Aseptic Storage

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Aseptic Storage

A DUE manufactures stainless steel AISI 304 and AISI 316 tanks, with capacities ranging from 2,000 to 40,000 litres, for the storage of finished drink before sending it to the filler.

For the intermediate storage of drinks to be treated aseptically, A DUE proposes the aseptic tank (EASY.ATK).
EASY.ATK is an aseptic buffer tank with relative accessories placed between the pasteurizer and the filler to compensate for the micro stops of the filler without losing product sterility.

EASY.ATK is sterile because it is sanitized, sterilized with steam at 140°C, fed with sterile product coming from the pasteurizer and kept overpressurized through the sterile gases supplied by the nitrogen-steam panel.

It is cooled with special external jackets to avoid product contamination.

The tank is designed in accordance with PED standards to resist the absolute vacuum and sterilization pressures.

The pressure inside the EASY.ATK must always be greater than 200 millibars to avoid air infiltration from the outside with the consequent risk of loss in sterility.

For this purpose an automatic pressurization control system is included which maintains the recipe parameters.

The aseptic storage system also features: connection valves to the sterilizer and filler and optional accessories such as magnetic drag stirrers, a dedicated CIP and a stand-alone electric panel.

Mixing tanks

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Mixing tanks

Extensive experience gained in the field allows A DUE to offer a wide range of solutions covering the phases of final syrup batch preparation, as well as processing of finished drink, water with mineral salts, juices with pulps or slurry and other particular products.

With the batching system all the ingredients are measured, proportioned and dosed in special mixing tanks dedicated for final syrup preparation.

A DUE tanks are designed “tailored” to the specific product and its rheological, chemical and physical characteristics.

Special mixing stirrers (vertical agitator, JET MIX systems, low speed multi-blade agitator, single blade agitator, counter-rotating shaft agitator, etc.), ensure perfect homogeneity of the product being mixed, even at low temperature and in presence of pulp, fruit pieces or suspended particles.

The tanks may be equipped with any type of accessory and electronic control instrument. Tests can be performed (degrees bx, acidity, colour control) directly in the tank.

Special Mixing design for sensitive product (Fluent® SW analysis)

 

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The system is designed in order to reach the pre-set contents of mineral salts in the water to be bottled.The main stages of the process are the following:

 Mineral salts dissolving in water (mineral salts high content stock solution);
 Stock solution dilution in the water destined to remineralising;
 Safety filtration for the undissolved salts;
 Final disinfection (UV treatment or ozonisation).

Process room

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PROCESS ROOMS

Sala processo

A DUE designs, manufactures and installs complete and automated process plants suitable for preparation of the following products:

 Final syrups and syrup concentrates;
 Syrups with fruit (“slurry”);
 Carbonated beverages (CSD);
 Non-carbonated beverages (NCB);
 Clear fruit juices, juices with pieces, pulp and fibers;
 Energy, fantasy and functional drinks;
 Non-alcoholic beer.

A DUE is able to provide a proper solution to satisfy any customer’s need:

 Starting from raw material receiving (sugar, powder ingredients, concentrates, juices etc.) up to product delivery to the filling area;
 Systems for primary water treatment (WTP);
 Interconnections to allow filling of various types of containers, such as PET, CAN, GLASS, POUCHES, Bag-in-Box;
 Supply of service equipment (Boiler, Chiller, Cooling Tower etc.).

A DUE is able to provide the beverage processing plants with the output capacity, ranging between 2.000 and 300.000 l/h, available in:

 Manual running;
 Semi-automatic running;
 Fully automatic running with management via SCADA of all processing phases.

EASY.RoomBlock – PREPARATION SKID

scheda tecnica BlokMixSEASY.RoomBlock

Special design compact “monoblock” system for syrups preparation.

Suitable also for preparation of the final beverages.

Pre-assembled on skid, with no need of costly assembly works.

Easy to transport, can be connected as a stand-alone unit.

Nominal production capacity: 2.000 ÷ 6.000 l/h.

scheda tecnica BlokMixS

Suitable for the low production capacity plants.

scheda tecnica BlokMixSReduced and compact dimensions.

EASY.Room – PROCESS AND PREPARATION ROOM

scheda tecnica sal sciroppis

EASY.Room

Complete processing plants for syrup and final beverage preparation.

Applications: carbonated and non-carbonated drinks, fruit juices, functional beverages, non-alcoholic beer, pieces-containing juices, concentrates etc.

