Nestle Binh An Growth: Aseptic System Training

Nestle Binh An
GROWTH
Aseptic system
Training
August 25th 28th, 2014
TM-TPVN/HT
7/23/16
Day 1:
Milk & Aseptic technology
TM-TPVN/HT
7/23/16
Aseptic processing systems

Absolute sterility not possible
Bacteria
N
Logarithmic destruction
Time/temperature would be
too drastic
Not possible to prove
by random testing
Not possible to prove sterility
(prove absence)
t Time
PSD.TPD&B.TH.3.02, AA05
Sterilization of food requires that all living

microorganisms be inactivated, including the
pathogens.
Product remains fresh for months without
refrigeration and preservatives.
Product:
Low acid (food pH > 4.5, milk pH > 6.5)
High acid (food pH < 4.5, milk pH < 6.5)
Product
Temp(C)
Time
Low acid
135-140
A few seconds
High acid
90-95
15-30 seconds
TM-TPVN/HT
7/23/16

UHT - Ultra High Temperature
Vegetative cells
Yeast
Spores
Pathogenes
Mould
Virus

UHT - Ultra High Temperature
Vegetative
cells
Pathogenes
Spores
Yeast
Mould
Virus

Ultra High Temperature processes
TM-TPVN/HT
7/23/16
Machine Introduction General

Product lifetime
TM-TPVN/HT
7/23/16
TM-TPVN/HT
7/23/16
TM-TPVN/HT
7/23/16

Pre-processing
Deaeration
Separation
Standardization
Homogenization
Pasteurization
TM-TPVN/HT
7/23/16

Deaeration with Tetra Alrox
TM-TPVN/HT
7/23/16

Homogenization
TM-TPVN/HT
7/23/16

Homogenization of dairy products
TM-TPVN/HT
7/23/16
Thermal treatment definitions
TM-TPVN/HT
7/23/16

Sterilization
A process applied to a product with the object of

destroying all micro-organisms (by heat treatment
exceeding 100C)
Sterile
Condition in which living cells are absent or killed.
Sterilizer
Equipment used for sterilization: autoclave, hydrostatic

sterilizer or aseptic processing plant
Commercially sterile product
Product which is free from micro-organisms that can

grow and contribute to its deterioration under the
intended storage conditions
Aseptic
Condition to prevent bacteriological contamination

The commercially sterile product must
Keep without deterioration
Remain stable and good commercial

value during storage
Free from micro-organisms and toxins

harmful to the health of consumers
Absolute sterility not possible
Thermal destruction is logarithmic
Not possible to prove by

random testing

D-Value
The express D65 = 1 min
means that the number of organisms is
reduced with 1 D when treated one minute
at a processing temperature of 65 C.
2 minutes exposure results in 2D
1D = 90% reduction = 1 LCR
2D = 99% reduction = 2 LCR
3D = 99,9% reduction = 3 LCR
4D = 99,99% reduction = 4 LCR
LCR: Logarithmic Reduction

Sterilization Efficiency
The Sterilization Efficiency of a
process is the number of LCR that
it gives on the most resistant
microorganism.

z-Value
Is the change in temperature in C required
to cause 10 fold change in D-value
z = (T1-T2)/(logD1-LogD2)
A certain micro-organism is
characterized by a z-value of 10 C

Most heat resistant of spores
Bacteria
D90-value (hrs)
B. Stearothermophilus
B. Subtilis
B. Cereus
> 100
30
C. Botulinum, strains A
D121-value (sec)
300
60
3
C. Botulinum, strains B/E <0,02
12
1,4
< 0,05

Typical killing data for some micro-organisms
Group of Orgsm
D-value (min)
Vegetative Bacteria
(heat sensitive)
65
Vegetative bacteria
(heat resistant)
10
65
Bateria spores
0,2
121
Yeast and Mould
65
Mould
3
(heat resistant ascospores)
90
Temp (C)

Definition of F0-value
The F0 makes it possible to compare the effect
of different time/temperature combinations
t
= sterilization time (s)
T = sterilization temperature, (C)

z = the increase in temperature
necessary to obtain the same
effect in one tenth of the time
F0 = 1 when heated one minute at 121.1C
F0 3 to achieve a commercially sterile product

Definition of C*-value
C*-value is an indicator of chemical
changes in the product associated
with heat treatment
C* = 1
= heat treatment at 135C for 30.5 s.
and z = 31.4C
= 3% destruction of thiamine

