Pasteurization Technology

March 10, 2011
District Michigan
MBAA
Technical Meeting
Grand Ledge, MI

Presentation Agenda
� Pasteurization Basics
� Tunnel Pasteurization Technology
� Flash Pasteurization Technology
� Technology Comparison
� Questions and Discussion

Theory and Objective of Pasteurization
� Elevated levels of heat will kill organisms
� Heat beer to arrest biological contamination
� Destroy viability of yeast
� Prevent post fermentation
� Brewers want Pasteurize not Sterilize
� Minimum temperature for target organisms
� Limited Pasteurization units

Time and Temperature
Curve
Maintaining the
time/temperature
profile is key to
preserving the
process or
protecting against
under and over
pasteurization

Pasteurization – Lethal Effect
� A lethal effect of 1 PU (Pasteurization Unit) is
obtained when product can be held at 140F for 1
minute
� Brewers typically target 10PU’s to 15PU’s
� Control of PU’s is essential
� Elevated PU’s can affect flavor degradation

Measuring Pasteurization Units
� Measure at “Cold Spot” of container
� Probe position in container
� Pasteurizer internal calculation
� Using sensing devices and programming
� Calculate PU’s
� Time above 120F
� Time in holding tube at Pasteurization temperature

Measuring Heat Transmission
Cold Spot is
usually
located at
¼” to 1”
above the
center of the
bottom of
the container
TEMPERATURE °F
140
135
130
125
120
115
110
105
100
95
90
85
80
75
70
65
TIME IN MINUTES
2 4 6 8 10 12 14 16 18 20 22 24 26 28
AVE. TEMP.
COLD SPOT TEMP.
INITIAL BEER TEMP. 40 °F (4.4 °C)
SPRAY AT 140 °F (60 °C)
T00384
60.0
57.2
54.4
51.7
48.9
46.1
43.3
40.6
37.8
35.0
32.2
29.4
26.7
23.9
21.1
18.3
TEMPERATURE °C

Lethal Rate Curve
PRODUCT TEMPERATURE
°C
62.2
61.7
61.1
60.6
60.0
59.4
58.9
58.3
57.8
57.2
56.1
48.9
°F
144
143
142
141
140
139
138
137
136
135
133
Average 12.35 P.U.'s
Cold Spot 8.60 P.U.'s
120 0.025
0 5 10 15
MINUTES
2.09
1.74
1.45
1.20
1.00
0.83
0.69
0.57
0.48
0.39
0.27
LETHAL RATE P. U. 'S / MINUTE
PU’s calculated for
product temperature
above 120ºF.
Area under the curve
equals the number of
PU’s achieved.
Cold spot PU’s less
than Average.

Pasteurization Unit Graph
PU / MINUTE =
1
-1
LOG
140 - °F
12.5
(°F - 140)
= 1.20226
PU / MINUTE =
-1
LOG
(°C - 60)
1
60 - °C
6.94
= 1.393
PU / MINUTE
40.0
30.0
20.0
10.0
7.0
5.0
3.0
2.0
1.0
0.7
0.5
0.3
0.2
0.1
TEMPERATURE °C
50 52 54 56 58 60 62 64 66 68 70
0.03
120 130 140 150 160
TEMPERATURE °F
10 PU’s
30 sec
= 157F
10 PU’s
10 min
= 140F

Barry-Wehmiller Advanced PU Limit
System
PU Accumulation
PU Accumulation Rate
120
125
130
135
140
145
150
Product Temperature [deg F]
155
160
165
170
175
1000.00
100.00
10.00
1.00
0.10
0.01
PU / minute

Validating Measurement
� Independent validation for tunnel
� Several manufacturers of independent PU
measuring devices
� Measure time and temperature
� Calculate and report PU values
� Machine internal validation for flash
� Redundancy on sensors
� Micro analysis

Verifying Pasteurization
Independent
measurement is
capable with tunnel
technology only.
Redundancy can
help reliability

Types of Beer Pasteurization Technology
Two basic types of beer pasteurization
1. Tunnel Pasteurization
2. Flash Pasteurization

Tunnel Pasteurizer

Tunnel Pasteurizer Overview
� General Description
� Pasteurizer Features
� Pasteurizer Systems
� Operational Controls
� Reporting/Recording

Pasteurizer – General Description
� Length - Width
� # of Decks
� Features
� Systems

Pasteurizer Features
� End Casings
� Removable
Top Covers
� Container
Water Blow-
Off
� Condensate
Return System

Pasteurizer Process Systems
� Regeneration Capability
� Heating System
� Belt and Drive System
� Spray System
� Pump Systems
� PU Control
� Controls, Alarms

Tunnel Pasteurizer Regeneration
Cold containers
entering require heat
Hot containers exiting
require cooling
Zoning
Set Point Balance
Maximum Regen
Compensation
Exit Temperature

Single Heat Exchanger System
Single Heat Exchanger with plate Heat Exchanger.
Closed Loop System with hot water available on
demand.