Fully customized installations, with different levels of plant automation (full manual control, manual assisted, semi-automatic o fully automatic).

Performances: > 99,5% of Batches fully in specs and ready for production in due time.

Nominal production capacity: 2.000 ÷ 300.000 l/h of final drink.

scheda tecnica sal sciroppis

Automation with use of most widely used development platforms.

SCADA interfaceable with Customer’s ERP.

Recipes and Archives management on PC.

scheda tecnica sal sciroppis

Best technologies selection to guarantee waste and losses reduction with highest efficiency.

Design accordingly to Sanitary Standard Norm World Wide.

Special Mixing design for sensitive product (Fluent® SW analysis).

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Beverage carbonation

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Beverage carbonation

A DUE has various carbonation systems for water such as EASY.CarboS andEASY.CarboV.

These two machines differ in the type of carbonation system: traditional (by absorption) for EASY.CarboS and with the Venturi effect (by injection) for EASY.CarboV.

They are also suitable for CSD drinks and wine.

EASY.CarboS is used to add carbon dioxide to water.

The system is equipped with a single-screw pump to feed water to the saturator and an in line CO2 pre-injection system. The saturation tank, with testing according to PED for an operating pressure of 6 bars, is suitable for the CIP cleaning.

The saturation column is appropriately insulated.

The system is equipped with an automatic CO2 regulator and recorder with electro-pneumatic functioning to automatically adjust the CO2 pressure in the saturation column depending on the saturator inlet product temperature.

Carbon dioxide is added at extremely low temperatures of 2° to 4° C and at a high pressure (6 bars), creating the best conditions for CO2 solubilization. The final CO2 content ranges from 4 to 8 gr/l.

The Saturator is available in different versions with production capacities of 5,000 l/h to 10,000 l/h.

EASY.CarboV, with automatic functioning, ensures excellent stability and quality of the finished product, thanks to the carbonation index precision and constancy: the CO2 dosage precision is ± 0.1 volumes.

The liquid is sent through an on-off valve to the stainless steel deareation / saturation column tested in according to PED 97/23/CE.

The equipment has a special patented carbon dioxide injection and dosage group, which produces CO2 nebulization and allows faster and more efficient gas solubility in the liquid and uniform distribution of the CO2 providing the desired carbonation.

It is also possible to vary and adjust the saturation process and the pelage.

EASY.CarboV is available in different versions with production capacities of 5,000 to 60,000 l/h and it is preset for connection to the closed circuit cleaning CIP UNIT.

Beverage deaeration and mixing

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Beverage deaeration and mixing

A DUE is able to offer different solutions covering the following processes:

Water deaeration: single stage or double stage, with possibility of CO2 or N2 injection.
Deaeration of syrup concentrates.
Various liquid ingredients In-line and continuous blending.
Control of the following parameters : Brix, CO2, pH, Temperature, Pressure, Flow rates, Consumptions, etc.

For the production of CSD, A DUE can provide EASY.Carbomix whose functioning consists of the following process phases:

water deareation;
syrup dosage;
CO2 dosage;
mixing;
storage under pressure.

Through the use of suitable flow meters A DUE’s EASY.Carbomix allows the automatic adjustment of the °Bx degree and of carbon dioxide content in the finished drink and total recovery of the product.

EASY.Carbomix may also be used for carbonated mineral water, natural mineral water or non carbonated soft drinks. For still water, a gas injection system suitable for N2 dosing is provided.

EASY.Carbomix is an automatic, single Premix unit with a flow rate ranging from 5,000 to 60,000 l/h.

The outlet °Bx – with testing, recording and automatic correction, even for diet drinks – is checked using special software and a refractometer with milliBx precision.

The outlet CO2 – with testing, recording and automatic correction – is checked using special software and a flowmeter with a precision of ± 0.1 volumes.
Connection is possible by modem for the remote control of all the machine working phases.

Compared to traditional Premixes, EASY.Carbomix has the following advantages: syrup/H2O mixing ratio adjustment according to the inlet syrup Bx value; working flow rate variation depending on that of the filler without having to stop the machine; reduction in syrup waste during the start-up, product changeover and production end phases; finished drink “flavour” changeover speed.

EASY.Carbomix – AUTOMATIC PREMIX UNIT

foto scheda tecnicaSEASY.Carbomix

Automatic blending and carbonating system for carbonated and non-carbonated beverages in-line preparation.

