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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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).

Concentrate handling

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CONCENTRATE HANDLING

A DUE is able to face and solve any problems concerning the handling of concentrates and liquid raw materials, with special care paid to the system as a whole.

A DUE has developed the tank concept as a container for liquid raw materials, seeing it integrated with the machinery and run automatically as all the equipment and components related to the production process.

Therefore, the concentrate storage tank may be implemented with:

insulation and thermostating systems,
atmospheric emission control,
homogenization systems,
anti-decantation systems,
transport, dosage, weighing and mixing.

The fruit concentrates delivered in aseptic or frozen drums are emptied and dosed through positive-displacement pumps and/or turnover systems that are also available with icebreakers and crushers.

To do this A DUE has concentrate dumping systems of various types: manual, automatic, semi-automatic, with single or multiple suction lance, which may be equipped with diaphragm and positive-displacement pumps.

The drum dumping systems may be equipped with idle and motorized roller conveyors. This prevents damage to the product due to an incorrect transfer or excess pressure.

One of the noteworthy auxiliary systems for concentrate emptying is the CLEAN-PIG SYSTEM, designed by A DUE to ensure simple and efficient emptying of the process piping in order to reduce the loss of product and environmental pollution.

The system, completely automatic, allows to empty piping by using sterile air to push the PIG from the sending station up to the arrival station.

Once emptied piping, the PIG will come back to the sending station, always through sterile air. Now it is possible to carry out a possible CIP sanification.

Beverage thermal treatment

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Beverage thermal treatment

A DUE designs and constructs pasteurization groups for finished syrup, finished drink, tea and tomato sauce, with a capacity ranging from 500 to 60,000 l/h, for cold, hot and aseptic filling.

The final beverages may necessitate an appropriate treatment in terms of chemical, physical and microbiological stabilisation that can include up to three distinct stages, such as: deaeration, homogenization and pasteurization.

A DUE studies, designs and manufactures the systems able to accomplish the above treatments, and in the specific case of pasteurization, can boast a portfolio covering a wide range of solutions in order to meet the most varied needs and requirements.

A DUE’s pasteurization groups include plate or tube heat exchangers. Thanks to the study of a special recirculation system it is possible to guarantee energy recovery of more than 90%.

A DUE’s pasteurization groups are also designed to better manage the surplus (ranging from 5% to 100%) coming from the filler.

Deareation consists of removing oxygen, which is the cause of harmful oxidation.

In the case of fruit juices, deareation improves the flavour, aspect and shelf life of the product.

In fact, the elimination of oxygen prevents the degradation of vitamin C, simplifies the filling process and prolongs shelf life of the product.

Homogenization consists of reducing and standardizing the size of the particles of fluid products in order to make them more stable and obtain a better taste and texture.

In fact, micronization reduces the weight of the particles, increasing their stability in suspension and avoiding their separation between the liquid phase and the solid phase.

In this way it is possible to reduce the use of emulsifying agents and additives.

The product is passed through a special homogenizing valve designed to generate pressure.

The energy associated with the fluid-dynamic effects that are created (turbulence, cavitation, acceleration, impact and cutting forces) allows micronization of the particles.

The use of high pressure homogenizers allows treatment of liquid products with dispersed or suspended particles of extremely variable dimensions, providing micronized particles with dimensions in the range of 0.4- 1 micron.

Pasteurization consists of the microbiological stabilization of product through special heat treatment.

Correct pasteurization also reduces the preservatives that are necessary to ensure the product’s shelf life.

The microbial load in fruit drinks is related to the raw materials (contamination of the fruit and vegetables because of the ground, dust and cleaning water), the environment (confined air, structures, climatic factors, moulds/yeasts, insects) and process hygiene (collection, transport, cleaning, transformation).

The main contaminating microorganisms are yeasts and moulds, but there may also be bacteria (acetic acid, lactic acid and spore-forming). Pathogenic microorganisms are rarely found in juices and soft drinks because of the acidity.

EASY.ThermP – PLATE PASTEURIZER

foto scheda tecnica pastorizzatore small
EASY.ThermP
Pasteurisation units for simple syrup, final syrup, finished drink and fruit juices.

