first exposed to hot water/steam for a specified period before it is cooled down rapidly using cold water. The pasteurizer has three sections: heating, holding, and cooling section. It is about 100 meters long and 40 meters wide. Bottled juices are transported through the tunnel using conveyor belts. The juice is heated to a temperature of 90-95°C for 15-30 seconds. Then, it is rapidly cooled down to 5-10°C using cold water. Finally, the bottles are sent to the filling machine. Thermal tunnel pasteurizers are suitable for larger production lines.
• Spiral Pasteurizers: These machines have a compact design. The juice is heated and then cooled as it travels through a spiral stainless steel tube. The spiral tubes are usually enclosed in insulated cabinets with hot water jackets or cooling jackets on the outside. This machine can also be used to freeze fruit juice, and it has a less complicated cleaning system than other pasteurizers.

All juice tunnel pasteurizers comply with the food hygiene standards required for processing and manufacturing food items. The machines are easy to operate, and juice producers can use them to make various processed liquids, including flavored milk, liquid eggs, soy milk, and tea. Despite the long manufacturing costs involved, the machines extend the shelf life of beverages up to 12 months without any added preservatives.

Specifications and maintenance of juice tunnel pasteurizers

The specifications of juice pasteurizer tunnels can be described through critical features such as product flow rate, temperature control system, cooling system, energy efficiency, sterilization standards, automation level, and dimensions.

• Product flow rate: Juice tunnel pasteurizers are available in different sizes, and the capacity typically varies depending on the machine's length, number of belts, and motors. For example, a 5-meter juice tunnel pasteurizer can handle 500 to 2000 bottles per hour.
• Temperature control system: Modern juice pasteurizers have microcontroller-based temperature controllers with RTD sensors. These controllers can maintain and adjust the temperature with an accuracy of +/- 2°F (1°C) within the pasteurization range. In addition to the accuracy of the controllers, the total time the juice remains in the pasteurizer also affects the pasteurization efficacy.
• Cooling System: After the heating section, there is a cooling zone in the pasteurizer, which is also part of the tunnel. The cooling system can be either a water brine or cooling coils. The juice or beverage in the pasteurizer should be cool enough for consumers to drink without fear of it being too hot.
• Energy Efficiency: Juice tunnel pasteurizers are energy-saving systems. The energy consumption of the machines can be between 10 and 15 kwh per ton of processed juice, depending on the machine's design and the juice's pasteurization temperature.
• Sterilization Standards: Juice tunnel pasteurizers comply with specific sterilization standards, such as the F0 value. The F0 value is cumulative sterilization that can be equivalent to certain temperature and time combinations to achieve the desired sterilization effects at different temperatures. For example, an F0 value of 6.4 represents a cumulative sterilization equivalent to 121.1 degrees Celsius for 30 minutes, which is sufficient to achieve the minimum requirement for the sterilization of juice in pasteurizers.
• Automation Level: Juice tunnel pasteurizers vary depending on whether they are entry-level machines, mid-range, or high-end units. Entry-level machines have more buttons and a simplistic control method. Mid-range units have more advanced controls and fewer buttons, while high-end units are fully automated with digital displays and automatic steps for self-control, etc.
• Dimensions: The size of the pasteurizer is important to determine where the machine can be placed in a food factory. For instance, 5-meter pasteurizers may have an average width of 2 meters and an average height of 3 meters.

Maintenance

The maintenance of juice tunnel pasteurizers mainly begins with cleaning and sanitizing. After that, routine inspections of the machines are essential to ensure that all parts are working correctly. The temperature and pressure gauges should be calibrated periodically to ensure accuracy, while the coolant levels should also be monitored. Drain valves, strainers, and spray nozzles should be checked periodically to ensure that no clogs affect the machine's performance. Any leaks, unusual sounds, or warning lights indicating potential hazards should be addressed promptly. Some parts like belts, bearings, and chains require lubrication and periodic replacements to avoid affecting the energy efficiency of the machine. Operating manuals and specific maintenance requirements according to the machines' models should be reviewed. More specifically, juice tunnel pasteurizer maintenance can be further classified into the following types:

• Monthly: Clean the entrance and exit of the juice tunnel pasteurizer. Thoroughly wash both sides and remove any residue.
• Quarterly: After disconnecting the power supply, clean the pasteurizer part by scraping off the accumulated dirt inside. This will help in maintaining the sanitation level.
• Biannually: Lubricate each part of the pasteurizer, such as the bearings, chains, and transmission parts. In addition, check and eliminate the belts of late food products to avoid possible mistakes. More specifically, the transmission and drive parts of the juice tunnel pasteurizer should be lubricated with Lithium grease, and the conveyor chains with Loso Chain oil.
• Yearly: Perform a thorough inspection of the entire juice tunnel and check for loosening of parts. In addition, inspect the heating elements of the juice tunnel pasteurizer, such as the boiler and electric heating elements, including the pasteurization mechanism, drain system, and cooling system. During inspection, replace electric heating elements if required.

