2014 MBAA Annual Conference

FLASH PASTEURIZATION
Advantages, weak points, remarkable points

2014 MBAA Annual Conference

June 5 - 7
Palmer House, Chicago, IL

Henri Fischer, Krones Inc., Franklin, WI

Submitter ID: 50
Abstract ID: 10413
Flash Pasteurization – advantages, weak points, remarkable points 2

Hygienic Filling - Introduction

 Maximum biological safety

 Maximum product quality and sensory purity

 Minimum installation costs

 Minimum energy costs

 Maximum product flexibility Photo: Thanks to Krones AG

Henri Fischer, Krones Inc., Franklin, WI

Flash Pasteurization – advantages, weak points, remarkable points 3

Why Pasteurization of Beer?

Pasteurization is the selective inactivating or killing of vegetative germs

 Prevents contamination of beverages → maximal biological safety

 ensures a safe (hygienic)product → maximal product quality

Pasteurization is part of the barrier concept of the preservation of beverages

Shelf live
Cool

Pasteurization
(temperature)
Alcohol
pH<4.5

 Extended shelf live → maximal transportation / storage stability

Henri Fischer, Krones Inc., Franklin, WI
Flash Pasteurization – advantages, weak points, remarkable points 4

Long term
Pasteurization heating sterilization

Milk
shelf life 7 days Reduction of
at 4-6°C spore forming units
up to LOG 9

Beer
shelf life
> 6 months
Heat holding time

Ultra high
Flash
temperature
Pasteurization Heating (UHT)

Milk
shelf life
6 months at 68°F [20°C]

UHT
Pasteurization high temp.
treatment heating
Juices / CSD
shelf life
12 months 140 178 212 248 284 320 °F
[60 80 100 120 140 160 °C]
Temperature
Henri Fischer, Krones Inc., Franklin, WI
Flash Pasteurization – advantages, weak points, remarkable points 5

Pasteurization Units (PU)

Pasteurization units (PU) are a function of D- and Z-value and a dimension for the effect realized
through the heat impact:

 Elimination of beer spoiling

MO‘s:

PU = t · 1.393 (Tp – 60 °C)

 Holding time is linear to the PU

 Elimination of CSD spoiling MO‘s: double holding time results in
PU = t · 1.393 (Tp – 80 °C) double PU
 Elimination of juice spoiling MO‘s:
– 80 °C)
PU = t · 1. 2589 (Tp  Temperature is power to PU
2 Kelvin more temperature results in
t = heat holding time (min)
TP = pasteurization temperature (°C) double PU
60°C - 140°F
80°C - 176°F
The effect of thermal treatment alternatively is monitored just by the temperature at a certain holding time!
Henri Fischer, Krones Inc., Franklin, WI
Flash Pasteurization – advantages, weak points, remarkable points 6

Reference PU Values

Bottom fermented beers 15 – 30 PU

(lagers)

Top fermented beers Up to 100 PU

Shandies / Alcohol free > 100 PU

change of 1 or 2 PU

Change of 0.1 – 0.3 Kelvin!

Henri Fischer, Krones Inc., Franklin, WI

Flash Pasteurization – advantages, weak points, remarkable points 7

Pasteurization of Beer: Comparison

 Tunnel / Chamber
(Beer 143 – 158 F [62 – 70 °C],
low/no alc. 154 – 167 F [68 – 75 °C])
20 minutes to 143 F [62 °C]
– hold for 20 min
- 20 min cool down

 Flash Pasteurizer (plate)

(Beer 152 – 167 F [67 – 75 °C],
low/no alc. 158 – 172 F [70 – 78 °C])
heating up and cool down beer flow – less
thermal load (O2 reactions)
holding time of about 30 seconds at 161.6 F [72
°C]

Henri Fischer, Krones Inc., Franklin, WI

Flash Pasteurization – advantages, weak points, remarkable points 8

Comparing Tunnel Pasteurization with Flash Pasteurization

Flash Pasteurization

 Thermal product treatment before filling process

 Short thermal treatment
 Separate container & closure treatment ?, hygiene level
?
 Lower costs for installation, energy
 Smaller footprint
 Filling temperature - warmer needed? (condensation)

Tunnel Pasteurization

 Product, container and closure are thermally

treated after filling process – very safe!
 Container internal pressure, glass break (delta T)
 Long thermal treatment, thermal load – cold spot
 Relatively higher costs for installation and energy Graphics: Thanks to Krones AG