Suitable to treat non-carbonated and/or carbonated beverages, clear or with fibres of small size and a low content.

Suitable for all types of filling technologies: cold, hot and ultra clean.

Nominal production capacity: 500 ÷ 60.000 l/h.

foto scheda tecnica pastorizzatore small

Holding Time accuracy: ± 5%.

Pasteurization temperature adjustable via operator interface. Tolerance: ± 1°C.

Outlet temperature adjustable via operator interface. Tolerance: ± 1°C.

Energy Recovery up to 90% (cold filling process).

foto scheda tecnica pastorizzatore small

Plate types: standard and “free flow”.

foto scheda tecnica pastorizzatore small

Can be integrated with vacuum deaerators complete of aroma recovery, homogenizers and saver tanks.

Water & Energy saving.

Should a tunnel cooler for containers be installed downstream, the full integraton with additional thermal recovery is ensured.

EASY.ThermT – TUBULAR PASTEURIZER

fosto scheda tecnica pasto tubularesEASY.ThermT

Pasteurisation units for final syrup, finished drink, fruit juices.

Suitable to treat viscous product containing small chunks, pulps and fibres.

Suitable for all types of filling technologies: cold, hot and ultra clean.

Nominal production capacity: 500 ÷ 60.000 l/h.

fosto scheda tecnica pasto tubulares

Holding Time accuracy: ± 5%.

Pasteurization temperature adjustable via operator interface. Tolerance: ± 1°C.

Outlet temperature adjustable via operator interface. Tolerance: ± 1°C.

fosto scheda tecnica pasto tubulares

Pipe type: smooth surface, corrugated, double wall corrugated, embossed tubes.

Design: tube-in-tube and multi-tube.

fosto scheda tecnica pasto tubulares

Can be integrated with vacuum deaerators complete of aroma recovery, homogenizers and saver tanks.

Water & Energy saving.

Should a tunnel cooler for containers be installed downstream, the full integraton with additional thermal recovery is ensured.

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EASY.ThermA – ASEPTIC PASTEURIZER

foto scheda tecnica sterilizers
EASY.ThermA

Sterilization units for finished drink (non-carbonated beverages, isotonic drinks, fruit juices and nectars) to be aseptically filled.

Systems suitable to treat viscous product containing small chunks, pulps and fibres. Combined systems for two-step-filling “double shot” (liquid & solid phases).

Suitable for all aseptic filling technologies.

Nominal production capacity: 500 ÷ 60.000 l/h.

foto scheda tecnica sterilizers

Holding Time accuracy: ± 5%.

Sterilization temperature adjustable via operator interface. Tolerance: ± 1°C.

Outlet temperature adjustable via operator interface. Tolerance: ± 1°C.

Time to be ready to fill will be within 2 h.

Energy Recovery up to 90% (PHE cold filling process).

80% recovery of the steam used during the sterilization phase.

20% reduction of the product losses during the water pushing phases.

foto scheda tecnica sterilizers

Positive differential pressure control in each step.

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Can be integrated with vacuum deaerators complete of aroma recovery, homogenizers and aseptic tanks.

Water & Energy saving.

In line blending

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In line blending

A DUE has in its portfolio in line mixers suitable for the production of soft drinks or flat drinks.

They are available in stainless steel Aisi 304 / Aisi 316 and may be equipped with any type of accessory and electronic control instrument.

A DUE has made a completely automatic machine, which ensures excellent quality and stability of the finished product and guarantees accuracy and consistency of the degrees Bx (precisions of ± 0.05° Bx are reached on the finished drink).

The dosage of the finished syrup in water – coming from a traditional syrup room or from a single automatic continuous dosing and mixing unit (EASY.InLine) – is kept constantly under control by flowmeters and ratio controllers. Special static mixers provide homogeneous mixing.

A DUE EASY.InLine2 is an automatic in line mixing premix for the production of soft drinks or flat drinks, suitable for connection to any type of filler.
Precision, reliability, flexibility, ease of management, compact dimensions, construction on a self-supporting frame and simplicity of installation and start-up are the strengths of the A DUE BLENDER.

