krones VarioFlash and VarioAsept
Thermal treatment for microbiologically safe products
Natural – tasty – longer lasting krones product treatment systems
Processes aimed at preservation and
safe hygienic processes are the key
factors in the manufacture of a prod-
uct. And that applies for all types of
beverage: depending on their ingre-
dients, beverages have a low or high
microbiological sensitivity, which
makes it essential to have a sophisti-
cated system of equipment for ster-
ile procedures in the stages before
filling. All these process stages bring
you to your most important objec-
tive: quality products and a high mar-
ket share.
The Krones VarioAsept and Vario-
Flash flash pasteurising systems, the
patented VarioSpin product deaera-
tion and the VarioStore buffer tanks
offer the right starting conditions for
all product treatment tasks. Large-
ly preassembled modules that are
tailored exactly to the application,
an efficient operating concept with
minimal staffing requirements and
variable output level – these are the
features indivisibly associated with
Krones technology for product treat-
ment.
VarioFlash B
The Krones pilot plant – your guarantee of success
krones product treatment systems
Product characterisation as a plan-
ning basis for thermal product treat-
ment can be carried out in the Kro-
nes process laboratory. Product
samples are analysed for pulp and
fibre proportion and size and their
dynamic viscosity, thermal conductiv-
ity and ingredients are determined.
Product data are backed up on a case Determining vis-
by case basis by test series in the cosity with the
process pilot plant. The systems are rheometer
configured to meet the customer‘s
specific requirements. The thermal
product treatment systems are fully
assembled and extensively tested in
the assembly hall. This allows all pro-
grams to be run under real-life con-
ditions (temperature, pressure and
volumetric flow) so that the customer
has minimum on-site installation and The customer and
commissioning expense. Krones engi-
neers in detailed
clarification
VarioFlash B in
the FAT (Factory
Acceptance Test)
Application krones product treatment systems
The major element of all process Depending on the product intake
steps in beverage production is the temperature and the customer‘s
preservation concept. One of the pro- requirements, an up to 100 % recuper-
cesses frequently applied is flash pas- ative circuit can be set up for cooling
teurising, which can be used for prod- after heating, or an additional cooling
ucts with low and high acidity. heat exchanger can be integrated.
Beer and slightly carbonated refresh-
ment drinks are normally heated at
72 to 85 °C for 20 to 60 seconds and
subsequently cooled down to the
required filling temperature.
Very acidic CO2-free beverages such as
juice drinks and soft drinks are flash-
pasteurised for a duration of between
30 and 60 seconds, e.g. at tempera-
tures of 84 to 95 °C, and then cooled
down to ambient temperature or hot-
fill temperature. These products can
then be distribu-ted at ambient tem-
perature.
All low-acid beverage types such
as Asian teas, mixed milk and cof-
fee drinks and ESL and non-perisha-
ble milk are heated at 125 to 150 °C,
depending on the initial concentra-
tion of bacteria, the shelf life and the
subsequent method of distribution.
Fresh milk is heated for 10 to 30 sec-
onds at 72 to 85 °C and always distrib-
uted chilled.
VarioAsept J in
the process room
Modules for thermal product treatment krones product treatment systems
Product ingredients, customer phi-
losophy and economic considera-
tions are major factors in choosing
between plate and tubular heat ex-
changers.
The tubular heat exchanger concepts
comprise monotube solutions as well
as various multitube panels.
In the case of tubular modules, allow-
ance must be made in production and
the CIP/SIP processes for the different
rates of expansion of the materials
used for the column jackets and the
inner tubes. The hygienic, 3-layer bel-
lows ensures a hermetic seal between
product and environment or heating
and cooling medium.
In addition to the heat exchanger, the
media feed, deaerator, buffer tank
and homogeniser modules are also
used. All modules ensure the abso-
lutely leakproof separation of prod-
uct, CIP media and process water,
allowing mixing of the media to be
precluded.