 Bigger footprint Henri Fischer, Krones Inc., Franklin, WI

Flash Pasteurization – advantages, weak points, remarkable points 9

Flash Pasteurizer

• Beer connection (BBT,

filler)
• Water connection
• Inlet pump, booster
pump, (pump to filler)
• Heat exchanger
– with secondary water
loop for heating (steam
or superheated water
connection,
recirculation pump,
controls
– (cooling media circuit)
• Holding tube
• Buffer tank with CO2,
sterile air connection

Graphics: Thanks to Krones AG Henri Fischer, Krones Inc., Franklin, WI

Flash Pasteurization – advantages, weak points, remarkable points 10

Complete Concept with Flash pasteurization

Filler concept:
 Hygienic conditions at filler (room,
floor, air recirculation, conveyors…)
 Hygienic filler design (incl. flush
system for valves and capper)
 Automatic controls
 External cleaning / desinfection
 Optional: rinser, housing

 Reliable CIP of all pipework and Photo: Thanks to Krones AG

machines!

 Fresh / flush water treatment

Henri Fischer, Krones Inc., Franklin, WI

Flash Pasteurization – advantages, weak points, remarkable points 11

Buffer / Flow control

Buffer Tank
BBT Flash Filler

Flow control Level flow

Filler consumption  Heat exchanger minimum flow rate!

(flow)  Reliability of measurements and
Tank level controls
 Adaption speed
Flash Flow
 Buffer tank size
 Effective buffer time
 Push out frequency
Henri Fischer, Krones Inc., Franklin, WI
Flash Pasteurization – advantages, weak points, remarkable points 12

Design and Control System MUST Ensure Product safety

 Over pasteurization: thermal overload to the beer->

flavor change
 Under pasteurization: microbiological conditions are not
safely guaranteed
 Under shooting saturation pressure : degassing in
product --> undefined pasteurization with insulating gas
bubbles
 Fault set points that are adapted to the product and
overall conditions – flash internal purge to drain or
rework tank
 Product recirculation: advantage of lowest product losses,
disadvantage of high thermal effect (other risks?)
 Internal push out: no thermal overload to the sensible
product
 Re-sterilization (with water) after undershooting – flash
internal Photo: Thanks to Krones AG

Henri Fischer, Krones Inc., Franklin, WI

Flash Pasteurization – advantages, weak points, remarkable points 13

Effects on Functionality

 Constant feed pressures and temperatures of product, water, steam (or

superheated water)
 Exact design of
 control valves (cv, control accuracy…)
 pumps (pressure, control accuracy…)
 pipe size and geometry (turbulences)
 heat exchanger (delta T)
 holding (length, bows..)

 Exact adaption to local situation is basics for correct engineering

Graphics: Internet
Henri Fischer, Krones Inc., Franklin, WI
Flash Pasteurization – advantages, weak points, remarkable points 14

Water

 Fast / big pressure changes can not be balanced by flow and pressure
control
→ flow change → PU change
→ pressure change → flow change → PU change
→ pressure change → deficient saturation pressure
 Water feed system design matters
 Pressure control
 Set point multiple pumps
 Position of pressure sensor
 Control speed and deviation
 Dead end / ring pipe
 Interaction with other big consumers

Henri Fischer, Krones Inc., Franklin, WI

Flash Pasteurization – advantages, weak points, remarkable points 15

Corrosion

 Chloride content of water

 Salt content of special products

→ heat exchanger material with high temperatures

→ otherwise corrosion (at least by time)
• Material fatigue/ damage – micro cracks
• Worse functionality
• No product safety with mixture

Henri Fischer, Krones Inc., Franklin, WI

Flash Pasteurization – advantages, weak points, remarkable points 16

Heat Exchanger
 Positive pressure differential
 Secondary circuit de-aeration
 Correct installation of plates (maintenance) (order, direction change end plates,
amount, glue etc. )
 Min. / max. wide! (support points, flexible piping!)
 Leaks
 Visible – to outside
 Seals after overpressure
 Seal with wear
 Not visible – inside
 Corrosion
 Breaks / micro cracks
 Checks – recommended in maintenance intervals!
 Pressurizing – even little leaks visible
 Colored liquids
 Gas
 Gels
 Fouling
 Biological → caustic CIP
 Stone → Acid
Graphics: Internet