EASY.InLine2 is available in different versions with production capacities of 5,000 to 60,000 l/h. Each model is able to adapt itself with the utmost flexibility to flow rate variations requested by the filling group during format changeover.

EASY.InLine2 also reduces syrup waste to a minimum during the initial and final production phases (flavour change), thanks to integrated systems which read the water/syrup thresholds precisely.

EASY.InLine2 is preset for connection to the closed circuit cleaning CIP UNIT. Furthermore, the special hydraulic circuit provides considerable hygienic/sanitary improvement compared to the traditional premixes with dosing pumps. The use of high quality components reduces maintenance costs by up to 80%.

EASY.InLine2 – IN LINE BLENDER

scheda tecnica in line blenders

EASY.InLine2

Unit for in-line and continuous blending of juices and non-carbonated soft drinks in general.

Final beverage Brix-degree control with feedback correction possibility.

Nominal production capacity: 5.000 ÷ 60.000 l/h.

scheda tecnica in line blenders

 

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

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

scheda tecnica in line blenders

Suitable for “clear” juices/products and those with pulps.

Modular and customizable system basing on the ingredients contained in a certain recipe.

scheda tecnica in line blenders

Quick flavor change over.

Stabilizer dissolving

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STABILIZER DISSOLVING

Stabilizers (often referred to as “gums” or “pectins” in a general manner) are additives substances that are added to the drinks with the aim of improving shelf life and flavor release.

The most commonly used are: Guar gum (E412); Xanthan gum (E415); Carboxymethylcellulose (E466); conventional pectins (E440i).

Sometimes it is appropriate to use the stabilizers mixed together in order to better combine their properties and increase the positive effects of each one (SYNERGISM).

The stabilizers do not exert their action unless they are fully and uniformly dispersed and hydrated in the water.

To this end, A DUE is able to propose EASY.Mix the best dissolving systems for: pectin, guar gum, xanthan gum and their mixtures (turbo emulsifiers, tri-blenders, hydrodynamic hoppers and dispersers).

The choice of the most suitable system depends on the desired viscosity of the solution, which in turn is determined by the chemical nature of the stabilizer in use and also by the concentration set point value.

11 stabilizer dissolvingDissolving group with integrated triblender: composed of nr.1 or nr.2 vessels equipped with fast propeller stirrer.

The triblender consists of a loading hopper for the powders vertically transferred by suction into the mixing chamber; a special mesh filter assures the homogeneity of the mixture.

The system is suitable for preparation of low concentration solutions starting from the powders with low dissolution difficulty, such as:

 Pectins: up to 0.5% at 50°C
 CMC: up to 0.2% at 20°C

11 stabilizer dissolvingbStorage and dissolution group composed of one 1000-litre vessel equipped with emulsifying system (a special geometry stirrer complete of a high shear propeller) and one self-priming pump for the ingredients transfer.

The group is suitable for preparation of the medium concentration solutions starting from the powders with medium dissolution difficulty:

 Pectins: up to 1.5% at 50°C
 Xanthan gum: up to 0.5% at 20°C
 CMC: up to 0.5% at 20°C
 Guar gum: up to 0.5% at 20°C

dispersore a vuotoStorage and dissolution group composed of one 1000-litre vessel equipped with vacuum disperser and one either centrifugal or positive displacement pump for the ingredients transfer.

The vacuum disperser allows to finely disperse the powder in the water, obtaining rapidly a homogeneous mixture, free of lumps and with a smooth texture. Even with limited quantity of water the liquid can be re-circulated until all powders are incorporated.

The group is suitable for preparation of the high concentration solutions starting from the powders with medium dissolution difficulty:

 Pectins: 3,0 ÷ 6,0 % at 50°C
 Xanthan gum: 1.5 ÷ 3,0 % at 20°C
 CMC: 2,0 ÷ 4,0% at 20°C
 Guar gum: 1.5 ÷ 3,0 % at 20°C

Available optionally: heat exchanger and supporting worktop for the powders.

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