Super Pro

Pasteurization Page 1 of 1
Pasteurization
OVERVIEW
A Pasteurization Procedure can be created by selecting the following menu option:
Unit Procedures } Heat Exchange } Pasteurization
Operating Mode Continuous or Semi-Continuous
Host Equipment Pasteurizer
Emissions Port No
(Vent)
Special No
Input/Output
Ports
This unit procedure simulates a pasteurizer and calculates microorganism inactivation and food
component degradation kinetics. The equipment is assumed to comprise three different heat
exchangers, namely, a heater, a cooler and a regenerator - all operating in a countercurrent flow
manner. The user has the option to include or exclude the regenerator from the setup.
SPECIAL INPUTS / OUTPUTS

None.
OPERATIONS
The following operation types are currently supported in the context of this unit procedure:
● Pasteurize, see Pasteurization
● CIP, see In-Place-Cleaning (CIP)
● Hold, see Holding
● SIP, see In-Place-Steaming (SIP)
Note that operations CIP, Hold, and SIP are only available in semi-continuous operating mode.
SEE ALSO
The following procedures offer a similar functionality:
● Heat Sterilization
● Heating
● Electric Heating
● Heat Exchanging
mk:@MSITStore:C:\Program%20Files%20(x86)\Intelligen\SuperPro%20Designer\v8.5\D... 10/2/2024
Pasteurizer Page 1 of 1
Pasteurizer
OVERVIEW
Size / Design Volumetric Throughput
Variable
Costing Variable Overall Heat Exchanger Area, Holding

(Built-in Model) Tube Volume
Costing Variable Overall Heat Exchanger Area in m2

(User-Defined
Model)
Emissions Port No
Hosts Pasteurization
A Pasteurizer is used to represent an equipment resource typically used to host a Pasteurization

procedure. Pasteurization is the process of heating to a specific temperature for a specific period of
time in order to reduce the population of microorganisms that are responsible for the spoilage of
liquid foods while at the same time maintaning their qualitative characteristics and nutrtional value
at high standards. The procedure can be executed in a continuous or semi-continuous mode.
For information on the equipment data interface, see Pasteurizer: Equipment Tab.
Pasteurizer_ Equipment Tab Page 1 of 2
Pasteurizer: Equipment Tab
Variable Definitions, Ranges and Default Values

The following table illustrates the meaning of the variables appearing in this tab, as well as their
default values and their generally acceptable range.
Variable Default Value Range
◙ Max Throughput 100,000.0 L/h Positive

The maximum volumetric throughput that a
unit of this type is available for purchase in
the market.
◙ Rated Throughput 3600.0 L/h Positive
The rated volumetric throughput.
◙ Holding Tube Diameter 10.0 cm Positive

The pasteurizer’s holding tube diameter.
◙ Holding Tube Length 1.0 m Positive

The pasteurizer’s holding tube length .
● Holding Tube Volume 7.85 m

3 Positive
The pasteurizer’s holding tube volume.
○ Is Regenerator Available? Yes Yes/No

Regenerator availability option of the
Pasteurizer_ Equipment Tab Page 2 of 2
pasteurizer unit.
2 Positive
◙ Heater Heat Transfer Area 1.0 m
The heat transfer area of the pasteurizer’s
heater.
2 Positive
◙ Cooler Heat Transfer Area 1.0 m
cooler.
2 Positive
◙ Regenerator Heat Transfer Area 1.0 m
regenerator (if available).
Symbol Key: ○ User-specified value (always input); ● Calculated value (always output); ◙ Sometimes input, sometimes output
SIZING: DESIGN MODE

In Design Mode, the user specifies the Maximum Throughput and the model calculates the Number
of Units, the Diameter, Length and Volume of the Holding Tube as well as the Heat Transfer Areas
of the heat exchnagers of the pasteurizer (i.e., the heater, cooler and regenerator, if available).
See also Pasteurization: Modeling Calculations.
SIZING: RATING MODE

