Công nghệ sản xuất nước giải khát hot fill Hot fill process

What Is the HotFill Process ?A beverage processing method that achieves microbiological stability by heat sterilizing a high acid product and filling while hot to sterilize the container, headspace, and closureGeneral Biological Microbiological Requirements for packaged products (long term shelf life outside of the “cold chain”): Free from live microorganism (CFU) to secure shelf live and avoid quality deterioration due to microbiological activities within the closed package Free from harmful ( toxic, pathogen ) metabolism and byproducts Free from active bio catalysts (enzymes) avoiding changes deterioration by autolysis Avoid visual {color, consistency}, chemical {composition }, physical { density, gas generation, viscosity } and organoleptic {smell, taste, sensory} deterioration by either live activities or decomposition effects of killed microorganism {autolysis}

Basics on Hot Fill Process

What Is the Hot-Fill Process ?

A beverage processing method that achieves microbiological stability by heat sterilizing a high acid product and

and filling while hot to sterilize the filling while hot to sterilize the

container, headspace, and closure.

Free from live microorganism (CFU) to secure shelf live and avoid quality deterioration due to microbiological activities within the closed

package

General Biological & Microbiological Requirements

for packaged products (long term shelf life

outside of the “cold chain”)

Free from harmful ( toxic, pathogen ) metabolism and by-products

Avoid visual {color, consistency}, chemical {composition }, physical { density, gas

generation, viscosity } and organoleptic {smell, taste, sensory} deterioration by either live

activities or decomposition effects of killed microorganism {autolysis}

Free from active bio catalysts (enzymes) avoiding changes & deterioration by autolysis

Hot Fill Basics

Product classification (according to pH)

High acid product Low acid product

Low acid teas

Milk Tea+milk Coffee+milk Flavoured milk

Ice Tea Sport drinks Apple juice Orange juice

Range of pH values for various juices

pH 4.6 is critical: pathogens cannot grow < pH 4.6

Growth Factor of Microorganism

9

Recommended Sterilizing Temperature approx 90 ºC

Recommended Sterilizing Temperature min 120 ºC

Hot Fill Basics

Temperature Classification of Microorganism

Hot Filling

Hot Fill Basics

Heat treatment parameters

 D Value : Thermal death time / decimal reduction time Value : Thermal death time / decimal reduction time

 Time required to kill 90% of microbes

 z Value : Thermal resistance constant Value : Thermal resistance constant

 Increase in temperature required to drop D 10 fold

 z is generally 5-10°C (9-18°F)

 F o Value : Time at 121°C to destroy an organism Value : Time at 121°C to destroy an organism

 C botulinum 12 log reduction (12-D)

Thermal treatment

 The destruction of a population of microorganisms is a function of time and temperature

 Both, temperature and time, are critical parameters :

 The effect of time on microbial destruction

 The rate of destruction with

temperature is a constant for any particular food environment

 We can calculate equivalent times

and temperatures

 For example: With z = 5.5,

95°C for 22 seconds = 90°C for 3 minutes

How do we calculate the time and

temperature needed to destroy microbes ?

0 5 10 15 20 25 30

8 7 6 5 4 3 2 1

65°C D=2.1 min

70°C D=0.93 min

75°C D=0.39 min

50 60 70 80 90 100

100 30 10 3 1 0.3 0.1 0.03 0.01

Temperature(°C)

Minutesfor 10-Fold Reduction

Effect of Temperature on Yeast Kill Rates

Z-Value = 13 °C

Equivalent Time-at-Temperature

Combinations

Log Reductions (Z-value

Log Reductions (Z-value = = 13°C 13 °C )

42.2 31.6 23.7 17.8 13.3 10.0 7.5 5.6 4.2 3.2 2.4 1.8 1.3 1.0 0.7 0.6 0.4 0.3 0.2 0.2 0.10

Sec

2530 2 1897 4 1422 8 1067 0 800.1 600.1 449.9 337.4 253.0 189.7 142.3 106.7 80.0 60.0 45.0 33.7 25.3 19.0 14.2 10.7 8.0

