Aseptic solutions

Zentis Polska Sp. z o. o. develops complex systems for aseptic solutions.

Zentis was the first company to introduce onto the European market a unique bag-in-box packaging system incorporating a dual membrane closure which protects aseptic components and safeguards the high quality of dairy products. This closure ensures that fruit preparations remain entirely sterile, from production to blending with the dairy product.

The complete system enables bag-in-box packaging to be connected directly to steel containers without any outside influence. Its simple structure and user-friendliness allow the components that are being mixed to be used efficiently, while eliminating potential contamination sources. The conventional process cannot fulfil the conditions required for aseptic processing.

The system for connecting a 20 l bag-in-box consists of two containers as well as valve and steam barriers that are connected up using specially developed slot systems. Dual equipping and the way the system works (while one container is being emptied, the membrane on the second is being sterilised) ensure that the dosing station can continue its work without interruption.

A steam barrier which enables the connection of steel containers (200 l, 500 l and 1,000 l) and 220 l octabins is included for medium and large-scale buyers.

Characteristic features

  • Unique connection system for bag-in-box packaging, protected by international patent
  • Specially designed static agitator
  • Dosing ratio automatically regulated
  • The system can work simultaneously together with multiple packaging machines

Benefits

  • Eliminates secondary contamination
  • Standardised mixing parameters
  • Process shortened
  • Energy saved
  • Complies with EU regulation
  • CCP eliminated
  • Washing time reduced
  • Ingredients saved
  • Rheological properties improved
  • Small dimensions

Dosing-mixing stations for yoghurt/buttermilk/kefir with and without control valve

This system enables the mixing of fruit preparations containing yoghurt/buttermilk as they flow through, with a total throughput of 1,000 to 7,000 kg/h of finished product. The dosing station is a compact system mounted on a frame which requires only the dairy product and energy transition medium to be supplied.

Technical description

The two components are metered by measuring the throughput of the ingredients that are being mixed. The required dosage is achieved by automatically adjusting the relevant throughput ratio on the basis of direct measurement at the pumps. The system is fitted with sensors which provide a safety function in the event that one of the dosed streams diminishes during the process. Parameters are adjusted on the pump feed side in order to control this. The white mixture is constantly monitored by means of electromagnetic measurements.

A consistent flow of yoghurt is achieved by regulating the pressure in the aseptic yoghurt container and by automatically controlling the regulatory valve. A modern Siemens S7-300 unit is used for this purpose. This method guarantees that the recipe is consistently followed.

A static mixer is used to mix the incoming flows in the system. The entire dosing and mixing process is performed under aseptic conditions: all of the parts of the system that come into contact with food are made of AISI-316L steel. The system is regularly cleaned using a CIP system.

Main subassemblies

  • With or without automatic control valve
  • Fruit pump
  • Static agitator or blade
  • Connection system for aseptic 200 l, 500 l and 1,000 l steel containers
  • Aseptic connection system for 20 l bag-in-box packaging
  • Flow meter for white mixture
  • Flow meter for fruit
  • Pressure vessel for white mixture (analogue probes, air filter, safety valve, air treatment station, pressure transducer)
  • Control cabinet
  • Sensors for specific product properties
  • Communication modem
  • AISI-316L steel

Technical parameters

  • Purified steam: pressure 3 bar and 0.6 bar
  • Compressed air: 6 bar
  • Power consumption: 5 kW/380 V

Dosing and mixing stations for yoghurt/buttermilk/kefir based on flow principle

The system uses a white mixture to make two different recipes at the same time. Production output totals 500 to 5,000 kg/h of finished product. The dosing station is a compact system mounted on a frame and therefore requires only the white mixture and energy to be supplied.

How it works

This two-channel dosing station enables the simultaneous preparation of two different tasting recipes for yoghurt products. The system has two independent dosing, mixing and measuring systems to which containers can be connected to hold the different flavour types. The white mixture – for both flavour recipes – is fed in via a buffer container. The throughput of the white mixture is regulated by means of the pressure in the buffer container and using automatic valves.

Dosing and mixing happen under aseptic conditions: all of the parts that come into contact with food are made of AISI-316L stainless steel. The dosing station is cleaned using a CIP system, which involves the channel through which the white mixture is fed. The washing sequences are activated automatically for both products. 

Dosing-mixing stations for quark/cream

This system enables homogenised quark to be mixed with other components in a flow process, i.e. cream and fruit preparations, with a total throughput of 800 to 2,000 kg/h of finished product. This station enables yoghurt to be mixed with fruit ingredients with an output of up to 5,000 kg/h. The dosing station is a compact system mounted on a frame which requires only the quark and cream and energy transition medium to be supplied.

Technical description

The three components are metered by measuring the throughput of the ingredients that are being mixed. The required dosage is achieved by automatically adjusting the relevant throughput ratio on the basis of direct measurement at the pumps. The system is fitted with sensors which provide a safety function in the event that one of the dosed streams diminishes during the process. Parameters are adjusted on the pump feed side in order to control this.

Dosing and mixing of the fruit preparation happen under aseptic conditions. The dosing station is cleaned by a CIP system. 

Main subassemblies

  • Quark pump
  • Fruit pump
  • Cream pump
  • Static agitator
  • Wash and return pump
  • Connection system for aseptic steel containers
  • Connection system for 20 l bag-in-box packaging
  • Flow meter for white mixture
  • Flow meter for fruit
  • Flow meter for cream
  • Buffer container for quark
  • Buffer container for cream
  • Switchgear cabinet
  • Product sensor

Technical parameters

  • Purified steam: pressure 3 bar and 0.6 bar
  • Compressed air: 6 bar
  • Power consumption: 5 kW/380 V

Pressure vessel

A single-layer pressure vessel made of stainless steel contains the buffer of product needed for continuous product processes. It is designed as a vertical cylinder with an interior diameter of 500 mm, closed off at the top and bottom by steel caps. The pressure vessel has a free-standing structure and is embedded in a base-plate.

How it works

An orderly supply of dairy product into the production system is regulated by means of the pressure vessel. The product flows into the pressure vessel through a nozzle at the bottom edge. A level sensor monitors the product level, and a fill level sensor is also used. A connector at the bottom end allows the product to come out of the container, and an air cushion pushes the dairy product out. The maximum permissible pressure in the container is 3 bar, and an inverse pressure of up to -1 bar is permitted for washing and evaporating. A safety valve protects the container against excess pressure.

Main components

  • Fill level sensors
  • Safety valve
  • Sterile air filters
  • Air treatment station
  • Pressure transducer
  • Washing head
  • Valves

Technical parameters

  • Maximum internal pressure: 3 bar.
  • Minimum / maximum permissible temperature - 1000 / 200 C.
  • Test pressure: 4.9 bar
  • Design pressure: 3 bar
  • Total capacity: 190 l
  • Maximum permissible outside pressure: 1 bar
  • Working media: dairy product + compressed air