Applications of juice tunnel pasteurizers

Juice tunnel pasteurizers are useful in different industries and applications. The following are some of them:

• Fruit processing industry

  In the fruit processing industry, juice pasteurizers are applied to treat fruit juices, such as orange, apple, pear, and berry juices, amongst others. The juices are heated to eliminate pathogenic bacteria and enhance shelf life.

• Beverage manufacturing

  Beverage manufacturers, both carbonated and non-carbonated, use juice pasteurizers to ensure public safety and compliance with regulations. The machines are applied to pasteurize fruit-flavored drinks, iced tea, and sports drinks, amongst others.

• Dairy industry

  In the dairy industry, juice pasteurizers are used to process beverages that combine fruit juice and dairy products, such as yogurt and smoothies. Also, they can be used to pasteurize juice-derived dairy beverages. The combination results in an extended product shelf life and safety for consumers.

• Catering industry

  In the catering industry, juice pasteurizers are used by large-scale food service operations, such as hospitals, schools, restaurants, and hotels. The catering facilities use the machines to produce safe and flavorful fruit juices and beverages for their customers.

• Export companies

  Companies that intend to export fruit juice have to ensure that their products comply with international standards. Thus, they can use a juice pasteurizer for pre-treatment before exporting the juice to foreign markets. Additionally, the pasteurizers can boost the juice's shelf life during transportation.

• Small-scale juice bars and kiosks

  Pasteurization is an important process that guarantees consumer safety; therefore, some juice bars and kiosks opt for pasteurization systems for their beverages. In this case, a juice tunnel pasteurizer is applicable to heat-treat freshly squeezed juices and avoid cross-contamination.

• Research and development

  Food scientists and technologists use juice tunnel pasteurizers for product development and research. The scientists can experiment with different juice formulations, evaluate the impact of pasteurization on juice quality, and create new juice processing techniques.

How to choose juice tunnel pasteurizers

Before investing in juice pasteurization tunnels, beverage makers and other buyers need to conduct thorough research to identify suitable juice pasteurizer machines for their needs.

• Production capacity

  Industry players need to determine the ideal capacity of the juice pasteurizer tunnel to meet their processing demands. Consider the preferred product volumes and whether the machine will efficiently handle the required capacity. Additionally, check if the equipment's design will allow for future expansion to avoid making another investment if the business grows.

• Quality preservation

  Buyers need to pick a juice pasteurizer tunnel that will maintain the product's nutritional value, flavor, and freshness. The ideal equipment will have precise temperature control to ensure optimal pasteurization without overdoing it.

• Flexibility and adaptability

  Choose a juice pasteurizer that can handle several varieties of juices with different acidity and composition. Additionally, the ideal machine will adapt various pasteurization schedules

• Automation and control features

  Consider the level of automation and control functions offered by the juice pasteurizer. Look for features like digital monitoring, automated temperature and time controls, and data logging capabilities for precise control and streamlined operation.

• Hygiene and Cleaning

  A hygienic and easily cleanable design is important to maintain product quality and comply with food safety standards. Consider machines with smooth, rounded surfaces, accessible in confined spaces, and efficient cleaning systems, such as CIP (Clean-in-Place) capabilities.

Juice tunnel pasteurizer FAQ

Q1: How long does the juice tunnel pasteurizer take to pasteurize juice?

A1: The duration of pasteurizing juice with a tunnel pasteurizer varies depending on factors like the volume of juice, desired pasteurization temperature, and the equipment's capacity. Tunnel pasteurizers use a continuous system. In this system, the juice passes through different heating zones. Each zone has a different hold time, but on average, pasteurization takes about 15 to 30 minutes. For large batches of juice, the tunnel pasteurizer is more time-efficient.

Q2: What temperature do juice tunnel pasteurizers use?

A2: Juice tunnel pasteurizers use various temperatures depending on the type and target microorganisms of juice. The temperature also depends on the desired juice flavor and shelf life. Generally, the temperature ranges from 60 to 80 degrees C. Higher pasteurization temperatures kill more microorganisms, resulting in a longer juice shelf life.

Q3: Are juice tunnel pasteurizers eco-friendly?

A3: Juice tunnel pasteurizers are not eco-friendly. They use a lot of energy and water. Additionally, the temperature required for pasteurization causes the juice to lose some of its nutritional value.