Pasteurization Conditions

°F

158.0 159.8 161.6 163.4 165.2 167.0 168.8 170.6 172.4 174.2 176.0 177.8 179.6 181.4 183.2 185.0 186.8 188.6 190.4 192.2 194.0

Min = Antilog °C – Equivalent to

(°C)

Z -Value

Microbial destruction

 At high temperatures, microbes are destroyed faster than quality factors such as color and nutrients are reduced :

 For this reason, a high temperature and short time, heat treatment is better for product quality than a lower temperature and longer time

Destruction of Pathogenic Microorganism Inactivation of Enzymes

Noticeable total cfu damage & reduction

Hot-Fill Technology for High Acid Beverages

Hot Fill Manufacturing Process

Major Control Points

 Understand and control initial microbial load of food ingredients and other incoming materials

 Meet processing conditions

 Product sterilization

 Filling temperature

 Head space and closure sterilization

 Final product temperature

 Sanitize incoming containers

 Protect the filling environment

 Perform system sanitation regularly

 Monitor the quality of cooling water

 Maintain GMP

Hot-Fill Line Main Components

Thermal Processing System

Secondary Packaging System

Finished Product Date Coder

Washer Containers

Culiniary Steam Treatment

Quarantine & Release

Hot-Fill PET Line Main Components

requirements for Hot Fill

 Washer validation

 Blend beverage- Magnetic Separator & Strainer.

 Blend beverage-Max Hold Time < 4 hrs (< 25*C).

 Blend Syrup- Max Hold; < 18 hrs (< 25*C)

< 24 hrs (< 15*C)

 Pasteurization 96-98*C for 5-10 secs.

 Auto Low Temperature Divert.

 Max Bev recirculation/bypass flow during

normal operation to be < 15% of beverage flow.

 Cool bypass beverage < 38*C.

requirements for Hot Fill

 Max time at Beverage full flow recirculation is one pass through the process (batch size X flow rate).

 Temperature recorders

 Return line from CIP circuit.

 Holding Loop Exit.

 Filler Bowl or entry to Filler Bowl.

 Recirculation cooling loop exit.

 Filling Temperature; Filler Bowl not less than 86*C.

requirements for Hot Fill

 Pasteurizer Heat Exchanger Design

 To minimize the potential for product cross contamination in the pasteurizer heat exchanger due to pinhole leaks or cracked plates by:

a) Monitor and record pressure readings in all sections of the pasteurizerb) Maintain sterile product pressure at 1-5 psi higher than non-sterile (Heating

or cooling medium) pressure by:

 Installation of an operational alarm activated by a pressure differential of less than 1-5 psi Automatic shut down for sanitation when pressure

drops to 0

 MOC –SS 304/316, 3A sanitary design, withstands 95-100*C for 30 minutes.

 Recirculation system

 enable partial to full-flow re-circulation (filler by-pass) capability

 provide a line to drain or flush the system

 cool re-circulated product typically to 38 °C, in a cooling heat exchange, before return to the process

requirements for Hot Fill

 Pasteurizer Heat Exchanger Design

 Water used as heating or cooling medium is drinking quality Hot process water medium is generated in a clean loop using steam.

 An inline meter is installed to measure flow through the heat exchange system.

 Before filling: pre-heat glass bottles

 Heat Closure before application by directing culinary steam at the inside surface for ≥ 0.1 second.

 Closure & Headspace Heat Treatment Invert

containers or otherwise ensure interior surface is ≥ 77°C for no less than

7 seconds or equivalent.

 Delay cooling for 45-60 seconds after filling.

requirements for Hot Fill

 Cooling Tunnel : Control in-package beverage temperature exiting the cooling tunnel to ≤ 40°C.

 Cooling water must be potable chlorinated (1-2 ppm)

 1-3 ppm free chlorine, < 8.0 pH, Hardness <100 ppm, Coliform, 0/100 ml,Total Count, < 25 cfu/ml.

