1、 General Redefining JNSD beverage line architecture with filtration&UV.White paper/Second edition Saving energy through innovation General Publisher Tetra Pak Processing Systems AB SE 221 86 Lund,Sweden Published February 2020 Tetra Pak International S.A No part of this publication may be duplicated

2、 in any form without the source being indicated.3 CONTENTS Introduction _ 4 Who is this booklet for?_ 4 A future path for JNSD _ 4 JNSD today _ 5 Rethinking the JNSD line _6 Innovation in practice _ 7 Focus issues _ 7 Formal test requirements _8 Target microorganisms _9 Food Safety _ 9 Food spoilage

3、 _ 10 Pilot plant design _ 11 Design based on target organisms_ 11 Developing the test plant _ 11 Pilot testing _ 13 Test process _ 13 Test results _ 13 Costs and environmental benefits _ 14 Operational assumptions _ 14 Operating costs _ 15 Water consumption _ 16 Investment cost _ 17 Summary_ 18 Nex

4、t steps _ 19 Tetra Pak your beverage advisor _ 20 4 INTRODUCTION Who is this booklet for?This booklet is for anyone in the beverage processing industry who works with juices,nectars,still drinks,or teas,which we will abbreviate as JNSD.In general,we can also refer to these beverages as high-acid pro

5、ducts with a pH 4.2.The solutions outlined in this booklet will be of interest to plant managers,quality managers,technical managers and those working with JNSD in a research or development capacity.A future path for JNSD The JNSD portion of the beverage industry is stable and conservative in many w

6、ays,with industrial practices built up over decades to ensure product safety and efficient production processes.So it isnt often that something new comes along to shake things up.As so much of JNSD builds upon the quality of water blended in these beverages,we at Tetra Pak examined and explored how

7、we could reconfigure the processing of ingredients while maintaining product safety and shelf-life and achieve much lower processing costs as a result.We did this by combining existing technologies filtration and UV treatment which can be used to purify water before it is blended with the other beve

8、rage ingredients.Our experimentation and innovative equipment and processing parameters yielded extremely satisfying results.While maintaining product safety and quality,this new JNSD line solution can greatly cut down energy-consuming heat treatments reducing overall energy costs by about 67%.It al

9、so reduces water used in cleaning in place(CIP)and sterilization in place(SIP)by about 50%.The engineering concepts we pilot-tested and verified are relatively straight-forward,as we explain in the following pages.We are now actively seeking beverage producers who would like to test our JNSD line co

10、ncept in their plants.Please consider joining us on this journey.5 JNSD TODAY The scope of this booklet is JNSD beverages including teas that have a pH level 4.2 in other words,beverages tending to the acidic end of the scale.This is because the natural acidity of fruit counteracts some of the commo

11、n microorganisms that lead to food spoilage.In JNSD solutions commonly used today,all ingredients are blended with water to give the final beverage,before going to the pasteurizer for heat treatment,in order to deactivate harmful microorganisms.This can be done with either in-line blending or batch

12、blending.The figure below shows the basic steps in the process,which we can label the current JNSD process.The problem with this general approach is that the pasteurization requires a great deal of energy to treat the entire beverage volume.This is true even with modern pasteurizers,which are very e

13、fficient at heating and cooling,by using regenerative heat.Moreover,when the system volume is large 2,000 litres,for example it means each product change creates a large product loss.In addition,CIP and other cleaning steps may require several system volumes to fully execute,which by themselves requ

14、ire additional water,energy and other resources.Clearly,this is a process that could benefit from reanalysis.Concentrate In-line Blending Water Pasteurization(Heat treatment)+Optional homogenization Aseptic tank Filling Figure 1:Current JNSD process 6 RETHINKING THE JNSD LINE If we wanted to transfo

15、rm a JNSD line to make it more energy-efficient and save operating costs,what would it look like?One approach that has already been tried and commercialized is to add water in the form of steam to the concentrate,followed by dilution with cold water.Other innovative approaches in our industry have f

16、ocused on achieving required quality levels,but not necessarily saving energy costs.We decided to take a new approach.We re-imagined the JNSD line by splitting the process into two separate streams,concentrate and water,and treating these two streams differently before blending.Traditionally,we past

17、eurize the full volume(concentrate+water)and the most energy-intensive process step is heat treatment.In our new line concept we pasteurize the smallest possible volume of product,in this case the concentrate.The rest,which is water,is treated separately using more cost-effective aseptic technologie