In Rating Mode, the user specifies the Number of Units, the Holding Tube Length and Diameter as
well as the Heat Exchange Areas of the heater, cooler and regenerator (if available).
COSTING
Equipment purchase cost is calculated as a combination of the Holding Tube’s volume and the total
heat exchange area of the heat exchangers. It is supplied by the built-in model assuming as
material of construction SS316.
For more information on this equipment, see Pasteurizer.
For information on the functionality of the options at the left side of the dialog, see Equipment Data
Dialog: Equipment tab.
Equipment Data Dialog: Equipment tab Page 1 of 2
Equipment Data Dialog: Equipment tab
This tab is part of the Equipment Data dialog (common to all equipment types). The dialog can be
viewed when selecting the Equipment Data menu option from a unit procedure’s command menu.
From this interface (common to all Equipment tabs of all Equipment Data dialogs) you can:
1. Choose a common (shared) equipment resource or if already sharing equipment, request a
dedicated equipment resource for this procedure.
2. Choose between Design vs Rating sizing mode, and
3. Request multiple sets of equipment units operating in staggered mode.
EQUIPMENT SHARING
By default the application assumes that each newly created procedure is assigned a new equipment
resource of the appropriate type matching the procedure type. If you later decide to force two
procedure (of similar type) to share the same equipment resource, you must visit this dialog and
from the upper left drop-down select (amongst all equipment of similar type currently existing in
your process) the name of the equipment that you want to assign to the procedure. Notice that as
soon as you choose a new name, the size variables (shown on the right-hand side) display the
values of the selected resource.
You may also want to visit this dialog when you want to reverse your decision later if need be. In
other words, if you have two procedures sharing the same equipment resource and later you want
to have each one have their own, you need to click on the ‘Request New’ button (which will be
active in case of procedures sharing equipment) and in the ’Name’ field type the name you wish to
be given to the new equipment (note that equipment resource names must be unique across the
entire process).
DESIGN VS RATING SIZING MODE
Equipment Data Dialog: Equipment tab Page 2 of 2
If you wish the application to size the host resource, then you chose design mode under the sizing
option. In that case, SuperPro Designer will set the size of the associated equipment resource
based on the most-demanding operation amongst all hosted procedures. Typically, there’s a
maximum size value (set by the user) and if the sizing exceeds that value, the application will
assume that multiple units (of equal size under the limit) will be needed.
If you know the size of the hosting resource, then you should chose rating mode under the sizing
box. In that case, the right-hand side of the Equipment tab will have all the size-related variables
(incl. the number of units) open for editing. When set in that mode, the simulation calculations of
all of the operations hosted by the equipment resource use the size of the equipment as a
constraint and if the conditions are such that this constraint is violated a warning will be issued. For
instance, if setting the dimensions of a vessel, it turns out that the charged amount of material
exceeds its volume a warning will be issued.
STAGGERED MODE
In order to reduce the ‘effective’ occupancy time of an equipment resource (per batch) you can
request to have multiple sets of equipment operating in a staggered mode. If you chose this option
then the application will provide default names for he extra equipment resources that are a
combination of the prefix “STG0x >>” and the name of the resource, where ‘x’ is 1, 2, 3, etc. If
you wish to provide specific names for those resources (as they will appear on the equipment
occupancy chart and/or the equipment gantt chart) you can click on the “Names” button and edit
the names of each of the staggered resources.
Pasteurization
GENERAL DESCRIPTION
This model calculates the sizing variables of a pasteurizer comprising a holding tube and three
individual heat exchangers namely, a heater, a cooler and (optionally) a regenerator. It also
accounts for the microorganism degradation and food component inactivation during the
pasteurization process.
UNIT PROCEDURE AVAILABILITY

● Pasteurization
PASTEURIZATION: MODELING CALCULATIONS

Heat Transfer Area Calculation
In design mode, the model calculates the individual heat transfer areas of the pasteurizer’s heater,
cooler and regenerator sections assuming countercurrent flow conditions for all heat exhangers.
The heat transfer area, Ax, is calculated by the following equation
eq. (A.257)
where:
● x stands for the heater, cooler or regenerator
● Qx denotes the thermal load of the heat exchanger (J/s)
● Ux is the overall heat transfer coefficient (W m-2 K-1)

