DS TRIPLE UHT PILOT PLANT

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1 DS TRIPLE UHT PILOT PLANT Truly, a great plant with small dimensions / /

2 TRULY, A GREAT PLANT WITH SMALL DIMENSIONS DS Triple offers unique and flexible pilot UHT systems for manufacturers (dairy, juice and specialty products), research institutes, universities as well as ingredient suppliers to the food and dairy industry. The plant can be supplied with all current thermal treatment using both indirect as well as direct heating. The plant can be set up for treatments covering the ranges of HTST, ESL and full UHT of low acid and high acid liquid food products ranging from: milk, cream, desserts, puddings, soups and sauces, ketchup, plant based drinks and juice and beverage products. The objective of the plant is to simulate the industrial production of liquid products using the various technologies to provide best possible scaleup information. The simulation and the data collected is meant to provide manufactures with effective means to ensure repeatability in pilot scale and reliable scalability. Ideal for: manufacturers (dairy, juice and specialty products) recearch institutes universities ingredient suppliers to the food and dairy industry 2

3 3 DS Triple UHT Pilot Plant

4 FLEXIBILITY SHOWS THE WAY Through its modular design, the DS Triple UHT pilot plant has been constructed to operate inside as well as outside of a standard plant design, so that a new product can be tested with the plant as is and in case of need, in alternative setups, mostly without having to make physical changes to the plant. Contrary to common practice, where the process setup is rigid, this allows development of products that involves changes to the process, creating high value products with very specific functionalities. Particular effort has been made to ensure that the key elements, such as the tubular heat exchanger, reflect the physical functionality of the commercial plants. This has been obtained by a careful balancing of the design of the tubular heat exchanger itself, endeavouring to match the production characteristics in large scale designs by exploiting the possibilities varying the flow of media and product in order to calibrate the heat exchange capacity of the individual sections. Once the temperature profile has been determined, possible product changes due to heating or cooling conditions can be determined and a root cause analysis can narrow down margins to be designed into the process, be it ingredient parameters or process related parameters. The four heating sections are designed with individually controlled heating circuits to allow for maximum operation flexibility and correctional interference in the initial runs. This will, in turn, allow for optimization by analysing and making use of the collected data. It is important to notice that the final cooling section is made with recirculation of the media in order to facilitate a gentle and effective cooling of high viscous products to avoid the detrimental effect of freezing the product on the cooling surfaces of the heat exchanger. The A-platform of the DS Triple UHT pilot plant is based on the tubularheat exchanger principle with further ability to add additional process options such as but not limited to: Holding cell module ( seconds holding) Deaerator module with flavour recovery technology Plate based HTST and UHT capability Steam Infusion for temperatures up to full UHT treatment Steam Injection UHT temperatures up to full UHT treatment The plant is as default designed for a capacity from l/h. However, to provide users the ability to resemble flow conditions, velocities, turbulences and plant residence times as they typically exist in commercial tubular milk UHT plants, the pilot plant capacity can be adjusted to operate at up to 250 l/h. The homogenizer is in aseptic designed, which allows for both upstream and downstream homogenization. The machine is equipped with a two-stage homogenization arrangement, capable of providing up to 350 bar pressure. The cooling sections are similarly designed with individual circulation circuits that enable close repeatability of any commercial UHT plant as well as freedom to alter capacities. All water circuit flows and temperatures are individually and automatically controlled. 4

5 PLANT OPERATION AND FUNCTIONALITY All individual plant sections are connected to the centrally positioned flow plate, which allows for an extensive range of configurations where switching from one setup to another is simple and easily achieved by its logical and concise design. To counter the issue of thermal losses the flow plate is shielded from heat loss, as it is integrated with the tubular heat exchanger and enclosed on the front side once it has been set up. The plant consists of a significant number of heat exchanger modules in 3 m. length. A specific required heating surface area can be freely selected at any of the 7 individual tubular plant sections to match any unique heating surface area requirement. The plant is equipped with two balance tanks, each holding 30 litres of product. The two tanks, both fitted with a small agitator, provide virtually loss free transition from water to product and reverse. An eccentric screw pump ensures high-pressure capability and reliable/stable flow for both high and low viscosity products with a minimum of shear. Multi-touch Screens Tubular Heat Exchanger Modules Balance Tanks Infusion Chamber Steam Injection Flash Chamber Flowplate Homogenizer 5

6 PLANT CONTROL SYSTEM The plant is based on automatic control, enabling full reporting from recipe throughout logging of all process parameter of each test run. The management of the plant is facilitated by an unique dual intouch operator station mounted strategically at the pilot plant panel to provide the perfect cockpit experience. This allows a close monitoring and effective management of the plant during runs with even the most complex products. The PLC software provides for fully automatic control and monitoring of all instruments and actuators at the pilot plant. The software consists of pre-tested modules for automatic operation, regulation, monitoring, alarming and operator dialogue. The software is tested and tailored for optimal commissioning and operation of the plant. The software includes: The operator software for the system is developed in a user-friendly manner which ensures an effective operator dialogue during operation as well as monitoring of the plant at two large 21,5 multitouch screens. The following operator dialogue facilities are available: Detailed mimic displays showing all controlled items in the process plant Process overview displays Operator displays for start/stop of process programs Component status in pop-up window faceplates Alarm monitoring displays Having two monitors at hand will provide the operator with a perfect platform for easy and fast plant control while at same time providing an amazing overview on all process parameters. PPE Events for MIS system (PPE: Production Performance Events) Automatic modules control Monitoring procedures Interlocks 6

7 FUNCTIONAL DESIGN / SERVICE ACCESSIBILITY Through innovative designs, detailed understanding of process needs, and precise engineering; our systems will simply deliver more to your business: Focus on Safety Designing a plant which is safe and easy to operate whilst simultaneously truly complying to all relevant European safety regulations and guidelines is a primary focus point and driver for DS Triple. Optimized for Service and Maintenance Practical easy and safe access to the plant for service and maintenance has been an equal important focus point during the design phase. Innovative plant design DS Triple has come up with a new design that reverses the traditional way of building pilot plants, by installing the service circuits and pumps along with the relevant valves collectively at the back allowing safer, better and easier access to all important parts of the plant. This ensures that the plant truly adheres to CE marking and provides for a favourable working environment for both operators and technicians. 7

8 DS TRIPLE UHT PILOT PLANT BENEFITS Offers the highest possible level of flexibility regarding plant configuration Provides a test production of a very wide range of products from low acid to high acid, from low viscous to high viscous Easy and reliable to operate with an automatic control system. A high level of repeatability Dual operator station with 21,5 multi-touch screens Automatic monitoring and display of all process data in a user-friendly manner Nominal flow capacity 100 l/h with the ability to process up to 250 l/h on liquid milk products Skid mounted and tested unit with a very fast installation and commissioning at site AISI 316L on all product contact surfaces Danish quality throughout! From design to construction and commissioning. Remarks in regards of general component standard As a free independent provider of UHT systems from pilot to commercial UHT units to manufactures all over the globe, DS Triple may select any type of pumps, valves, homogenizers and instruments in accordance with the preferences of the end-user. DS Triple A/S 8600 Silkeborg Denmark Tel: mail: sales@dstriple.dk