18、s such as filtration,UV light,or a combination of both.Lets call this design proposal a low-energy JNSD line for the moment.Concentrate Pasteurization(Heat treatment)+Optional homogenization Aseptic in-line blending Filling UV+Filtration Water Figure 2:Low-energy JNSD line 7 INNOVATION IN PRACTICE T

19、o test our solution,we began by framing an overall question:Using a combination of UV and filtration,what would the optimal treatment of water be for producing commercially sterile JNSD and tea with pH 4.2 with minimal energy consumption,investment cost and water consumption?Our objective was to del

20、iver a production concept for JNSD based on existing or new technologies that would allow quick product changeovers with minimal product losses,reduced water consumption and low total cost of ownership,without jeopardizing food safety.Focus issues In order to build a functioning line for the product

21、ion of commercially sterile JNSD and tea with pH 1.5 m/s.The beverage water was inoculated with a mix of the spoilage organism and the surrogate organism for the pathogen.After adding each organism,a sample was taken to determine the starting value(cfu/cm2).The inoculated water was pumped through th

22、e filter and UV equipment at a predetermined flow and temperature.The flow of the water was 1100 l/h,at a temperature of 10C,and the UV dose was chosen based on the UV sensitivity profiles that were made to find the surrogate organism.The juice concentrate had to be diluted with water to 50Bx before

23、 it was pasteurized,and cooled to 30C.The recommended pasteurization temperature for commercial production is 80-95C,depending on the product.Since it was not possible to fill the aseptic tank with the apple juice concentrate and pasteurized water in parallel it was first filled with the treated wat

24、er and then with the heat-treated apple juice concentrate.This sequence was chosen to give potential process survivors in the water minimal access to the nutrients in the apple juice.Treated water and juice concentrate were then blended in the aseptic tank and filled into aseptic 250 ml Tetra Brik A

25、septic packages,which were then incubated at room temperature(20C)for 3 weeks.The incubated packages were analysed by checking the apple juice for cloudiness.Any cloudy content was streaked on malt extract agar and MRS (De Man,Rogosa and Sharpe)agar for identification of the organisms causing the cl

26、oudiness.Test results The concentration of Aspergillus brasiliensis spores were 97,000 cfu/ml and the concentration of surrogate organism was 23,000 cfu/ml.A total of 7,858 packages were incubated and checked for growth.Growth was found in only one package,due to Aspergillus brasiliensis.This gave a

27、 log reduction of 11.3 with 95%confidence.The reduction of the surrogate organism was 10.6 log.The required 5 log and 9 log reductions due to food safety and food spoilage,respectively,were thus achieved and surpassed using a combination of filter and UV treatments.14 COSTS AND ENVIRONMENTAL BENEFIT

28、S We calculated the operational cost for our UV and filter solution,focusing mainly on energy consumption,CIP costs and water consumption.We also evaluated the capital(investment)costs of buying and installing the new equipment needed.Operational assumptions The water consumption in the current solu

29、tion and the low-energy proposed solution using UV and filtration to treat the water was calculated based on the following scenario:Production efficiency is set to 80%in this calculation,which is a typical line efficiency figure.This gives a production volume of 2,560,000 litres(32,000 l/h*100 h*80%

30、).Scenario for calculations Production time 5 days/week,20 h/day CIP/week 3 SIP/week 3 Product changes/day 3 Capacity 32,000 l/h 15 Operating costs The energy parameters and values used for the cost calculations are the following:Table 1:Operating costs Scenario for calculations Steam 30/1,000 kg El

31、ectricity 0.15/kWhr Cooling factor 3 Production time 20 h/day,250 days/year Pump efficiency 50%dP product 8 bar dP hot water 3 bar dP filter+UV 2 bar Capacity 32,000 l/h Solution Pasteuri-zation Filter +UV Total (k/year)Savings due to low-energy line Current 138 NA 138 Low-energy 34 12 46 92 k/year/

32、67%The estimated operating cost for the current solution is 138 k/year.With the new low-energy solution the operating cost for treatment of the water with filtration and UV is estimated at 12 k/year and the heat treatment of the concentrate at 34 k/year,totalling an operating cost of 46 k/year.This

33、represents a saving of 92 k/year or 67%,compared to the current solution.(Target was 40%.)16 Water consumption The system volume in the current solution is 2,000 litres.In the new low-energy solution,the system volume for the concentrate portion is 700 litres and for the water portion 300 litres.The

34、 tables below show the resulting water consumption per week.Table 2:Water consumption in current solution:system volume 2,000 litres Table 3:Water consumption in low-energy solution:system volume concentrate 700 litres,water 300 litres Step Number of steps per week Number of system volumes per step