Henri Fischer, Krones Inc., Franklin, WI

Flash Pasteurization – advantages, weak points, remarkable points 17

Steam

 Fast / huge pressure deviations can not be balanced by control → PU

deviation
 Balancing with (mechanical) pressure reducer / control valve
 Respect design / pipework
 Interaction with other big consumers
 Adequate dimensioning of pipework
 Condensate system
 Counter pressure not too high
 Respect pressure losses
 Adequate dimensioning of pipework
 Prevent „U-legs“

Picture: Spirax Sarco

Henri Fischer, Krones Inc., Franklin, WI

Flash Pasteurization – advantages, weak points, remarkable points 18

Cleaning - CIP/SIP

A lot of different suppliers and brand products

Different active chemicals, basic effect similar

 Compatibility of chemicals with materials (Chlorine!)

 Temperature and recirculation time
 Wash off (residuals, flush amounts)
 CO2 – NaOH reaction
 Effective NaOH concentration

D645_37

Photo: Thanks to Krones AG

Henri Fischer, Krones Inc., Franklin, WI

Flash Pasteurization – advantages, weak points, remarkable points 19

CIP
 Time
 Check best by automatic system (CIP master)
 Pulsing of valves
 Tank spray
 Temperature
 Production temperatures (heat exchanger)
 Chemicals (cleaning optimum, corrosion)
 Flow rates
 Flow rate / turbulences (Reynolds)
 During pulsing of valves / sections / dead legs
 Flow / pressure to filler
 Sample valves
 Vacuum valve of buffer tank (hard to clean, best: vacuum proof tank)
 Spray ball buffer tank
 pressure
 blocking

Henri Fischer, Krones Inc., Franklin, WI

Flash Pasteurization – advantages, weak points, remarkable points 20

Saturation Pressure

 Low pressure: de-aeration of beer -> insulation at resulting bubbles –

undefined heat transfer - undefined / low pasteurization effect!!

 Has to be respected in every spot in the flash, especially in the hot zone
 Most critical after pre-warming before booster pump
 Stay always above theoretical saturation pressure plus safety (+ 1 bar)
 No foaming!

Backpressure valves at drains

Manually pressure maintaining valves – spring loaded

Set to respective pressure at about 43 PSI [3 barG]!

Henri Fischer, Krones Inc., Franklin, WI

Flash Pasteurization – advantages, weak points, remarkable points 21

Saturation Isotherme (beer)

Relation:
A certain amount of CO2 is bound in a certain liquid at a certain
temperature at a certain pressure!

temperature
CO2 content

pressure
Henri Fischer, Krones Inc., Franklin, WI
Flash Pasteurization – advantages, weak points, remarkable points 22

Temperature and Pressure Diagram

temperature / pressure diagramme
3 stage flash pasteurizer
beer, max. 6,0 g/l CO2 [3.1 %V/V]
16,00 bar 80,0 °C

r
ba

r
ba

ba
[232 [176°F]

0
72,0 °C

,1

0
,8

,8
14
PSI]

13

13
70,0 °C

r
[161.6°F]

ba

r
65,4 °C

ba
[158°F]

0
r

,3
ba

5
,9
12
[149.7°F]

11
0
,4

12,00 bar 60,0 °C

11

r
[140°F]
ba
[174 90
PSI]
9,

50,0 °C
[122°F]
p in bar g

t in °C
8,00 bar 40,0 °C
[116 [104°F]
PSI]

r
ba
30,0 °C

90
4,
[86°F]
12,6 °C
4,00 bar 20,0 °C
r
ba

r
[42.8°F] [54.7°F]

ba

r
ba
[68°F]
50

[58 PSI] 6,0 °C

20
6,0 °C
2,

00
2,

2,
[42.8°F]
10,0 °C
[50°F]

0,00 bar 0,0 °C

IN P1 EXCH P2 HEAT HT EXCH COOL MV BT P3

section
system pressure [bar g] saturated pressure incl. safety factor [bar g] saturated pressure [bar g] temperature [°C]

Henri Fischer, Krones Inc., Franklin, WI

Flash Pasteurization – advantages, weak points, remarkable points 23

Pressure Situation During the Process

 Pressure in the whole system at every temperature

→ Min. saturation of the beer respecting the CO2 content

Defined by:
 Design
Pump design
 Feed pressure
 Booster pressure
 Pos. Pressure differential (heat exchanger)
 Buffer tank pressure control
 Control
• Measures
• Alarm deviations

