Project: Bits & Pieces

Project No.: NO-0404003-16

Customer: Arla Foods Esbjerg Mejeri

Process description

1. Introduction

This description concerns plants for aseptic treatment of sauces with particles. The following functions
are described:

A Mixing of particles and basis sauce (horisontal mixing tanks)

B UHT sterilisation (SSHE – cylinders)
C Aseptic storage of sauces (horisontal buffer tanks)
D Filling line (Combibloc)
E CIP (routes and distribution)

2. Process description

Unit based plant for aseptic treatment of sauces with particles. The plant is as minimum designed for
treatment of products in accordance with the description regarding performance.

The capacity is 2000 kg/hour.

It is a known fact that the basic sauce is prepared in the existing mix plant and that the products are
filled on Combibloc aseptic filling lines. The design of the plant makes it possible to obtain commercial
sterility at any time, cf. the performance criteria.

A. Mixing of particles and basic sauces (horisontal mixing tanks)

(Flow diagram NO 0404003-F4, rev. A)

Two horisontal mixing tanks, type Flex-Mix Processor (4000 litres) equipped with the following:
- Frame type agitator for a gentle but efficient mixing and treatment of particles
- High shear mixer designed for an efficient dispersing/homogenising of hydro colloids, etc.
- Water circuit for heating/cooling and temperature control
- Vacuum system for venting and transport of powder/solid matters
- Powder funnel for a dustless filling into bags of powder, solid matters and compounds
- Lifting equipment for product trolleys
- Discharge pump designed for particles

Basic sauce according to recipe is filled into the two horisontal mixing tanks. Various raw materials
such as powder can here be added manually via vacuum injection and direct disperging without
external product loop, particles by means of product trolleys, or fluid ingredients via mobile tanks.

Heating, cooling and adjustment of temperature can be carried out during the mixing process by
means of the water circulation loop on the jacket.

A gentle and efficient stirring during rest or during the mixing process ensures homogeneity of the
product.

The mixing of particles and basic sauce takes place as a “flip/flop” process, i.e. mixing in tank 1 while
tank 2 is feeding the balance tank of the UHT plant and vice versa in order to ensure a continuous feed
of product to the UHT plant. Transfer of product from the mixing tanks is done by means of positive
rotary pumps, one for each mixing tank, thus the pump is close to the tank outlet.

B UHT Sterilisation (SSHE – cylinders)

(Flow diagram NO 0404003-F5 rev. A)

Process description Page 1 of 3

Project: Bits & Pieces
Project No.: NO-0404003-16
Customer: Arla Foods Esbjerg Mejeri

The UHT plant is equipped with a horisontal balance tank (250 litres) incl. of frame type agitator, which
ensures a homogeneous mixing of particles and liquid.

Five sections of scraped surface heat exchangers (SSHE), type VT+680, equipped with the following:
- Dashers for a gentle but efficient treatment of particles
- P1 heating via the hot water circuit
- Stabilising holding cell at 90-95°C (Option)
- P2 and P3 heating by means of steam
- Holding cell, 5 combinations, manual coupling before start of plant
- K1 cooling by means of tower water
- K2 cooling by means of chilled water loop
- Hot water sterilising loop
- Aseptic back-pressure pump
- Dosing station for acid and lye

The UHT plant to be sanitised and sterilised by means of hot water.

The process sequences in the scraped surface heat exchangers take place af follows:

P2/- and P3/ - the product is hereafter heated to a nominal temperature of 130°C by means of indirect
steam (the plant is however capable of handling temperatures between 121 and 140°C). The product is
subsequently sterilised in the holding cell.
K1/- after the sterilisation the product is cooled by means of tower water (25°C) to approx. 40°C
K2/- final cooling of product to 20°C by means of chilled water (1°C) cooling loop.

The UHT plant is provided with an aseptic back-pressure pump and a plant for production of sterile
water for flushing of shaft seals. Furthermore the plant is provided with batch CIP, dosing station for
acid and lye, Cl booster pump, sterilising cooler and balance tank for CIP, SIP and start-up.

C Aseptic storage of sauces (horisontal buffer tanks)

(Flow diagram NO 0404003-F6/F7 rev. A)

Two horisontal aseptic tanks (20,000 litres) equipped with the following:
- Frame type agitator for gentle but efficient treatment of particles
- Separate product inlet and product outlet
- Jacket for cooling of the tank after the sterilisation
- Air regulation and sterile air filtration equipment
- Valve matrice between UHT ring line and sterile tank
- Tank for product collection from product/water mixing phases from the UHT ring line.

The valve matrice between the UHT ring line and the sterile tank is built up around 2 aseptic valves
with a piston closing device to ensure an efficient valve closing in case of products containing particles.
The valves have a long spindle travel, and steam/condensate flushed spindle barrier. A leakage space
is built in between the 2 aseptic valves in the valve matrice, which is sterilised by means of steam
together with the UHT ring line or the sterile tank, depending on which system is sterilised first. The
leakage space is CIP cleaned via valve lift, either from the UHT ring line or the sterile tank, however,
only if both systems are not under sterilisation or not sterile.

The finished and sterile product is led to a preselected horisontal tank. Each tank is dedicated to one of
the two filling machines.
Product cannot be led to tank simultaneously with filling to the filling machines.
Storage time for product in the aseptic tanks is max. 24 hours according to the performance criteria
(however commercial sterility can be guaranteed up to 48 hours).During storage the product is stirred
constantly but gently until the filling is finished.

The product is transferred from the horisontal tank to the filling machine by means of sterile air
overpressure.

Process description Page 2 of 3

Project: Bits & Pieces
Project No.: NO-0404003-16
Customer: Arla Foods Esbjerg Mejeri

CIP and sterilisation to be carried out before start of next production cycle.

D Filling line (Combibloc)

(Flow diagram NO 0404003-F8/F9 rev. A)

Two filling machines, type CB6 / CB5 (Arla delivery):

The filling machines are designed for two-stage filling and are equipped with two balance tanks on
each machine.
1. for product from SSHE UHT plant
2. for product from existing VTIS

The products from the two UHT plant are thus mixed to the desired product.

The valve matrice between the sterile tank (particle products) is built according to the same principle as
the valve matrice between the SSHE UHT ring line and the sterile tank.

E CIP (routes and distribution)

Routes:
Each main unit to be cleaned separately, i.e. the following units relate to each other:
A Mixing of particles and basic sauce (Flow diagram NO 0404003-F4 rev A)
Powder hopper and mixing tanks to be cleaned from a central CIP system. There are 2
CIP objects (mixing tanks) which are cleaned together with the joint powder hopper.

B UHT sterililsation (Flow diagram NO 0404003-F5 rev A)

The UHT plant has a separate CIP system, and besides the scraped surface heat
exchangers also cleaning and sterilisation of ring line and valves at the sterile tanks
are included.

C Aseptic storage of sauces (Flow diagram NO 0404003-F6/F7 rev A)

To be cleaned from a central CIP system. Inclusive of cleaning and sterilisation of pipe
line past the filling machines.

D Filling machines (Flow diagram NO 0404003-F8/F9 rev A)

Separate cleaning - not included in the quotation.

Distribution:
CIP liquids to section A, C, D to be distributed from existing CIP plant via the ring line.
Chemicals to be supplied to section B via the existing lye and acid ring line.

A vibration screen is inserted in the joint CIP return line from the Bits & Pieces plant for separation of
product particles from the CIP liquid before this is pumped back to the existing CIP plant.

Process description Page 3 of 3