Aseptic Pulp Production Technology
International Citrus and Beverage Conference
September 2012
Gianluca Parisini
John Bean Technologies
Parma, Italy
Outline
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Citrus Pulp Production
Pulp Recovery System Comparison (Frozen, Aseptic)
Energy Comparison
Sterilizer Critical Design Factors
Aseptic Filler
Shelf Life Study of Aseptic Pulp
Future R&D
Citrus fruit section
Seed
Segment
wall
Juice sacs
(Pulp)
Albedo
Oil sacs
Segment
Flavedo
(Peel)
Citrus Pulp
• Market Applications
- Concentrate and single strength juices
- Blended beverages
- Flavored carbonated beverages
- Juice cocktails for alcoholic beverages
• Production Incentives
- Product line extension
- Utilization of discarded material (pulp
cells)
- Outside sales, Internal consumption
- Increase overall plant yield
- Pulp is higher in value than secondary
solids
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Pulp Production
• Production of high quality pulp
- A good mixture of different size
pulp
- Excellent floating characteristics
- Virtually free of defects
• Variables to consider
- Fruit variety and condition
- Extraction parameters
- Defect removal system
- Pulp recovery system
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Pulp Production
Pulp quality in influenced: pre-process
Raw material quality
Proper washing system
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Single fruit layer
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Appropriate detergent
Efficient fruit grading
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Pulp Production
• Work with your extraction supplier to discuss the impact of extractor
components and settings on pulp size and quality.
• Size distribution is influenced by extractor and finisher settings.
• Defects can be minimized by proper cyclone design, installation and
operation.
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Pulp Recovery System
There are three major categories of pulp recovery systems
in the market
• Frozen pulp system
• Low Density Aseptic Pulp System (LDAP)
• High Density Aseptic Pulp System (HDAP)
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Pulp Recovery System
Frozen pulp system:
• Pulpy juice is pasteurized
• The pulp is then concentrated in a finisher (180 – 220 quick
fiber) and filled under non-aseptic conditions
• The pulp must be stored and transported in a frozen state to
prevent growth of microorganisms
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Pulp Recovery System
Low Density Aseptic Pulp System (LDAP)
• The pulp is concentrated in a concentrating finisher to a low or
medium density (typically 30-50% pulp)
• Pulp is then sterilized and filled aseptically into a container
• Aseptic pulp does not need to be frozen
• Can be stored and transported with or without refrigeration
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Pulp Recovery System
High Density Aseptic Pulp System (HDAP)
• The pulp is concentrated in a concentrating finisher to a high
density (typically over 90% pulp or 900 g/L)
• Pulp is then sterilized and filled aseptically into a container
• Aseptic pulp does not need to be frozen
• Can be stored and transported with or without refrigeration
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System Comparison
System
Advantages
Disadvantages
Frozen Pulp System
• Lower Capital Cost
Solution (no aseptic
filler required)
• Pulp can be damaged
by freezing and
thawing.
• Pulp must be frozen
during storage and
transportation.
• More negative impact
on juice quality due to
“return juice” that is
pasteurized along with
the pulp and returned
to the juice stream.
System Comparison
System
Advantages
Disadvantages
Low Density Aseptic Pulp
• Does not need to be
frozen during storage
or transportation.
• No return juice results
in higher juice quality
• A larger sterilizer is
required to achieve
same amount of pulp
as a high density
system.
• More shipping of juice
(water) than high
density.
• Higher capital cost than
frozen system.
High Density Aseptic Pulp
• Does not need to be
frozen during storage
or transportation.
• No return juice results
in higher juice quality
• Smaller sterilizer
• Less shipping of water
• Higher capital cost than
frozen system.
Pulp recovery process (Frozen)
Preprocessing
Extraction
Defect removal
Concentrating
Pasteurization
No-Aseptic
Pulp
Finished
Juice
Primary
Finisher
Drying
“Return”
Juice
Finished
Juice
Filling
Pulp recovery process (Frozen)
Preprocessing
Extraction
Defect removal
Concentrating
Pasteurization
No-Aseptic
Pulp
Finished
Juice
Primary
Finisher
Drying
“Return”
Juice
Finished
Juice
“Return” Juice higher in bottom pulp, viscosity and
limonin.