Henri Fischer, Krones Inc., Franklin, WI

Flash Pasteurization – advantages, weak points, remarkable points 24

Beer Supply Problems – Mistakes in the BBC

 Admission
 Keep saturation pressure → otherwise foam → results in issues (pressure, flow,
sensors…)
 Correct amount→ otherwise losses, dilution
 Pipe end opposite to emptying flow filled too? → undefined amount for push out,
dilution with tank
 Tank Changeover
 Water plug between tanks? → Dilution
 Swing bends de-aerated→ gas bubbles
 Gas bubbles between tanks? → flow / pressure / sensor issues
 Pressure fluctuation when switching tanks? → flow / pressure issues
 Signal exchange
• No short signal fall offs → flash control will react with push out / interruptions
 No signal if no product available → flow / pressure issues, wrong reaction of flash
→ Mistakes in the cellar result in issues at the flash pasteurizer!

Henri Fischer, Krones Inc., Franklin, WI

Flash Pasteurization – advantages, weak points, remarkable points 25

Oxygen Intake

 Cellar
 D/A-water
 Water from cellar at beginning
 Internal push outs with flash internal water supply
 D/A-water for intermediate sterilization (saturation pressure!!)
 Filter
 Buffer tank
 Components
 Seals
 Pumps
 Pipe connections (screw connections, clamps…)
 Admission to filler

Henri Fischer, Krones Inc., Franklin, WI

Flash Pasteurization – advantages, weak points, remarkable points 26

Beer Dilution

 Cellar
 Mix phases
 Leakage proof connections
 Counted / calculated amounts
(espec. before flash)
 Sensor delay times

Henri Fischer, Krones Inc., Franklin, WI

Flash Pasteurization – advantages, weak points, remarkable points 27

Calibration of Sensors

 More often:
 O2
 Orig. gravity
 Alcohol
 Turbidity
 Conductivity
 Conductivity water and flow meter

 Rarely / (never):
 Pressure sensors
 Flow meter
 Temperature sensors
Graphics: Orbishere Internet

Henri Fischer, Krones Inc., Franklin, WI

Flash Pasteurization – advantages, weak points, remarkable points 28

Henri Fischer, Krones Inc., Franklin, WI

Flash Pasteurization – advantages, weak points, remarkable points 29

MAINTENANCE!

 Maintenance interval
 Preventive action!
An ounce of prevention is worth a pound of cure. [Benjamin Franklin]
→ qualified personnel
→ external maintenance, vendor maintenance programs

Photos: Thanks to Krones AG

Henri Fischer, Krones Inc., Franklin, WI

Flash Pasteurization – advantages, weak points, remarkable points 30

Henri Fischer, Krones Inc., Franklin, WI

Flash Pasteurization – advantages, weak points, remarkable points 31

Microbiological checks - Step control

 Isolate / detect contamination spot

 Duration / time to respect
 Sporadic results point more to periphery
 Layers in buffer tank

Henri Fischer, Krones Inc., Franklin, WI

Flash Pasteurization – advantages, weak points, remarkable points 32

Fault diagnostics – Bug Fix

 „Keep calm, act carefully“

 Defined and factual fault detection and description

 When did the issue happen ?

E.g. program step, exact situation

 Collect as much information as possible for the experts

 „Murphy´s Law“ is not always the reason for a fault !

Very often it is the most obvious, most simpliest reasons which

result in issues. (e.g. proxy loose)

 Use the advantage of diagnostic (IT-) tools if possible

Henri Fischer, Krones Inc., Franklin, WI

Flash Pasteurization – advantages, weak points, remarkable points 33

Example: Trending Curves, Fault messages

Photo: Thanks to Krones AG

Graphics: Thanks to Krones AG

Henri Fischer, Krones Inc., Franklin, WI

Flash Pasteurization – advantages, weak points, remarkable points 34

Conclusion

Often external factors result in issues at the flash pasteurizer

Operation
Cellar

Media Signal
exchange
supply

Maintenance

Photo: Thanks to Krones AG

Henri Fischer, Krones Inc., Franklin, WI

 2014 MBAA Annual Conference

QUESTIONS?

Henri Fischer
Educated Brewmaster
Product Manager Processing
KRONES Inc., Franklin, WI

 414-409-4740
 [email protected]