35、Water consumption(l/week)CIP 3 7 42,000 SIP 3 1,5 9,000 Product change 15 1,5 45,000 Total 96,000 Step Number of steps per week Number of system volumes per step Water consumption(l/week)CIP 3 7 21,000 SIP 3 1,5 4,500 Product change 15 1,5 22,500 Total 48,000 The water consumption is estimated to de

36、crease by 50%from 96,000 l/week to 48,000 l/week when implementing the low-energy solution,thus surpassing the target for decreased water consumption.(Target was 25%.)17 Investment cost The customer investment costs for the current and the low-energy solutions are based on a system capacity of 32 m3

37、/h.The choice of UV equipment and effective UV dose were arrived at by extensive experimentation,based on a UV transmission of 90%in the water.Given the final choice of UV equipment,the additional investment cost to the customer was only 5%more than the current solution.(Target was a maximum of 10%.

38、)Given the operational savings of 92k/year,and the cost of typical systems,the additional 5%investment cost is paid back well before the ROI target of a maximum of 6 months.(The exact costs are commercially sensitive.)The requirements on reduced water and operational cost,as well as payback time les

39、s than 6 months on the extra investment,were thus met.18 SUMMARY As Tetra Pak food scientists and processing engineers,we set ambitious goals for rethinking and redesigning the traditional JNSD line.This resulted in the design of a new low-energy JNSD line;it split the beverage volume into two separ

40、ate treatment lines for concentrate and water,which were later blended and packaged.Preliminary research identified target organisms and determined which levels of filtration and UV treatments would be required to render them harmless.Combining filters and UV treatment with the correct specification

41、s,we constructed a pilot line to validate this low-energy treatment concept,and ran operational tests involving nearly 8,000 juice packages.The findings were highly successful,as the following table demonstrates.The required log reductions due to food safety and food spoilage were achieved and surpa

42、ssed with a combination of filters and UV treatment.The requirements on reduced water and operational cost,as well as payback time on investment,were also met or surpassed.Table 5:Pilot results for quality,performance and cost-benefits Requirement Target Actual Log reduction for target pathogen micr

43、oorganism.5 log 10.6 log Log reduction for target spoilage microorganism.9 log 11.3 log Reduction in energy consumption costs of the equipment,compared to the current solution,in programme 15-95-25 C(regenerative 85%)for still drinks.40%67%Reduction in water consumption for CIP and SIP,compared to t

44、he current solution,in chosen production scenario.25%50%Investment cost compared to a similar conventional line.+10%5%Return on investment of the additional investment cost(compared to a similar conventional line).6 months 6 months 19 Next steps The engineering concepts we pilot-tested are relativel

45、y straightforward,and can easily be applied by upgrading existing JNSD lines,or building entirely new ones.We are now actively seeking beverage producers who would like to test our low-energy JNSD line concept in their plants,with their beverage formulations.If you share our thirst for excellence an

46、d innovation,as well as radical cost savings,please get in touch.For further advice or consultations on redesigning JNSD lines,or to propose joint research and development projects,please contact:Maria Norlin, 20 TETRA PAK YOUR BEVERAGE ADVISOR Tetra Pak offers complete line concepts and technology

47、support for producers of JNSD and tea products as well as many other beverages and food products thanks to our well established industrial and technology profile:Extensive knowledge of processing technologies,as well as how best to implement them Product Development Centres and dedicated technology

48、specialists Valuable knowledge and experience through partnerships with suppliers of technology,ingredients and supplies Processing modules and line concepts for all known technologies End-to-end offerings,handling everything from incoming raw ingredients to pallets of finished products on your load

49、ing dock As an innovator,Tetra Pak actively explores and develops the challenges of the beverage industry.We collaborate with customers,universities,and other business partners to develop new applications and find the best solutions for producing new products with flexibility.We develop customized s

50、olutions for your needs and maintain a leading position in developing new process line concepts.At our Product Development Centres,customers can carry out product trials together with Tetra Pak specialists with unique comprehensive expertise in food processing and packaging.The centres provide highl

51、y flexible pilot plant facilities for processing and packaging trials,which ensures fast and reliable industrial scale-up.Customers can experiment with recipes and use the latest processing equipment.We also have pilot plants for rental where trials are conducted for customers on-site with the support of our expertise.For further information,please contact:Maria Norlin, 21 Tetra Pak and Protects Whats Good are trademarks belonging to the Tetra Pak G Tetra Pak International S.A,Tetra Pak Processing system AB,2020-02