Basic Concepts
Single Heat Exchanger System
� Benefits of the Single Heat
Exchanger System
� Low Maintenance
� Only one heat exchanger
� Plate Heat exchanger
� Efficient use of energy
� Condensate return
� Less Pump
Horsepower required

Typical Heat Exchanger Skid – Large
Machine

Pasteurizer Main Belt
� Intralox 400 and 1900 with
Enduralox
� Twentebelt Combinox and
Eyelink
� Regina 3120
� Rexnord 5997 with DTS-C

UHMW Wear Strip Attachment
Allow for UHMW expansion
Easy install and replacement

Main Drive SEW Motor/gearbox

Spray and Pump System
� Pressurized water flow rate
designed to optimize thermal
heat transfer rates
� Up to 6.8gpm/ft²
� Thermal Dynamic Models
� Manual Blow Downs
� Even flow across the deck
� Predictable Heat Transfer
� Removable spray headers
� 3 1/2” header, 3/8” nozzles

Spray System Filter
Screens
Redundancies for Maintaining Spray Consistency
� Belt side guides
� Belt mesh pattern
� Dual pump inlet screens
� Spray header design
� Spray header blow down

Filter Screen External Access Doors

Spray System Blow Down

PU Limiting
� Hot Zones
� Add cold water
to zone reservoir
� Re-heat on start
up

Advanced PU Control System
� Advanced PU Control System controls the
pasteurization process:
� Guarantee very tight PU control
� Preserve the process curve in stop/start
conditions
� Move process to container if container can not
get to process

Possible to have hot water on
one header and cold water on
another header from the same
manifold

Utility Control Technology ‘IntelliFlow’
� The IntelliFlow System:
� Used in conjunction with Advanced PU Control
� Water temperature separation technology
� Eliminates requirement for water re-heating
� Provides benefits of PU control without added
utility consumption

Pasteurizer Control Items
� Sensors, proximity switches, instruments
� Safeties and Alarms

Pasteurizer Safety and Alarms
� Hot zone pumps 2º below set point for 30 seconds
will stop belt
� Pressure sensors all zones below 2psi for 15
seconds stops pasteurizer
� All levels satisfied before pasteurizer will start
� Belt speed monitored by checking starwheel pulse
duration to time set in recipe
� Drive overloads – spring and proximity

Pasteurizer Recording Capability
� Data collected from Sensors:
� Temperature of all zone sprays
� Speed of belt
� Levels
� Data collected in the pasteurizer PLC
� Data sent to remote storage
� Data can be extracted to workable files
� Reports can be generated

Flash Pasteurizer
Volutherm Series
Flash Pasteurizer

Flash Pasteurization
� Pasteurization occurs prior to filling
� Short Time High Temperature (HTST)
� Heat Exchanger (plate or tube)
� Fixed or Variable flow rates
� Pasteurization calculated by Holding Time and
Temperature
� High Efficiency (90% regeneration)
� Controls are Key!

Flash Pasteurizer 180 Hl/Hr

Flash Pasteurizer 320 Hl/Hr

Flash Pasteurizer 360 Hl/Hr
Flexibility to design
units to fit various
applications
Juice unit with Heat
Exchanger mounted
on the floor for
accessibility on
larger pasteurizers
Often times machines
can be designed to
handle different
products on the same
unit

Flash Pasteurizer – 250 Hl/Hr

Flash Pasteurizer Features
� Constant PU Variable Flow rate Unit.
� Pressure Balance System.
� 90% Energy Recovery.
� Status and Process Alarms.
� Digital Paperless Chart Recorder.
� Fully Automatic Operation.

Flash Pasteurizer Design

Flash Pasteurizer
Components

Product Flow Meter
An Electromagnetic flow measuring system is used to monitor the flow of the
product at the discharge of the pasteurizer.

Product Flow Control Valve
(Detail View)
4-20mA Electrical Input Signal.
Resulting in a 0-100% Valve opening.

Product Temperature Measurement
PT100 Temperature probes monitor the temperature of the fluids
Within the pasteurizer.
As the temperature changes the resistance measured by a
Transmitter fitted inside the temperature probe changes.
The input signal to the pasteurizer control system is electronic
4 – 20mA.