 Homogenizer : should be able to homogenize at 200 bar ; not less than 95% of the beverage should be below 2u.

requirements for Hot Fill

CIP Step Pre-pasteurization (mixing /

blending tanks, storage tank, clarifier, homogenizer)

Post-pasteurization (heat exchanger, pipelines, filler)

•Rinse with hot water (>60°C) till residue is nil and thereafter for 3 more min

•Sanitize with hot treated water

•Rinse with hot water (>60°C) till residue is nil and thereafter for 3 more min

•Sanitize with hot treated water 93-99°C for 5Min

• Hot Acid circulated for 20 minutes (with nitric acid of 0.6 - 0.8 % v/v)

Simple Syrup Splitting using Magnetic Flow Meter

Requirement: Simple

syrup must be split using calibrated Magnetic flow meter

Purpose: To ensure

transfer of accurate quantity of syrup required for an unit and to avoid any variation in beverage

quality

Reference: India Division

Maaza Beverage Brix CAP

Washer Validation for sensitive beverages

 Proper Pre-inspection & Post Inspection stations.

 Double ended, two soak washer.

 Caustic 2.8 +/- 0.2%, 77+/-2*C @ > 8 mins.

 Low Soak Temp & Rinse pressure security.

 Auto caustic & additive dosage.

 Final rinse water to be potable & 5u filtered.

 Micro of washed containers.

 Validation protocol; 8 hours run.

 Re-qualify washer

 Every new package initial qualification

 Every 6 months following initial qualification

 Each time washer is taken down (drained) for service or maintenance or recharge.

 When washing conditions are changed (liquid concentration, detergent formula, soak time, additives, or temperature).

Homogenizer & Particle Size Distribution Analysis

• Particle Distribution Analysis is very important to know the pattern

of distribution of particles in the homogenized beverage.

• It is based on the Laser Diffraction Technology.

• Helps to know the % of particles over a defined range of particle size.

• Helps to study the Homogenizer Performance and Efficiency.

MAGNETIC TRAPS

A Typical Hot-Fill Thermal Processing System

Heat Exchanger

Balance Tank

Heat Exchanger

Tank Mix

Filler

Divert Valve

Filte r

Holding Loop

Magnetic Trap

FILLER BOWL

CROWNER

In-feed Star Wheel

Crowner In-feed Star wheel Crowner out-feed Star wheel

1 2 3 4

5 6

Temperature Scanner ( Camera )

Pneumatic Cylinder

Juice –Online Low Temp Rejection System

Heat Exchanger / Hold Loop

Trim Cooler

Incoming Product

Filled Package

@

89°C

97º C

5-10% Re-circulation

Balance

Tank

Heat Exchanger / Hold Loop

Trim Cooler

Incoming Product

Filled Package

@

89°C

95º C

Product Return Cooler Saver

Tank

Hot-Fill Process

Production Stops Due to Process Deviation

• In case of production stops filled uncrowned bottles to be removed after 1 minute.

• Package < 81*C at Cooling Tunnel entrance to be rejected.

Hot-Fill Process

Water Interface Recirculation

Balance Tank

Product Return Cooler

Heat Exchanger / Hold Loop

Trim Cooler

Water Recirculation (Water automatically replaces incoming product)

95º C

1 Pass- Citrus products and 3 pass for non-citrus

Heat Exchanger / Hold Loop

Trim Cooler

Incoming Product Replaces Water

Filled Package

Design Considerations for Thermal

 Optimize product yield by designing for

minimum water interface

 Reduce thermal abuse by minimizing product recirculation during filling, processing, and line stoppage

Filler- One Example model

Filling Environment Must Be Protected to Avoid Post Pasteurization Contamination

 Filling/Capping must be done in a positive air pressure environment

 Air turn over rate is 20-30 air changes / hour

 Monitor, inspect and replace air filter routinely

 Avoid materials in the filling room that cause

contamination (specifically corrugated boxes)

Heat Exchanger Design

PLATE HEAT EXCHANGER TUBE TYPE HEAT EXCHANGER

PRODUCTS WITHOUT OR WITH PULP UP TO

D.1 MM LENGTH 4 MM AND 5% OF THE

VOLUME OF THE BOTTLE

PRODUCTS WITH PULP WITH BIGGER DIMENSIONS

Two Common Types of Heat Exchanger Design

Closure Design & Application Are Critical in Avoiding Post Filling Contamination

 An improper applied closure will allow air & water to contaminate the product during cooling

 Thread design on the closure & finish must create a hermetic

seal

 Closures are sterilized by applying culinary steam jet to the liner.