Applications: soft drinks with and without fibres, including carbonated mineral water, still mineral water or non-carbonated beverages.

Final beverage Brix-degree control with automatic correction.

Installations with different configurations are available, providing for flow capacity wide range variations in combination with maintained °Bx and Vol CO2 high accuracy performances.

Nominal production capacity: 5.000 ÷ 60.000 l/h.

foto scheda tecnicaS

Outlet °Bx variation (steady production) σ=0,02 °Brix.

Outlet °Bx variation (transitional phases) σ=0,1 °Brix.

Outlet CO2 Vol/l variation (steady production) σ=0,08 Vol/l.

Outlet CO2 Vol/l variation (transitional phases) σ=0,15 Vol/l.

O2 content down to 0,2 ppm into deaerated water.

Deareation efficiency mantained from 30% to 100% of nominal flow rate.

foto scheda tecnicaSUse of mass flow meters.

Continuous control of °Bx degree and of CO2 content with feedback correction possibility.

Deaeration by means of single-stage or double-stage vacuum pump with or without CO2 stripping.

foto scheda tecnicaS

Complete drainability of the unit.

Improved citrus sacs  care.

Quick product change-over with minimal waste.

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Water treatment

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WATER TREATMENT

The main raw material for the preparation of all soft drinks is water.

In view of this A DUE can offer:

 Sand filters;
 Activated carbon filters;
 Cartridge microfiltration;
 Ultrafiltration;
 Reverse Osmosis Systems;
 UV sterilization groups;
 Ozone sanitizing systems.

A DUE supplies tailored water treatment systems according to the requirements of each customer, designed by combining technology and modularity depending on the initial characteristics of the water and the final quality desired.

They are automatic and equipped with all the control instruments, with reduced maintenance times and costs.

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Tailored EASY.Water, designed by combining technology and modularity depending on the initial characteristics of the water and the final quality desired.

Fully automatic, with capacity from 1 to 100 mc/h.

Basic phases of water treatment:

Water Chlorination

Finishing Process:

 adsorption on activated carbon
 polishing cartridge filtration
 Reverse osmosis systems – EASY.RO (optional)

Prefiltering Process:

 specific filtering beds
ultrafiltration – EASY.UF (optional)

Final disinfection process:

 ultraviolet disinfection (UV)
 ozone sanitizing systems – EASY. Ozone

Less-Water Bev. Tech (nicknamed NIAGARA) is a research project aimed at reducing water consumption and wastage in the beverage industry through an innovative combination of water treatment technologies, among which Ultrafiltration (UF).

Ultrafiltration (UF) is a pressure-driven separation process suitable for retaining biomolecules, bacteria, viruses, polymers, colloidal particles and dissolved organics (partially).

LWBT-90www.lesswaterbevtech.com/en/en-home

The system is designed in order to reach the pre-set contents of mineral salts in the water to be bottled.The main stages of the process are the following:

 Mineral salts dissolving in water (mineral salts high content stock solution);
 Stock solution dilution in the water destined to remineralising;
 Safety filtration for the undissolved salts;
 Final disinfection (UV treatment or ozonisation).

EASY.Water – WATER TREATMENT PLANT

WTPsmallEASY.Water
Plants for the process water treatment.

Suitable to treat primary water, city water and raw water to be used for beverages preparation.

Plants customizable basing on the initial characteristics of the water and/or on the final desired quality.

Execution and components according to the standards for food and beverage processing plants manufactures in force.

Nominal production capacity: up to 100 m3/h of inlet water.

WTPsmallWater recovery up to 90% (multi-stage osmosis).

WTPsmall
Double Reverse Osmosis.

G2G technology.

Integrated CIP system.

WTPsmallLow operating costs.

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Automation and control

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Automation and control

The control room is the heart of the plant, since it is the operating center to monitor and control the whole technological process.

A DUE develops internally all management software for processing rooms making use of the most important and popular platforms (e.g. Wonderware/System Platform, Siemens WinCC  TIA Professional, Rockwell Factory Talk, etc.)

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CIPs

The automatic management of the specific recipe of each drink, the continuous monitoring, recording and storage of all the main process parameters, are the operations that ensure quality and traceability of the finished product.

All this is only possible with a high level of plant automation.

