new particulate filling - tetra pak · 2020. 8. 14. · tetra brik ® aseptic 80 slim, tetra brik...
TRANSCRIPT
Particulate Filling
December 2017
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Key elements for particulates filling
What impacts particulates filling capability
Quality Control
Product characteristics
Processing Filling machine& settings
Package
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Product characteristics
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Hardness and dimension are crucial for the characterization
Wide varieties of particulates in the market
CITRUS VESICLES / SACSCollapsed / whole vesicles
SOFT / GELATINOUS PARTICLESNata de Coco
Aloe
SOFT / HARD FRUIT PIECES Peach cubes
Pineapple pieces
FIBERSTomato peels
fruit wires
HARD PARTICLESSeeds
cereal / nuts / grains
stone cells
Note: Definition may differ from country to country or from customer to customer / 4
How do particulates impact filling capability?
► It is critical to understand the following:
− Size, content and physical properties of particulates
− Property of carrier
► Before performing filling trials it is very important
to characterize products to be able to execute
filling process in the best possible way.
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Processing for Particulates Filling
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Processing line critical process parameters
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HEAT / HOLD TIME PARTICULATES
DISTRIBUTION
PARTICULATES
INTEGRITY
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…particulates might need different heat/hold profile
Heat/Hold time depends on particulate types…
6.000 lph, 95C / 15s, 15% particulates 6x6x6 mm
120º C
100º C
80º C
60º C
40º C
20º C
0º C
400 SEC350 SEC300 SEC250 SEC200 SEC150 SEC100 SEC50 SEC0 SEC
Liquid
Particulates
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Particulates distribution
Aseptic tank and agitator design are crucial to control particulates
distribution and ensure particulates integrity
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Particulates integrity
► Pumps need to be designed for gentle
handling of sensitive products
► Heat exchanger to be selected according
to the product type
► Pipe diameter in the heat exchanger needs
to be matched to the size of particulates
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3 typical particulates processing layout design
► Aseptic single line – single stream
► Aseptic single line with in-line dosing of particulates
► Aseptic dual line – double stream
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Aseptic single line – single stream
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Pulp
particulates
Carrier
Mixing
tanks
Aseptic
storageFillingSterilizer
ADVANTAGES
• Traditional design
• Simple operation
• Lower investment level
LIMITATIONS
• Particulate size
• Long holding time for juice
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Aseptic single line with in-line dosing of particulates
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Pulp
particulates
Juice
Mixing
tanks
Aseptic
storageFillingSteriliser
Mixing
tanks
ADVANTAGES
• Effective deaeration of juice
• Improved particulate integrity
• Cost efficient line
LIMITATIONS
• Extended holding time
for juice
• Medium investment level
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For superior product quality
Aseptic dual line – dual stream line
Aseptic
storage
Aseptic
mix/storageFilling
SteriliserMixing
tanks
Pulp
particulates
Aseptic
storageSteriliser
Mixing
tanksJuice
ADVANTAGES
• Good particulate integrity
• Effect deaeration of juice
• Optimal holding time for juice
LIMITATIONS
• Higher investment level
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Processing investment level
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ASEPTIC SINGLE LINE FOR HOMOGENEOUS
NON PARTICULATES PRODUCT: 100%
ASEPTIC SINGLE LINE – SINGLE
STREAM FOR PARTICULATES: 150%
ASEPTIC SINGLE LINE WITH IN-LINE
DOSING FOR PARTICULATES: 175%
ASEPTIC DUAL LINE – DUAL STREAM
FOR PARTICULATES: 300%
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Tetra VertensoTM
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Tetra Pak design for optimal processing solution
Tetra Vertenso™ is the integrated solution for particulates
Tetra Therm® Aseptic DrinkPre mix tanks Tetra Alsafe®
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Roll fed filling equipment for particulates filling
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Two elements are crucial for particulates filling
What enables particulates filling on roll fed machines?