● ΔΤM,x is a mean temperature difference (K), calculated by
eq. (A.258)
● :
where:
● TF temperature of the pasteurizer’s feed stream (K)
● TH,in is the temperature of the stream entering the heater (regenerator cold stream exit
temperature) (K)
● TH,out is the temperature of the stream leaving the heater (pasteurization temperature) (K)
● TC,in is the temperature of the stream entering the cooler (regenerator hot stream exit
temperature) (K)
● TC,out is the temperature of the stream leaving the cooler (final exit temperature) (K)
● THA,in, THA,out and TCA,in, TCA,out denote the inlet and outlet temperatures of the heating and
cooling agent streams, respectively (K).
Notice that while a logarithmic mean temperature difference is employed for the heater and the
cooler, an arithmetic mean is employed in the case of the regenerator. This is a necessary
modification required by the fact that the same liquid, at the same flowrate, is heated and cooled in
the regenerator so the logarithmic mean temperature difference is “forced” to infinity.
The regenerator efficiency defined by:
eq. (A.259)
expresses the percentage of the temperature increase that is achieved by the regenerator w.r.t the
overall required temperature increase (i.e., in order to reach the desired pasteurization
temperaure). According to the literature, regeneration efficiencies of up to 94-95 % can be
achieved in efficient modern pasteurization plants.
Holding Tube Size Calculation
In design mode the diameter of the of the holding tube (in m) is calculated by:
eq. (A.260)
where:
● Q is the volumetric throughput (m3/s)
● ρ is the density of the pasteurized liquid (kg/m3)
● μ is its viscosity (Pa s)
● Re is the Reynolds number that corresponds to the flow in the holding tube
The volume of the holding tube (in m3) is calculated by the following equation:
eq. (A.261)
where:
● τ is the residence time in the holding tube (s)
● η is a holding tube efficiency
The latter is used in order to “enforce” that even the fastest liquid molecule (i.e., with respect to
the average velocity in the tube) is sufficiently pasteurized.
Finally, the length of the holding tube (in m) is calculated by:
eq. (A.262)
and the average velocity of the pasteurized liquid that flows inside it (in m/s) is given by:
eq. (A.263)
Inactivation and Degradation Kinetics

The death of microorganisms during the residence of a liquid within the holding tube of a
pasteurizer is commonly represented by the following equation (Wang et al, 1979):
eq. (A.264)
where:
● N is the number concentration of viable cells (# / L)
-1
● k is the specific death rate constant (s )
● t is the process time (s).
By integration of the above equation under the constant specific death rate assumption (i.e., k is
not a function of time) one gets:
eq. (A.265)
where N0 in the initial number concentration of viable microorganism cells. By changing the
logarithmic base, the above equation can be transformed into:
eq. (A.266)
The quantity D, commonly known as the decimal reduction time, expresses the time required at a
given temperature in order to achieve a 90% reduction in the number of viable cells of a population
(i.e., one log cycle). The temperature dependence of D is assumed by the model to follow the
Canners’ (or constant z) model expressed by:
eq. (A.267)
where:
● z is the thermal resistance factor (K)
● D(T) is the decimal reduction time at the pasteurization temperature T (s)
● D(TR) is the decimal reduction time at a reference temperature TR (s)
A similar kinetic model in used in order to calculate the degradation of a desired food ingredient
resulting from pasteurization so the user can assess, as well, the impact of the pasteurization
process on the quality of the food .
Capital Cost
The equipment purchase cost is calculated as a combination of the the individual costs of the heat
exchangers and the holding tube. The heat transfer area is used as the costing variable for the
heat exchangers while the volume is used as the costing variable for the holding tube.
References
1. Wang, D. I. C., C. L.Cooney, A. L.Demain, P. Dunnil, A. E. Humphrey, and M. D. Lilly (1979).
Fermentation and Enzyme Technology, John Wiley & Sons.
2. Z.B. Maroulis, Saravacos G.D. (2003). Food Process Dresign, Marcel Dekker, Inc.
3. M. Lewis and Heppel N. (2000). Continuous Thermal Processing of Foods. Pasteurization and
UHT Sterilization, Aspen Publishers, Inc., Gaithersburg, Maryland.
4. Dairy processing handbook, Tetra Pak Processing Systems AB, Lund, Sweden.
PASTEURIZATION: INTERFACE
The interface of this operation has the following tabs:
● Oper. Cond’s, see Pasteurization: Oper. Cond’s Tab
● Inactivation/Degradation, see Pasteurization: Inactivation/Degradation Tab
● Labor, etc, see Operations Dialog: Labor, etc Tab
● Description, see Operations Dialog: Description Tab
● Batch Sheet, see Operations Dialog: Batch Sheet Tab
● Scheduling, see Operations Dialog: Scheduling Tab
The Scheduling Group of Variables Page 1 of 2
The Scheduling Group of Variables