 Minimize splashing product on threads during transfer from filler

to capper

 Hot Treated water spray is used to clean bottle threads prior to capping

 Optimize torque during application to provide a hermetically

sealed bottle that can be easily opened by the consumers (12 - 20

kg ･ cm)

 Cap Vision system is used to eliminate bottles with cocked caps

Water Spray on Bottle Finish

Meant for packages using Closures

Headspace Sterilization Is Critical

to Achieve Commercial Sterility

 Head space and inner surface of closure are

sterilized with hot product (Min 80 ° C, 30 sec)

 Containers are typically inverted to fully

expose the head space & closure to

sterilization temperature

 Head space should be minimized:

 To maintain package integrity (short filled PET

bottles will ovalize upon cooling)

 To reduce oxygen

 Additional Head space is sterilized by

showering in the first section of Tunnel Cooler

54°

C



Head Space Sterilization Bottle Inverter

Adequate Product Cooling

 The cooling tunnel must be designed to accommodate filling speed and required product exit temperature

 Even product distribution in the tunnel

 Cooling water must be potable chlorinated (1-3 ppm)

 Tunnel must be inspected and cleaned routinely

 Cooling Tunnel Water; pH< 8, TH < 100, TPC< 25/ml & Coliform NIL

EXTERNAL HEAT EXCHANGER COOLING SYSTEM

To the heat exchanger

Condensat

e Air Steam

 Access for cleaning and maintenance

 No bottles jamming or falling

 MOC ensures potability of water used

1 heat retention area 2-8 cooling areas

Cooling Tunnel- Product Vs Cooling Water Temperature profile

Cooling Tunnel Exterior

Measure Closure and Headspace Heat Treatment

Can be achieved in First Zone of Cooling Tunnel by showering Hot water for a duration so as to heat interior surface of liner at ≥

77°C for not less than 7 seconds

Name   Max Temp   Time Above

75.0°C   Time Above 65.0°C

 CIP Cycle Example:

 Hot water (>60°C) circulated for 10 minutes

 Hot caustic, 65-70°C circulated for 20 minutes (with an

active alkalinity of at least 1%)

 Rinse 5 - 10 minutes with Hot water (>60°C) water

 Hot Acid circulated for 20 minutes (with nitric acid of 0.6 - 0.8 % v/v)

 Rinse 5 - 10 minutes with Hot water (>60°C) water

 Rinse 5 minutes with treated water

 Hot sanitation step must be performed prior to

production start-up

 An chlorinated water or acid sanitizer solution must

be left in the system during downtime

Proper Clean In Place (CIP) & Sanitation

Ensure System Sterility

Hot Fill Manufacturing

Critical Control Points

 Understand and control initial microbial load of food ingredients and other incoming materials

 Meet processing conditions

 Product sterilization

 Filling temperature

 Head space and closure sterilization

 Final product temperature

 Sanitize incoming containers

 Protect the filling environment

 Perform system sanitation regularly

 Monitor the quality of cooling water

 Maintain GMP

Cause of hygiene Problems

50% of the hygienic problems are related to poor CIP

Aseptic transfer CIP Packaging machine

Packaging material Operationa l

Flo w

Time

Concentra- tion

ture

Tempera-Mechanical cleaning effects

Velocity = Turbulence Time dependent

Temperature independent

1,5 m/s is required to achieve an adequate mechanical cleaning effect

1,5 m/s

Required velocity in pipe

 Usually smaller than yeast or mold

 Found everywhere, even in extreme environments :

 Pyrulobus : grow at 113°C

 Picrophilus : grow on pure sulfuric acid

 Are living with us : on skin and digestive tractus

 We carry 1-2 kg, 1014 bacteria, 500 species

 Some pathogens :

 E coli O157:H7 , Listeria , Salmonella , Staphylococcus , etc

 No heat & acid resistant

 Some heat resistant, some require high

temperature to grow

 e.g., Alicyclobacillus