With 50 years of experience in the beverage industry, A DUE has developed its own automation and process control philosophies based on the following principles:

 flexibility;
 intuitive management;
 access control;
 data acquisition;
 operation reports;
 data sharing through networks;
 integrability;
 traceability.

The above-mentioned concepts are applied to PLC and supervision system programming, which, suitably integrated with the main fieldbus, form the basis for complete automation of the process systems.

Batchs

SCADA (“Supervisory Control And Data Acquisition”) information systems are used to monitor and control the industrial processes.

The purpose of the Supervisory system is to control a complex reality, where the acquisition of a large quantity of data in real time, their processing, interpretation and presentation are essential for an activity to function.

In fact, the decisions concerning the running of the plant itself are taken on the basis of these data and they cannot be collected manually.

The Supervisory software is active in each processing phase to historicize the data coming from all the machines being used and adjust their functioning.

System composition

The Supervisory system consists of one or more PC connected to the PLC of the plant through an ethernet network, where the main software is installed to allow the plant functioning, to guarantee its protection and monitoring.

The Supervisory system is supplemented with the assistance through remote access (VPN), provided in standard configurations of all our plants.

By means of the ethernet network the Supervisory system exchanges all data relating to the plant with the PLC of each machine, making the information available in real time.

Besides this, the data are also saved in the system HD and displayed in historical trends, lists of events, alarms and reports.

Real-time supervision

The Supervisory system allows to display interactive mimic charts of the plant.

The following charts can be displayed:

devices activation status (pumps and valves),
field analog values (pressures, flow rates, levels, etc.),
 alarms and messages subdivided according to the processing areas,
digital sensors and limit switches,
coloured visualization of the plant piping, according to the type of fluid (water, syrup, washing solution, steam, etc.),
state of the various cycles with a specific indication on the ongoing phase,
 product recipes,
 CIP recipes,
 trends.

All the above data can be accessed quickly and intuitively through simple surfing within the available in the Supervisory System pages.

Line Control

The Supervisory system is able to command the whole plant, by operating utilities and cycles and modifying the system parameters and all the recipe data that are present.

Data historicizing

The main feature of the Supervisory system is data historicizing.

Alarms: there is an alarm history archive containing the alarm detailed indications.

Events: there is a log-event management, which records such events as: the cycle start/stop, the password login/logout, the manual/automatic switching of various devices, system parameters variations.

Analog signals (Trends): the field analog values are recorded and can be displayed in trend curves.

The data relating to Alarms, Events and Analog signals can be directly accessed from the Supervisory System. Alternatively, the above data can be exported in a CSV-format.

Reports: the files are generated in CSV-format and contain the key data relating to the specific system activities, such as: execution of recipes, washing, pasteurizing etc.

By way of example, the data stored and grouped according to the concerned machine types are the following:

 Batch Control: recipe data, quantities actually dosed, batch start/end date and time.
 CIP UNIT: recipe data, collected process parameters, washing start/end date and time, washing cycle result.
 Blender: recipe data, collected process parameters, start/end date and time of the blending cycle..
 Pasteurizer: recipe data, process phase start/end date and time, recirculation times.

Password

All operations controlled by the Supervisory System are subject to log-in of individual Users who have a multi-level access to the system through the dedicated passwords.

Cleaning

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Cleaning

A DUE’s CIP UNIT are able to ensure maximum hygiene of the process system and filling group.

A DUE can provide manual, automatic or semi-automatic CIP UNIT that may be adapted to already existing process technologies if necessary.

A DUE’s CIP UNIT are modular systems and suitable for further expansion, moreover, they allow to control all the main sanitizing process parameters (washing cycles, detergent and disinfectant concentration, contact times, temperature) for an efficient removal of organic material, biofilm and excellent disinfection.

However, to obtain excellent sanification/sterilization process results it is important for all the piping and equipment involved in the production process to be designed and built very carefully to ensure the absence of stagnation points that are difficult to clean.

EASY.Clean - AUTOMATIC CIP UNIT

foto scheda tecnica CIPs
EASY.Clean
Modular CIP unit for processing plant washing.

Possibility to manage different washing programs simultaneously and to recover up to 4 washing solutions.

foto scheda tecnica CIPs

Control of all key CIP parameters: washing cycles, concentrations of detergents and disinfectants, contact times and temperatures.

Possibility of self-washing (CIP of CIP).

Fully programmable with wide range of treatment configurations.