VarioAsept J –
comprising media connection, tubular
heat exchanger, product
deaerator and buffer tank
Figures, data, facts krones product treatment systems
Output range ■■ Prepared for integration in a high-
er-level process control system
The product treatment systems are ■■ Short start-up phases through
configured to the customer‘s specific upstream Factory Acceptance Tests
requirements. The performance spec- and pre-parameterisation
trum of the modular systems ranges ■■ Support available with the
from 5,000 to 60,000 litres per hour. Krones Lifecycle Service contract
Design features
■■ High level of automation for relia-
ble operating processes with auto-
matic product change-over by sig-
nal exchange with the PLC
■■ Large recipe memory for reliable
and reproducible production using
predefined parameters
■■ Open, easily accessible and hy-
gienic design on a frame made of
stainless steel All pumps are
■■ Quick-change device for changing positioned for
the mechanical seals of the pumps easy access on
■■ Standard, hygienically optimised one side
or aseptic fittings used accord-
ing to the heating processes (flash
pasteurising, UHT), filling process-
es and customer specifications
■■ Menu-led operation via iPan-
el Compact with 15-inch touch-
screen, with processes represent-
ed in the active flow diagram and
operator interventions document-
ed by the transponder system
Quick-change device for the pump‘s
mechanical seal
VarioFlash – thermal product treatment krones product treatment systems
for hygienic filling processes
VarioFlash B VarioFlash H
■■ Application: Beer and mixed beer ■■ Treatment of CO2-free fruit juices
drinks (including light and CO2-free and soft drinks with high-temper-
drinks) with cold or ambient tem- ature discharge
perature discharge ■■ Product discharge in hot-filling
■■ Flexible PU adjustment and out- without buffer tank
put-controlled hot water circuit ■■ Intelligent hardware and software
for particularly gentle and reliable structure for product heat reten-
product heating of beer and mixed tion in the filler
beer drinks
■■ Buffer tank for automatic output Type designation
adjustment in the event of fluc-
tuations in production, reducing B = Beer
(avoiding) start-up and shut-down H = Hotfill
processes and minimising product J = Juice and slightly carbonated
loss and media consumption soft drinks
VarioFlash J
■■ Processing of spritzer products and
CO2-free drinks with cold or ambi-
ent temperature discharge
■■ Flexible PU adjustment and out-
put-controlled hot water circuit
for particularly gentle and reliable
product heating
■■ Hygienically optimised fittings,
instrumentation and control after
the heat retention unit
■■ Steam-locked valves and pumps
prevent recontamination
VarioFlash J in
the bottling line
VarioFlash krones product treatment systems
Your benefits
■■ Flexibility in the production ■■ High accuracy
process The buffer tank is fitted with a
Short product change-over times capillary level monitoring facility
(last/first bottle) of no more than that ensures precise, temperature-
30 minutes with intermediate compensated content measure-
water rinsing can be achieved ment.
using the Krones filler with addi-
tional hardware and software. ■■ Precise traceability of all processes
All process-relevant parameters
■■ Minimised recontamination risk are saved and archived by an elec-
Maximum product safety is deliv- tronic data writer.
ered by reliable separation of the
media by means of double seat ■■ System-friendly media guide
valves and a positive pressure dif- The CIP run-off for sampling valves
ference from product to heating/ prevents damage to the electrics
cooling medium combined with and pneumatics caused by clean-
the vacuum-tight product tank ing agents. The CIP collecting pans
and hence hot and cold cleaning of in the complete module facilitate
the mandrel fittings without draw- run-off of the cleaning media.
ing in atmospheric air.
VarioFlash H
with product dearator, rework tank,
homogenisor and Contiflow (mixer)
VarioAsept – thermal product treatment krones product treatment systems
for aseptic filling processes
VarioAsept J
■■ Used for the treatment of juice
products, soft drinks, teas and
mixed coffee and tea drinks
■■ Comprises tubular or plate heat
exchanger, optional deaeration
module and homogeniser, buffer
tank and media feed
VarioAsept M
■■ Applications in milk products
■■ Equipped with an additional heat
retention section in the pre-heat-
ing area
■■ Controlled denaturation of the
milk proteins at approx. 90 °C
to prevent greater fouling in the
heater and to ensure long service
life (production times without CIP/
SIP)
VarioAsept M
VarioAsept krones product treatment systems
Your benefits
■■ Temperature control by choice ■■ Aseptic product change-over
The heating process can be option- The water rinsing between last/
ally controlled with a precise first bottle of no more than 35
F-value or temperature control or minutes (for Krones standard lay-
through flexible PU adjustment. out) ensures high production flex-
ibility.