This group of variables are always presented for viewing and/or editing on theOperations Dialog:
Scheduling Tab and will be used to capture the following attributes:
1. The start time of the operation
SuperPro Designer calculates the start time of an operation using two settings:
(a) A reference event and (b) a time shift (positive or negative) from that event.
The reference event can be one of the following:
(a) The beginning of the batch
(b) The start time or end time of another operation in the same or another procedure.
2. The duration of the operation
It is assumed that the entire duration of an operation is made up from three parts:
(a) The setup time
(b) The process time, and
(c) The turnaround time
Users may elect to specify each portion of the entire duration separately or lump them together
in one or two values alone.
The process time of an operation can often be (optionally) calculated based on some performance
variable of the operation: for example, a charge operation may compute its process time based on
a user-specified charge rate. In some operations the process time is
The process time can be dictated from a master-slave realationship.
always calculated (e.g. Column Load in a chromatography). When the process time can be
calculated based on some other attribute of the operation, it is also displayed in the Oper. Cond’s
The Scheduling Group of Variables Page 2 of 2
tab.
As another alternative to calculate the duration of an operation, a user may elect to match the
duration of one operation (master) to the duration of another (slave). This option is available to
several operations and, when available, it is set from the Oper. Cond’s tab of the operation (The
process time can be dictated from a master-slave realationship.):
After selecting to set the process time by a master operation, clicking on the ‘Setup’ button will
bring up the The Master-Slave Relationship Dialog that will allow the user to select the master
operation.
The Master-Slave Relationship Dialog Page 1 of 7
The Master-Slave Relationship Dialog
This dialog appears when you click on the Setup... button when choosing to have the duration of an operation (slave) be determined by
the duration of another (master).
The operation you choose as the master, may exist in the same procedure as the slave or in another procedure. To remind you the
slave operation, its name, unit procedure and host equipment are mentioned near the top of the dialog.
Once you have specified the unit procedure that includes the master operation, then you must specify which operation(s) will dictate
the duration of the slave operation. You have two choices:
1. Single master operation. In that case the three parameters of the slave's duration (setup time, process time and turnaround time)
are matched one-to-one to the master's operation parameters. If the master operation exists in a multi-cycle procedure, then you
have two choices for how to determine the process time of the slave operation:
a) If you check the option named ‘Match Duration per Cycle’, then the process time of the slave operation will equal the master’s
process time per cycle (even if the master is in a multi-cycle procedure).
b) If you do not check the option named ‘Match Duration per Cycle’, then the slave operation’s process time will be set to span the
time from the start of the process time of the first cycle to the end of the process time in the last cycle.
2. You can choose a string (sequence) of operations, determined by a starting-master operation and an ending-master operation (in
the same procedure). In that case, the setup time of the slave will be matched to the setup time of the starting-master operation.
The turnaround time of the slave will be matched to the turnaround of the ending-master operation. Finally, the process time of the
slave, will be matched as follows:
a) If you check the option named ‘Match Duration per Cycle’, then the process time of the slave will match the span between the
start of the process time of the starting-master operation and the end of the ending-master operation during one cycle alone.
b) If you do not check the option named ‘Match Duration per Cycle’, then the process time of the slave will match the span
between the start of the process time of the starting-master operation in the 1st cycle and the end of the ending-master operation
in the last cycle.
As an example that demonstrates the above options, consider the following two procedure simple recipe:
The objective is to have the transfer out operation from the Blending Tank (V-101) match the filtration operation in P-2. Since the
amount being transferred is determined that it cannot be handled in one cycle by the Nutsche Filter, the number of cycles in the P-2
procedure has been set to 3.
As you can see from the above Gantt chart, the transfers out of V-101 will have to match the filtration times as they occur in P-2.
Clearly, this is a case where we need to define a master-slave relationship, where the master operation (dictating the timing) would
be the filtration operation in P-2, and the slave will be the transfer-out operation in P-1. Notice that in our example there is CIP
operation that occurs before the filtration of operation in each cycle, and there is a sequence of other operations that deal with the
cake (Cake Wash, Drying, Cake Transfer-Out, Gas-Sweep) and then the filtration cycle is ready to start over. Depending on how
accurate one may choose to represent the time-match between the master and the slave operation you can follow one of the next
approaches.
1. Approximate Operation Time Match (Captures only Occupation Time).
If you do not particularly care to simulate the duration of the transfer operations to match identically to the filtration times, but you
only need to capture the fact that vessel V-101 is 'busy' during the entire period, then you may follow this approach. Let the number
of cycles in P-1 stay as 1, and setup the master-slave relationship from the transfer out operation's dialog as follows:
As you can see, in this approach we have the ‘Match Duration per Cycle’ option unchecked. In this case, the duration of the transfer
operation will be set to equal the entire span as shown in the previous Gantt Chart. Therefore, the full Gantt chart in this case will be:
If you wish to match exactly the times that the filtration operation executes with the times of the transfer operation, then you have two options (2a and 2b):
2a. Exact Operation Time Match: Change Number of Cycles in Slave Procedure
First, set the number of cycles of the transfer procedure (P-1) to equal the number of cycles of the filtration procedure (in this case
3). To find out how to change the number of cycles for a procedure, see Procedure Data Dialog: Scheduling Tab.
Next, since there some operations executing before and after the filtration operation in each of the P-2's cycle, we will include a Hold
operation before the transfer out and another Hold operation after the transfer out to match the dead time before and after the
transfer out operation. Since there's only one operation happening before the filtration operation (the CIP cleaning) we will make the
before-transfer-out hold a slave directly to that CIP operation (on a per-cycle basis), so the master-slave relationship will be as follows
For the hold operation after the transfer out, we need to make it match a sequence of operations that happen after the filtration (cake
wash, dry, cake transfer out and gas sweep) again on a per-cycle basis. To setup this master-slave relationship we will use the
multiple master option and use as the start-master the cake wash operation in P-2 and as the end-master the gas sweep operation in
P-2:
After the above setup, the Gantt chart will be as follows:
2b. Exact Operation Match: Keep Number of Cycles of Slave Procedure to 1