Energy recovery and low consumptions.

foto scheda tecnica CIPs
Modular skid available without tanks (in case of use of existing tanks).

In line ingredient dosing

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In line ingredient dosing

The sugar syrup, concentrates and minor ingredients must be accurately dosed and mixed to obtain the finished syrup.

Depending on the type of recipe, A DUE can propose EASY.InLine (continuous running in-line dosing system) or EASY.Core (discontinuous “batch” preparation and dosing system).

EASY.Core is a preparation and dosing unit that can simultaneously or sequentially transfer the single components for the preparation of finished syrup or finished drink. Several recipes can be prepared at the same time.

EASY.Core is a compact single unit consisting of a double set of mixers and tanks working alternately.

These mixers are used to dissolve the powders or empty the liquid concentrates.

The capacity and number of mixers are defined according to the recipe and production capacities requested by the customer.

With EASY.Core sugar syrup, liquid sugar and water are dosed and transferred, too.

It is also possible to equip the unit for the transfer and dosage of concentrates or juices packed in 1000 l. pallet tanks or stored in existing tanks.

The main feature of the EASY.Core is the total control of all the ingredients transferred into the preparation tank through different flowmeters (mass), run by special software tuned by A DUE.

EASY.InLine is a completely automatic in line and continuous dosing and mixing unit with centralized process control.

The electronic instruments and the mass or magnetic flowmeters ensure dosage constancy and precision.

EASY.InLine mixes in line and simultaneously more than ten different premixed basic products or ingredients.

EASY.InLine can also be used for the preparation of finished drink: from fruit juices and nectars to soft drinks and from tea to sports drinks.

EASY.InLine has a production capacity that can vary between 5,000 and 70,000 l/h of syrup or finished drink.

To ensure total quality of the product being processed, EASY.InLine double checks in line and in parallel the fundamental values (concentration, temperature, °Bx, acidity) of the single inlet ingredients and also double checks the °Bx and pH values of the finished syrup coming out of the machine.

Thanks to the use of high precision instruments, it is possible to reach a precision of ± 0.02 °Bx and ± 0.2 pH units.

EASY.InLine is characterized by its high degree of automation and performance stability, its total recovery of concentrates at the end of production, the reduction of production waste and its CIP cleaning cycle presetting.

Using a PC it is possible to constantly keep under control all the parameters and production variables and it is easy to use thanks to an operator interface controlled by advanced software.

EASY.Core – INGREDIENT MANAGEMENT

sched-batch-controls
EASY.Core

System for sequential dissolving and dosing of minor ingredientes, concentrates and juices for final syrups preparation.

Simultaneous or sequential batch dosing with the possibility of handling from 3 to 7 ingredients.

Nominal production capacity: 5.000 ÷ 60.000 l/h.

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Full control of all the ingredients transferred by means of the flow measuring instruments (mass type) to the preparation tank.

sched-batch-controls
Design optimized for high efficient cleaning in place.

Total product recovery.

Final product formulation management.

EASY.InLine – IN LINE INGREDIENT DOSING

scheda tecnica Dosiline

EASY.InLine

Automatic unit for continuous dosing and blending suitable for the final syrups preparation, in monoblock execution.

Systems customizable basing on the number of ingredients to dose (typically 4 or 5 ingredients).

Nominal production capacity: 5.000 ÷ 60.000 l/h.

scheda tecnica Dosiline

Outlet °Bx variation (steady production) σ=0,02 °Brix.

Outlet °Bx variation (transitional phases) σ=0,1 °Brix.

scheda tecnica Dosiline

Enhanced control systems for key parameters (flow capacity, °Brix).

scheda tecnica DosilineNo additional tank required.

Total product recovery (with water or gas).

Liquid sugar management

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Liquid sugar management

A DUE storage tanks are designed and built for the storage and dosage of sugar syrup, liquid sugar and High Fructose Corn Syrup (HFCS).

A DUE ensures perfect management of the sugar syrup loading, storing, unloading, transfer and dosing control phases.

The tanks can be equipped with a blade stirrer or a JETMIX system, of very simple and reliable design, which ensures considerable homogeneity of the syrup held in storage and allows to avoid entrapment of air bubbles in it.

The tanks are equipped with:

  manual or automatic loading and unloading systems (mixproof valves or flow exchange plates),

  transfer pumps with mass or magnetic flow meters,

 UV filters for reintegration air or for syrup being transferred to control the microbiological load,

  insulation option.

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