Product Temperature Control
Pressure Reducing Valve
A pressure reducing valve is designed for
maintaining the pressure downstream of the steam
supply valve to an adjusted set point value.
Set point approximately 2.0bar
The valve closes when the downstream
pressure rises.
Pneumatic Control Valve
The hot water that is used to raise the beer to the
required pasteurization temperature is heated using
steam controlled by the pneumatic controlled valve.
This valve uses a pneumatic control signal to adjust
The amount to which it opens and so the amount of
steam that can flow into the plate pack

Process Recording
� Touch Screen HMI
� Select recipes
� Operational functions
� Adjust parameters
� Alarm displays
� Digital Paperless Process Logger
� Records temperatures
� Records flow rates
� Records pressures
� CIP and Run modes

Process Recording
�Temperatures
�Pressures
�Calculated PU’s
�Production / CIP Flow rate
�Production / CIP / SIP Mode
�Product In Machine

Central System Operation

Central System Operation

Flash Pasteurizer – Benefits and Features
� Performance tolerance to with in 1PU
� Variable flow, variable temperature
� Maximum regeneration
� Quality monitoring, alarms, reports, archiving
� Machine self-diagnostics
� Operation safe-guards for PU protection
� Gentle product handling (HTST)
� Compact footprint, Low energy use

PROCESS COMPARISONS

Process Comparison Factors
� Application Issues
� Operational Issues
� Quality Issues
� Economic Issues
� Equipment Issues

Application Issues
� Tunnel
� Wide range of products
� Carbonated or non-carbonated
� Container limitations
� Flash
� Wider range of products
� Product limits for plate and frame
� Carbonated or non-carbonated

Operational Issues
� Tunnel
� Controls and Complexity can be less
� More forgiving
� Reduced requirement for micro control
� Manual machine cleaning
� PU Control required for line conditions
� Flash
� Cleaning and Sanitation Increased
� Line availability reduced
� Enhanced microbiological testing
� CIP systems are critical
� Buffer systems for handling line conditions

Quality Issues
� Tunnel
� Taste affects possible with prolonged stops
� Validation using independent device
� Reduced requirement for micro control
� Exit temperatures
� Flash
� Minimal taste affects
� Potential for recontamination
� Validation – trust sensors, redundancy
� Ability to re-circulate
� Disinfecting caps and containers – filler contact points

Economic Issues
� Tunnel
� High capital costs for new equipment and installation
� Operating costs can be high
� Reduced costs for monitoring quality
� Increased line utilization
� Flash
� Capital cost can include warmer, filling room upgrades
� High efficiency reduces utility cost (warmer?)
� Less floor space required

Example Comparison for Flash and Tunnel
� Example Selection:
� Brewery
� Bottle production line operating at 800bpm
� Target PU’s at 10 +/- 2
� Target BOT at 75°F

Example Comparison for Flash and
Tunnel
� Equipment Cost
Flash Process Tunnel Process
Volutherm 200B –
$300,000
Buffer Tank - $50,000
Warmer - $375,000
Clean Room – $275,000
Total equipment -
$1,000,000
New Double Deck sized
correctly to optimize utility
consumption and provide low
product exit temperatures
- $1,500,000

Example Comparison for Flash and
Tunnel
� Utility Consumption
Flash Process Tunnel Process
Volutherm 200B
New Double Deck Tunnel
Water - 140 gal/chase out Water - 0gpm, running mode
Steam – 8,000 btu/min
- 100gpm run-out
BWCo Warmer
24mins
Water – 0gpm normal Steam – 20,000 normal run
Steam - 31,500btu/min
- 72,000 start-up
Total Steam -39,500 Avg. steam - ~
btu/min
35,000btu/min

Example Comparison for Flash and
Tunnel
� Floor space requirement
Flash Process Tunnel Process
Volutherm 200B – 200 sq. ft.
Buffer tank and valves stand
- 80 sq. ft.
Warmer 826 SD
- 280 sq. ft.
Total - 480 sq. ft.
New Double Deck Tunnel
1120 sq. ft.

Summary of Process Comparison
� Capital Cost – Similar when considering clean room
� Utility Consumption – Similar when using warmer
� Process Considerations – Culture change for flash
� Cleaning Materials/Sanitizing Agents and Micro
Control requirements – Higher costs for flash
� Available Packaging Line Time – Higher for tunnel
� Floor Space – Flash has reduced space requirement

Time for a beer….
�Thanks for listening!