In this second option, we maintain the number of cycles of the source procedure (P-1) to 1, but in a similar spirit of the above case
(2a) we will introduce a hold operation before the filtration and a hold operation after the filtration that we will match (on a per cycle
basis) - same as in 2a above. To reproduce the fact that the same sequence happens three times, we will add two more times the
same sequence of hold / transfer-out / hold. This time, the duration of hold will be made to match the duration of the first hold in P-1.
The duration of the second transfer out will be made to match the duration of the first transfer out:
And finally, the duration of the follow-up hold will be made to match the duration of the second hold in P-1:
After repeating the last three steps once more, then we can have a similar Gantt chart as above, but now we only keep one cycle.
Procedure Data Dialog_ Scheduling Tab Page 1 of 1
Procedure Data Dialog: Scheduling Tab
Notes
1. A cycle for a unit procedure in batch mode is a completed sequence of operations (as dictated in the
operation queue; for more details, see Procedure Cycle and Cycle Time). If you set the number of
cycles in this dialog to anything larger than 1, it implies that the specified sequence of operations is
executed this many times (per process batch) to complete the unit procedure. If a batch procedure is
set to operate in a continuous process, then:
- the number of cycles cannot be set (it’s always assumed to be 1), and
- the Holdup Time field (may or may not be editable) appears.
2. If the a batch unit procedure’s operation sequence has more than one operations in it you cannot switch
its mode from batch to continuous. First visit the Add/Remove Operations... dialog and remove all the
operations but one and then come back to this dialog to switch the operation mode to continuous.
3. If you set the unit procedure’s mode as continuous then this unit procedure (and its contained
operation) will no longer appear on any Gantt charts and the hosting equipment resource will not
appear in the Equipment Occupancy Chart.
4. The cycle time, absolute start time and absolute end time of the procedure are only shown for display
purposes and cannot be set by the user. The units of time shown (sec, h, day, etc.) follow the user’s
choice as set by the Physical Units Options Dialog (accessed by clicking Preferences } Physical Units
Options on the flowsheet’s right-click menu).
5. The’ Omit from Scheduling Calculations’ option is checked if the procedure’s hosting equipment resource
has been excluded from scheduling calculations as set from Equipment Data Dialog: Scheduling Tab. If
that is the case, then the following flag (‘Omit from Gantt Chart’) is automatically checked as well.
6. The ‘Omit from Gantt Chart’ option if checked will force this unit procedure (and all its contained
operations) to not appear on the Gantt Charts. The operations in this procedure can still be used as
references for start / end times of other operations in other procedures. By default all batch mode unit
procedures and their contained operations, appear on the Gantt chart. However, there may be
occasionally a need to hide a particular procedure that appears on the flowsheet for mass & energy
simulation purposes only (e.g. an in-line intelligent mixer) so that it doesn’t clutter the chart.
Procedure Cycle and Cycle Time Page 1 of 1
Procedure Cycle and Cycle Time