PARTICULATES SEALING KITTransversal sealing
PARTICULATES FILLING KITRegulating valve
Counter pressure flange in the filling pipe
assembly
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2
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* Please note that once the kit is installed, the equipment can work with homogenous product. / 18
PAPER TUBE WITH PRODUCTα
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Mandatory for all particulates products
Particulates sealing kit
β TRANSVERSAL SEALING PARTα
β
β
Dollies Radius 15 “Mushroom”
Installation of Radius 15 dolly to apply effective pressure and push the product out from the sealing area
*Not needed for homogeneous products
Flat Dolly Mushroom dollies*
J CUTTING RAIL
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Required for specific particulate dimensions
Particulates filling kit
PRODUCT REGULATING VALVE
Servo valve
Shuttera
b
a
COUNTER PRESSURE FLANGE c
c
New shutter
wider opening section
wider longitudinal section
b
Standard shutter
Standard flange
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Tetra Pak Particulates packing capability
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Wide range of packages
► Particulates sealing Kits are available for all packages except:
Tetra Brik® Aseptic 80 Slim, Tetra Brik® Aseptic 100 Base and Tetra Brik® Aseptic
125 Slim (due to Transversal Sealing – 6mm fin height too narrow – geometrical
design constrain)
► Particulates filling kits are available for all packages except:
Tetra Brik® Aseptic 80 Slim, Tetra Brik® Aseptic 100 Base and Tetra Brik® Aseptic
125 Slim (due to Transversal Sealing – 6mm fin height too narrow – geometrical
design constrain) + Tetra Brik® Aseptic 500Base, 500Edge, 500 Slim,1000
Base,1000 Mid,1500 Slim, 2000 Slim, Tetra Gemina® Aseptic 1500 Square.
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Package portfolio with particulates
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Filling and sealing kits can be installed on:
Tetra Pak® TBA/19
0100, 0200, 0300, 0400, 0500
Tetra Pak® A3/CompactFlex
0100, 0200, 0300, 0400
Tetra Pak® A3/Flex
0200, 0300, 0400
Equipment portfolio for particulates
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Sealing kits (only for citrus sacs up to 3%) can be installed on:
Equipment portfolio for particulates
Tetra Pak® A3/Speed
0200, 0300, 0400
Tetra Pak® TBA/22
0500
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Selection of the right material and opening for each product
► The package material should be selected according
to the product content
► Straws, caps should be selected according
to the particulate dimensions
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Importance of package functionality
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For aseptic roll fed systems
Tetra Pak particulates capability
Light Green / Green
Feasible
Orange
To be assessed
Hard particles
< 0.2 mm
up to 3% ww
Nata de Coco
& Grass jelly
7 mm
up to 8% ww
Orange
vesicles
up to 20 mm
up to 8% ww
Passata / Tomato Frito
(no or small particles, no seeds)
Peach 6 mm
up to 5% ww
Orange vesicles
>8% Soft cereals
2x2x2 mm
Tomato Sauce
with garlic/basil
(small particles)
Apple 4 mm
up to 5% ww
Carrot smoothies
3 mm
up to 5% ww
Aloe vera
4 mm
up to 2% ww
Grass jelly
4 mm
up to 5% ww
Peanuts
4 mm
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With particulates sealing kit
Light green zone
ElementMaximum
Dimension
Particulate
HardnessWet weight
Nata de coco &
Grass Jelly*7 mm Gummy and slippery Up to 8%
Grass Jelly* 4 mm Gummy and slippery Up to 5%
Tomato Passata / Tomato
Frito (no or small
particles, no seeds)
Seeds: 0.2mm
Skins: 3x3mmMedium Up to 3%
Orange Vesicles
(collapsed)
20 mm (length)
randomly distributedSoft Up to 8%
Aloe vera 4 mm Soft Up to 2%
Please note: this product is borderline between light green and green zone. Product characteristics have to be evaluated on a case by case basis. / 27
Light green zone applications
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Filling Machine availability:• Tetra Pak TBA/19 all dev steps
• Tetra Pak A3/Flex 0200, 0300, 0400
• Tetra Pak A3/CompactFlex 0100, 0200, 0300, 0400
Assumptions in order to successfully pack particulates: • Homogeneous distribution inside the product
• Installation of sealing kit
Packages:Almost all packages can be fulfilled with particulates except for:
• TBA 80 Slim/ TBA 100 Base/TBA 125 Slim (due to TS – 6mm fin
height too narrow – geometrical design constrain)
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With particulates sealing & filling kits
Green zone
ElementMaximum
Dimension
Particulate
HardnessWet weight
Peach 4x4x4 mm Gummy and slippery Up to 5 %
Apple 4x4x4 mm Slippery Up to 5 %
Carrot Smoothies 3 mm Soft Up to 5 %
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Green zone applications
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Filling Machine availability:• Tetra Pak TBA/19 all dev steps
• Tetra Pak A3/Flex 0200, 0300, 0400
• Tetra Pak A3/CompactFlex 0100, 0200, 0300, 0400
Assumptions in order to successfully pack particulates: • Homogeneous distribution inside the product
• Installation of sealing kit & particulates kit
Packages:Almost all packages can be fulfilled with particulates except for:
• Tetra Brik® Aseptic 80 Slim, 100 Base and 125 Slim (due to TS –
6mm fin height too narrow – geometrical design constrain) + Tetra
Brik® Aseptic 500 Base , 500 Edge, 500 Slim,1000 Base,1000
Mid,1500 Slim, 2000 Slim, Tetra Gemina® Aseptic 1500 Square.