Lactulose value
Indirect measurement of chemical changes
Lactulose is a type of milk sugar formed at

elevated temperatures and indicates the
extent of chemical changes to the product
e.g. the heat load
Lactulose is the way of measuring the

heat load on UHT milk, and also has
the advantage that its formation is
possible to calculate theoretically,
given the time-temperature curve
UHT treatment
Finding the optimal combination

of temperature and time
Sterilization effect
Chemical changes
Break
TM-TPVN/HT
7/23/16
Basic microbiology
Bacteria
Yeasts
Moulds
Basic microbiology
Multiplication of bacteria
1024
10 000 000
bacteria bacteria
30 min.
Generation time
30 min
11,5
hours
Basic microbiology
Temperature
conditions for
Maximum
Optimum
bacterial
growth
Minimum
Basic microbiology
Classification
of bacteria
by temperature
preference
Thermophilic
45 C
Mesophilic
20 C
Psychrophilic
7 C
Psychrotrophic
Basic microbiology
The influence of Temperature
Bacterial development in raw milk
Mio Bact/ml
Hours
Time-temperature combinations
TM-TPVN/HT
7/23/16
Time-temperature
Lethal effect on bacteria
TM-TPVN/HT
7/23/16
Time-temperature
Destruction of enzymes and micro-organisms
TM-TPVN/HT
7/23/16
Time-temperature
Combinations needed for destruction of spores
Lunch
Milk properties
Analyse of milk
The common tests carried out
on milk supplies are:
taste and smell

cleaning
sediment
somatic cell count
bacteria count
protein content
fat content
freezing point
Milk properties
Composition of Cow's Milk
Fat 4.1%
Protein 3.4%
Lactose 4.8% MSNF
Salt 0.7%
Water 87%
Total solid
=
Dry matter
Milk properties
Size of Cow's Milk Constituents
Whey Proteins
Bacteria
Lactose
Casein
Fat
Salts
0,0001
0,001
0,01
0,1
1,0
10,0
Particle size
100,0
Milk properties
Structure of milk
Fat globule
Skim milk
Milk properties
Raw milk quality
for processability:
pH
alcohol stability
6.65-6.80
>75%
for sterility level:

limit of heat resistant spores
Milk properties
Comparison of processability of Buffalo milk and Cows milk
Quality
Cows milk
Buffalo milk
Fat content (%)
3,2 - 4,8
6-7
Protein content (%)
3,2 - 3,4
4,3 - 4,5
Casein content (%)
2,6 - 2,8
3,51 - 4,36
Whey proteins (%)
0,6 - 0,8
0,53
75
142,2
6,65 - 6,80
6,9
80
72
Colloidal Ca (mg/100ml)
pH
Alcohol stability (%)
Milk properties
Quality paameters for raw material UHT products
Improvement of
hygienic
conditions in raw
material
production
Total Count
Flavour
Adulteration
Somatic Cell Count
Etc.
Factors pertaining to
the suitablity of
production
Spore Count
Protein Stability
pH
Dirt particles
Thermoresistant
enzymes
Etc.
Types of milk
UHT systems
UHT systems
Full range of solutions
Direct heating
Injection
Infusion
Indirect heating
PHE
THE
UHT systems Selection guide

Objective advice!
Premium
quality
4 UHT technologies
Tetra Pak masters
them all
Your demands
decide!
DIRECT
DIRECT
UHT UHT Product
properties
injection
infusion UHT
INDIRECT
INDIRECT
UHT
PHE
THE
Outstanding
efficiency
Types of UHT
Direct or indirect?
Direct UHT
Steam injection or steam infusion
Almost instantaneous heating & cooling
Low impact on quality
Higher operating cost
160C
Direct
Indirect
140C
120C
100C
Indirect UHT
80C
Tubular or plate heat exchanger

Somewhat slower heating and cooling
Somewhat higher impact on quality
Lower operating cost
60C
40C
20C
Pasteurization
20
40
60
80
100
120
SEC
Available TP Portfolios
Indirect systems
Tetra Therm Aseptic Flex
Direct systems
Tetra Therm Aseptic VTIS
Aseptic tank system
Tetra Alsafe LA
Aseptic dosing
Tetra Aldose
Aseptic dosing
Tetra FlexDos
Cost-effective
Efficient operation by indirect

heating in tubular heat exchanger
Applications from white milk to
high viscous ice cream mix
Capacities from 2,000 - 40,000l/h
TA Flex Simplified flowchart
Tetra Spiraflo
Tubular heat exchanger (THE)

Floating ends for thermal expansion
Tetra Alex homogenizers
Improved efficiency
with counter-pressure
Efficient break-up of
clusters
Minimal number of
spare parts
Premium product quality
Direct heating by steam injection or

steam infusion
Applications from white milk to high
viscous ice cream mix
Capacities from 2,000 - 30,000l/h
TA VTIS
Simplified flowchart
Direct steam injection
Instant heating, temperature equilibrium and condensation