A unit procedure is assumed to capture the execution of a sequence of operations. A completed
sequence of operations from the beginning of the first to the end of the last (as mentioned in the
procedure’s queue) is called a unit procedure cycle, and the time elapsed is called the unit
procedure’s cycle time.
When processing (in a single step or unit procedure) the material that is part of a single batch
sometimes the demands on equipment resource capacity are such that it necessitates multiple
units to be used. Very often, due to monetary considerations (if the associated equipment is very
expensive or unavailable) or more likely, due to under utilization of a given equipment resource,
instead of engaging multiple equipment units in parallel, it is decided to split the material in a
number of ‘mini-batches’ and process each one separately through that equipment and then
afterwards merge them again, thereby, making most efficient use of the available equipment. For
example, consider the case where a large amount of material needs to be passed through a
chromatography column. If the column’s total cycle time (including equilibration, loading, wash and
regeneration) is relatively small compared to the time between batches (aka process cycle time),
then instead of demanding the use of multiple columns (say 5), it is often preferable to divide the
material into 5 equal amounts and process them through the column one by one and later merge
the product streams and wastes. SuperPro Designer makes it very easy to accommodate such
processing requirements, without having to show the actual split of the material into 5 cuts and
represent each chromatography step separately (this would require 5 distinct icons with products
that later merge together). The key is to setting the number of cycles parameter of that
procedure to a number larger than one (default); in our case 5. When this is done, SuperPro
Designer will assume that the sequence of operations contained in the unit procedure
(equilibration, load, wash and regeneration) will repeat itself in an identical manner.
SuperPro Designer assumes that as soon as the first cycle ends the next starts right away.
Note that you cannot schedule individually each of the cycles when to start. Also, you cannot
use as start time reference (for the scheduling of other operations) the start or end time of an
operation in any intermediate cycle. When the start time of an operation (in a multi-cycled
procedure) is used as a reference, then the time that the operation starts during the first
cycle is used. When the end time of an operation (in a multi-cycled procedure) is used as a
reference, then the end time during the last cycle is used. If you need to schedule or
reference start or end times of operations during all cycles of a procedure, then it is
recommended that you represent each cycle as a separate unit procedure. Also, if you need to
have some action(s) happen before the first cycle only or after the last cycle only, then you
must represent each cycle as a separate unit procedure.
.
The number of cycles for a unit procedure can be set from the Procedure Data Dialog: Scheduling
Tab.
Holdup Time Page 1 of 1
Holdup Time
When a batch unit procedure, such as chromatography, is set to operate in a continuous
surrounding, SuperPro Designer needs to infer the amount of material that gets processed per
cycle. The implicit assumption is that in order for this unit procedure to function cyclically in an
otherwise continuous environment, there must be a tank that accumulates material for a certain
time (at least while the procedure is in progress) and then feeds the next cycle of the unit
procedure. This time we call holdup time. Obviously, this time must be at least as long as the
cycle of the unit procedure (but it could be longer). For unit procedures whose cycle time is set
directly by the user (in other words, the cycle times of all contained operations have process times,
setup times and turnaround times directly set by the user) the holdup time is assumed to be equal
to the cycle time of the unit procedure. In that case, the user does not need to supply the
procedure's holdup time (its field will not be editable in the procedure's operating mode dialog).
However, if the duration of at least one operation of the unit procedure is calculated by the system,
then the user must set the holdup time (the field is editable). Care must be taken to set the holdup
time to a reasonable value: if the value set is too small, then there will not be enough time for the