■■ Long production times
Aseptic intermediate cleaning ■■ Low product losses
with caustic at the product treat- The collecting system for mixing
ment temperature of the heat phases, the integrated buffer tank
exchanger can be carried out with- and automatic output adjustment
out any pause in production by the in the event of production fluc-
aseptic filler as the filler is supplied tua-tions in upstream and down-
by the aseptic buffer tank. stream systems contribute to high
cost effectiveness.
■■ Reliable media separation Plate heat
Leakproof aseptic valves and a ■■ System-friendly media guide in exchanger
positive pressure difference are CIP steps
major contributors to high prod- The CIP run-off for sampling valves
uct safety. prevents damage to the electrics
and pneumatics caused by clean-
ing agents, while the CIP collecting
pans in the complete module facil-
itate run-off of the cleaning media.
Tubular heat
exchanger
System expansions krones product treatment systems
VarioSpin product deaeration in the Your benefits
UHT system
Quality defects in the product caused ■■ Nozzle system operates indepen-
by gases, in particular oxygen, can dently of product viscosity and sys-
be prevented by using a deaerator, tem output
allowing the residual oxygen content ■■ Swirl nozzle also used for the CIP
in the product to be maintained at up processes
to 0.3 ppm, depending on the product ■■ No interior parts in the tank
characteristics and initial gas level. ■■ A smaller deaeration tank can be
Deaeration is achieved by ensuring configured in place of traditional
homogeneous distribution of the deaeration systems
product over the greatest possible ■■ Flavour vapours produced are
area on the inside surface of the con- recovered in a one or two-stage
tainer. A swirl nozzle system ensures condenser
gentle, efficient and foam-free distri-
bution of the product in the vacuum The compact design of the system
phase. allows only a low product quantity
to be processed in the system at any
time. The plus points of this concept
include excellent deaeration figures
and the avoidance of temperature The compact
damage and microorganism develop- deaerator unit
ment before the heater stage.
The homogeniser ensures a uniform
product composition, guaranteeing
uniform heat transfer in the heating
phase.
System expansions krones product treatment systems
VarioStore tank system for aseptic Your benefits
systems
The intermediate storage and buffer- ■■ Available as an independently
ing of products in the product treat- operating aseptic buffer tank with
ment process is crucial for an effec- its own PLC or integrated into a
tive and finely tuned production thermal product treatment sys-
process. The Krones VarioStore range tem, depending on the application
of sterile tanks includes versions with ■■ Up to three process gases can be
or without agitator and a tank vol- connected for superimposing pres-
ume of between 20 and 50 m³. sure on the products
The vacuum-tight tank is comple- ■■ Tank cooling can be configured
mented by a valve manifold with with water return system
aseptic product valves, sterile steam- ■■ Product homogenisation in
locks and the necessary process gas VarioStore, in a version with mag-
feed. netic agitator and hermetic sepa-
ration of sterile and ambient areas
or with condensate-rinsed bar agi-
tator
■■ Sterile gas filtration with redun-
dant 0.2 μm filter plus inline steam
sterilisation
■■ Content display in aseptic version
by means of capillary differential
pressure measurement
Subject to technical changes · The illustrations can contain optional auxiliary equipment · 0 900 22 847 5 · PDF_en · 05/13
IT solutions Lifecycle Service krones Service Line
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includes IT solutions which we devel- isfied with conventional solutions? cal problem? Or you have an urgent
oped especially for the beverage and The krones Lifecycle Service will sup- question about you line? No problem:
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High-performance technology with Make your colleagues high perform-
low consumption of resources offer- ers: The training of krones Academy
ing safety for humans and the envi- provides first-hand trade information
ronment – this is all guaranteed by proven in field. You will find the suit-
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efficient and environment-compati-
ble machines and lines.
krones ag Phone +49 9401 70-0
Böhmerwaldstraße 5 Fax +49 9401 70-2488
93073 Neutraubling E-mail info@[Link]
Germany Internet [Link]