Filling
Pulp recovery process (HDAP)
Preprocessing
Extraction
Defect removal
Concentrating
Finished
Juice
Primary
Finisher
Finished
Juice
Filling
Pasteurization
Processing cost of frozen vs. aseptic
Energy source
Frozen HD pulp
Aseptic HD pulp
Aseptic LD pulp
Heating
136,000 Kcal/h
85,000 Kcal/h
152,000 Kcal/h
Cooling tower
86,000 Kcal/h
60,000 Kcal/h
102,000 Kcal/h
Chilling energy
(up to 2 °C)
86,000 Kcal/h
48,000 Kcal/h
86,000 Kcal/h
Freezing
energy
(up to -15 °C)
80,000 Kcal/h
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Costs refer to 1,000 l/h of processed pulp (2,000 l/h of pulp at 50%)
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High Density Pulp Sterilizer
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High Density Sterilizer - Features
• Target is commercial sterility: no microorganisms (pathogens
included) are able to spoil the product in the normal ambient storage
and distribution conditions.
RECIRCULATION
COOLER
FEED TANK
COOLING
FILLER
CRITICAL
CONTROL POINT IT
PRODUCT IN PRESSURE
HEATING
ASEPTIC AREA
NORMAL WORKING MODE
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High Density Sterilizer - Features
• Product is gently mixed by flow promoters
- Consistent and uniform product heat treatment
• Small product to heating medium temperature differential
- Eliminates product degradation
• Large annular spacing
- Lower pressure drop compared to competitive systems - reduces
product degradation
• Designed for aseptic application
- Aseptic seals and valves
- Steam barriers for all joint
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High Density Sterilizer - Features
• Pump selection and design is important for pulp integrity
• Low shear piston pump is able to operate with high viscosity
products up to 150 bar
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Regeneration
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Optional indirect regeneration section
provides energy savings
Regeneration requires initial higher
investment and more equipment space
68°F
REGEN
PRE-HEATER
125°F
FINAL
HEATER
210°F
HOLDING
REGEN
PRE-COOLING
194°F
86°F
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153°F
TO FINAL
COOLER
PulpCON™ Density Control For
Pasteurizer
Concentration
controlled 850 g/l
+/- 50 g/l
Concentrating
Finisher
Control
pressure or
paddle velocity
Patent pending
Feed Tank
4 GPM
PulpCON™
HD
Sterilizer
High Density Aseptic Filler
• 4 drums on pallet / bin
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55 – 300 gallon bags
1” or 2” cap
Single / Twin / Triple head
30 bags/h per head (drums)
12 bins/h (dual head)
pH < 4,5
Wide range of spouts can be used
1 inch Short 'A' Cap
1 inch Tall 'A' Cap
1 inch Cap
2 inch "A" Cap
Aseptic packaging system
55 GALLONS BAGS
Available in metallized structure (silver standard
or golden high barrier) or clear structure, a
range of bags with aluminum foil, assuring the
maximum oxygen barrier, is also available for
very delicate products. Also available in 20 kg25 kg format.
300 GALLONS BAGS
For bin containers, developed with particular
care for practical handling, transport and
storage. Available in metallized and transparent
material in standard or high barrier structure.
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Orange pulp quality: shelf life study
Started in JBT Parma pilot plant 6 month ago
I.
HDAP orange pulp sterilized at 96.5˚C for 200 seconds
II. 3 different packaging material: plastics materials and aluminum
III. 5 different storage temperatures: -20, 4, 20 , 30 , 37˚C
IV. Analysis done: Minolta color , Ascorbic acid, Hydrosoluble color at 420 nm,
Hydroxymetilfurfurale
RESULTS
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No significant variation between sample stored at -20˚C and 4˚C.
Significant variation at higher storing temperature. Less evident is the
effect of the packaging material.
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R&D - Radiofrequency
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Radiofrequency trials were conducted to sterilize high density orange pulp
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RF wave frequency is 28 MHz and it excites the rotation movements of the
water molecules
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R&D - Radiofrequency
• RF technology reduces the heating time from 300 seconds for
standard machine with heat recovery, to 80 seconds
• Potential improvement in pulp quality due to reduced heating time
and simple pipe design
• Large pipe, no mixing device (in the heating zone) resulted in less
back-pressure due to bigger and simpler piping
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R&D - Radiofrequency
Mixing tank
Piston
pump
Preheater with 4tubes (50°C-60°C)
RF heater
Annular
cooler
Aseptic
Filler
• Results expected by Q1 2013
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www.jbtfoodtech.com