contained operations to execute; if the value is set too high, then the accumulated material that
needs to be processed per cycle of the unit procedure becomes too large and if some of the
contained operations’ process times depend on the amount of material processed, then their
operating times become too large, leading to a process cycle time that may be too large (or at
least larger than the set holdup time). It is very easy to de-stabilize the interdependency between
equipment capacity and holdup time if the process time calculation of at least one of the operations
in the procedure’s queue, depends linearly on the amount processed: Higher holdup times lead to
larger capacity demands which in turn lead to higher process times (and procedure cycle times)
that raise the lower limit on holdup times. An effective way to circumvent this self-feeding cycle is
described below:
A challenging case involving the holdup time appears when all contained operations have their
times set by the user. As mentioned previously, in that case, the holdup time is calculated by
the program as the time between the start of the first operation and the end of the last
operation. If that time happens to be very large and independent of the amount processed
per cycle (e.g. it could be due to large reaction/fermentation time) then the sizing demand on
the hosting equipment resource may be exceedingly large. To circumvent this predicament
you can set the hosting equipment resource to operate in a staggered mode. In that case, the
effective value used to estimate the amount of material processed per cycle would be the
cycle time divided by N+1, where N is the extra sets of staggered equipment resource units,
thereby reducing the capacity demands. For more details on the staggered mode of operation
see Staggered Mode.
Staggered Mode Page 1 of 1
Staggered Mode
As explained in detail in the scheduling calculations (see Scheduling Calculations) the cycle time of
a process cannot be lower than the longest occupancy time amongst all equipment involved. When
the occupancy time of an equipment resource is too long (compared to rest of the equipment) it
forces a very long time between consecutive batch starts and therefore it introduces a much
undesirable under-utilization of a the rest of the equipment in the process. For example, when
modeling a fermentation process the fermentation itself could take a week, when all the
downstream purification steps don’t take more than several hours. If we had to wait till the
fermentor becomes available before we start a second batch, then clearly we couldn’t start a batch
for a week at a time. Notice that while the fermentor would be busy for a week the rest of the
equipment would be idle for 6+ days. To avoid such undesirable utilization of process equipment,
we can request the equipment resource behind fermentation to involve 6 extra sets of units
operating in staggered mode. This will reduce the ‘effective’ equipment occupancy time for the
fermentation step from 7 days to 7 / (6+1) = 1 day. Now, the calculated minimum cycle time will
be 1 day and by starting a batch every day we also make best use of the rest of the equipment.
You can request a staggered mode for an equipment resource from the Equipment Data Dialog:
Equipment tab.
If the number of units for an equipment is set (or calculated) to be more than one, then when
turning on the staggered mode for a given equipment resource, the application must assume
that for each shift of the staggered equipment there must be an equal number of units
operating in parallel. Note that these extra units will add to the capital cost of the process.
The extra staggered units will be given names constructed from the name of the original equipment
plus the “STG01 >>”, “STG02 >>” prefix. If you wish to provide your own names you can do by
visiting the Equipment Data Dialog: Purchase Cost Tab names dialog that is accessible from the
Equipment Data Dialog: Equipment tab.
Scheduling Calculations Page 1 of 1
Scheduling Calculations
All scheduling calculation are performed after the mass and energy balances have been calculated
as some of the inputs to the calculations (e.g. operation durations) may be calculated at the end of
M&E balance calculations.
Equipment Data Dialog_ Purchase Cost Tab Page 1 of 2
Equipment Data Dialog: Purchase Cost Tab
This tab is part of the Equipment Data dialog (common to all equipment types). The dialog can be
viewed when selecting the Equipment Data menu option from a unit procedure’s command menu.
Variable Default Range