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Installation time required - Carton Value - Continuous filling
Example of particulates kit capability
Machine
Down time
Filling kit Sealing kit Total
Lig
ht
Gre
en Tetra Pak TBA/19
Tetra Pak A3/CompactFlex
Tetra Pak A3/Flex
Not required
30 mins
10 mins
10 mins
30 mins
10 mins
10 mins
Gre
en
Tetra Pak TBA/19
Tetra Pak A3/CompactFlex*
Tetra Pak A3/Flex 0200 and above
20 hours
16 hours
1 hour
30 mins
10 mins
10 mins
20h 30 mins
16h 10 mins
01h 10 mins
Please Note: exception for the Tetra Pak A3/CompactFlex 0400, which requires less than 30 minutes installation time. / 31
How can we support you in developing new product recipes
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The concept and new
product formulation is
taken to the customer to
trial in real commercial
production
Understanding
customer need and
product characteristics
A particle size analysis
(PSA) performed by
aseptic performance
specialists to define
product characterisation
and feasibility
A Tetra Pak expert
would visit customer
site to verify current
installation based of
both processing and
packaging equipment
This step consists of a
package performance
data analysis to
understand production
and package
performance
Commercial production
is continued monitored
to assure the
performance of the line
From customer need to commercial production
Initial
question
Product
Charaterization
Processing,
Packaging,
Assessment
Feasibility
evaluation
Industrial
Qualification
Production
Scale up
PD
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Initial
question
Product
Charaterization
Processing,
Packaging,
Assessment
Feasibility
evaluation
Industrial
Qualification
Production
Scale up
PD
C
Light green and green zone product development process
From customer need to commercial production
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Initial
question
Product
Charaterization
Processing,
Packaging,
Assessment
Feasibility
evaluation
Industrial
Qualification
Production
Scale up
PD
C
Orange zone product development process
From customer need to commercial production
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Customer interaction and PDC key competencies
Product Development Centre
Validation
Production
set-up & criteria
Formulation
and production
Analysis
Food
technologists
Laboratory Production
facility
Production
operators
Customer
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Customer Innovation Centers (CIC): global support in processing and packaging of particulate products
DENTONCapability: particulate up to10mm.
Particulate filling / sealing kit for:
Tetra Pak A3/CompactFlex 330ml
DreamCap
LUNDCapability: products up to 20mm.
Particulate filling / sealing kit
TBA/19 (TBA250B)
PUDONGCapability particulate up to 3mm.
Particulate filling / sealing kit
Tetra Pak A3/CompactFlex
(TBA 200E Sq)
GOTEMBACapability: particulate up to
4mm.
Particulate filling / sealing kit
TBA/19 (TBA200S)
SINGAPORECapability:particulate products up
to 3mm.
Particulate filling / sealing kit
TBA/19 (TBA250E)
PUNECapability:
particulate up to
3mm.
Particulate sealing
kit TBA/19
(TBA250E)
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Tetra Pak® particulatesCapabilities evolution
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