Very low fouling outstanding cleanability
Unique verified performance
Steam infusion
Patented air
insulation design
reduces fouling
Patented, even
steam distribution
Flash cooling
High-precision temp. control
Large product surface gives

instant cooling
Low carry-over
Unique, built-in condenser

gives short pre-sterilization
and cleaning times
Extremely low hold-up

volume
Easy access for inspection,

service and maintenance
Processing principles
UHT milk manufacturing process
Pre-sterilization
Production
(Aseptic Intermediate CIP AIC)
CIP
Day 2:
UHT
TM-TPVN/HT
7/23/16
UHT Operation
Tetra Therm Aseptic Flex - NG CM

Ser. No.: T5844151227
Indirect UHT
Continuous aseptic processing module
Using Tubular Heat Exchanger (THE)
Product: Milo
TM-TPVN/HT
7/23/16
Technical data
Tetra Therm Aseptic Flex - NG CM

Ser. No.: T5844151227
Indirect UHT
Continuous aseptic processing module
Using Tubular Heat Exchanger (THE)
Product: Milo
TM-TPVN/HT
7/23/16
Technical data
Noise Emission
Product configuration
Connection data
Specification, heat exchanger
TM-TPVN/HT
7/23/16
Main components and functions
Feed module
Booster module
THE
Homogenizer
Local control panels (FCP)
Motor panels (MCC)
Homogenizer panel (MCC)
TM-TPVN/HT
7/23/16
Main components and functions
TM-TPVN/HT
7/23/16
P&ID detailed tracing - Use colored P&ID

Main sides
Pre-heating
Holding cell
Aseptic side
Cooling
Balance Tank
Hot water side
TM-TPVN/HT
7/23/16

Measuring points
TC44
TSL42
PT05
PC78
TC67
TT08
PC74
PC68
TM-TPVN/HT
7/23/16

Hot water circuit
M10
TM-TPVN/HT
7/23/16

Hot water circuit
M9
TM-TPVN/HT
7/23/16
Machine Introduction Main steps
Sterilizing
Production
AIC
CIP
TM-TPVN/HT
7/23/16
Activations diagram
Sterile water Production AIC Shutdown EM Emptying
TM-TPVN/HT
7/23/16
Activations diagram
Full CIP
TM-TPVN/HT
7/23/16
Activations diagram
Adapted Cleaning
TM-TPVN/HT
7/23/16
Activations diagram
Header batch sub-program
TM-TPVN/HT
7/23/16
Machine steps
Process cycle: Phases and Steps
Step 1 17: Sterile water
Step 21 45: Production
Step 51 55: AIC
Step 70 71: Shutdown
Step 80 85: Emergency emptying
Step 101 149: CIP (Full cleaning)
TM-TPVN/HT
7/23/16

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What is the purpose of aseptic processing?

What is the purpose of aseptic processing?

What are the main steps involved in aseptic processing?

What are the main steps involved in aseptic processing?

Nestle Binh An

Aseptic processing systems

Aseptic processing systems

Sterilization of food requires that all living

Aseptic processing systems

Aseptic processing systems

Aseptic processing systems

Machine Introduction General

Aseptic processing systems

Aseptic processing systems

Aseptic processing systems

Aseptic processing systems

Aseptic processing systems

Aseptic processing systems

Thermal treatment definitions

Thermal treatment definitions

A process applied to a product with the object of

Condition in which living cells are absent or killed.

Equipment used for sterilization: autoclave, hydrostatic

Commercially sterile product

Product which is free from micro-organisms that can

Condition to prevent bacteriological contamination

Thermal treatment definitions

Keep without deterioration

Remain stable and good commercial

Free from micro-organisms and toxins

Absolute sterility not possible

Thermal destruction is logarithmic

Not possible to prove by

Thermal treatment definitions

Thermal treatment definitions

Thermal treatment definitions

Thermal treatment definitions

C. Botulinum, strains B/E <0,02

Thermal treatment definitions

Yeast and Mould

Thermal treatment definitions

= sterilization time (s)

T = sterilization temperature, (C)

Thermal treatment definitions

Thermal treatment definitions

Indirect measurement of chemical changes

Lactulose is a type of milk sugar formed at

Lactulose is the way of measuring the

Finding the optimal combination

taste and smell

for sterility level:

Fat content (%)

Protein content (%)

Casein content (%)

Whey proteins (%)

UHT systems Selection guide

Tubular or plate heat exchanger

Tetra Therm Aseptic Flex