Value
◙ Purchase Cost 0.0 Positive

The cost estimated to purchase each of the
equipment units involved. Not editable unless set
directly by user.
◙ Purchase Cost Reference Year Varies 1990 -

The year for which either the built-in model or the today
user’s cost model estimates the cost for equipment.
It is editable only if the cost (as a value) is directly
set by user.
○ Purchase Cost Estimation Mode Built-in 1 of 3

For each equipment type there may be a set of Model
choices for the material of construction. Each choice
carries with it a factor (material factor) that scales
up or down the cost in relation to construction with
the assumed default material of construction.
Specification Choices / Comments

For more details on choices for estimating the purchase cost for equipment , see Purchase Cost.
• Set by user vs Built-in Cost Model vs User-Defined Cost Model
By default, a built-in cost model is used to estimate the cost of equipment given its size. If
estimates are not deemed appropriate then the user can either provide their own cost vs size
model (see The User-Defined Cost Model (UDCM)) or set the cost directly for this unit. If the
estimates for PC are for a year prior to the year of the project, the application will adjust the
prices using the published chemical engineering index to account for inflation.
Equipment Data Dialog_ Purchase Cost Tab Page 2 of 2
• User-Defined Cost Model

To provide a power-law based model that is to replace the built in model of cost vs size, select
the last choice and then click on “Parameters”. For more on the ensuing dialog, see User-Defined
Cost Model Dialog. System and User database may contain any number of materials of
construction. For a given equipment type (e.g. Chromatography Column) a material of
construction factor may or may not be defined. If you select a material and the factor does not
exist in the databank, you will be notified and the factor will default to 1.0. You can simply
overwrite the value to any positive number you deem appropriate in this interface and it will
only be associated with is equipment. If you wish the association between a material of
construction and a cost factor.
• Multiple Pieces of Equipment
If multiple pieces of equipment (of equal size) are engaged to operate in parallel (or in
staggered mode), then the purchase cost displayed in this tab is the cost of a single equipment
item. The purchase cost associated for this equipment resource will be that of a single piece
times the number of equipment items required to carry out the procedure.
• Material of Construction
The estimated PC assumes a default material of construction (the actual type varies from type to
type but the most common choice is SS316). To account for other materials of construction, and
to view other PC adjustment factors, see Equipment Data Dialog: Adjustments Tab.
Purchase Cost Page 1 of 1
Purchase Cost
A very important component of the economic expenditure especially for new (green field) projects, is
the total capital cost for the equipment necessary to carry out the process. SuperPro Designer has
built-in models that estimate the cost for each equipment type based on its size variable. As some of
the formulas used for the cost estimate have been given to us by manufacturers we do not publish
them. However, if you do not agree with the program’s estimates, you can either provide a fixed value
for the specific (as sized) equipment or supply your own cost vs size model that will be used to
estimate the cost given the value of the sizing parameter. We call this model the User-Defined Cost
Model or UDCM for short.
If you have allocated the equipment resource to a database equipment, see Equipment Allocation, then
its purchase cost is read from the database and no other choice exists for its estimation.
All built-in models for cost estimation produce the cost in US$ at a given year. The cost is
brought up to the project’s date by adjusting for inflation using the published Chemical
Engineering Index. When specifying your own UDCM you also need to specify the year for
which the estimates are valid. If the project year is different then the costs will be adjusted
the same way.
THE USER-DEFINED COST MODEL (UDCM)

This model can be provided by a user as a cost vs size correlation that will be used by the application to
estimate the cost of a piece of a equipment if the built-in model produces unacceptable results.
The general formula used for the model is a power-law type: C = Co (Q/Qo)a
where, (Co, Qo) is a pair of reference size and cost, and a is an exponent (usually less than 1).
The user is supposed to provide the triplet of (Co, Qo and a) as well as a range of size values (Q)
where the triplet of values generates a valid estimate. Note that if it is not possible to have a single
triplet of values for the entire range of expected sizes (Q), then you can divide the entire range into
smaller segments and provide a different set of triplet for each range. Please note that the variable
used to feed the cost vs size UDCM is fixed for a given type of equipment resource. The units can be
changed but will always be of the same units type as the variable. For example, for vessels the size is
expected to be the volume of the vessel in volume units; for a plate-and-frame filter, the UDCM is
supposed to estimate the cost as a function of the filter area in area units. Also, it is assumed that the
cost estimate is in currency that is (at the time) selected as the chosen currency for the current
process file (see Currency). As part of the UDCM definition, the user is supposed to provide a year for
which the cost estimate is valid. SuperPro Designer will update the cost to the current year that the
project is carried out by using the chemical engineering index to account for inflation.
User-defined cost models may be also imported from the database. These UDCMs have been either
defined in the User Defined Cost Models Databank or were first introduced in equipment of the process
and then deposited into the database for safe keeping and/or for re-use in other equipment of the
same type.
When specifying the UDCM for an equipment resource, it only applies for the specific resource
used in that process step (unit procedure). It does not replace the cost estimation option used
for all equipment (of similar type) employed by your process. If you wish to use the same cost
model for all equipment of the same type, then you must either specify the same model in all
other equipment present in your process (one-by-one), or specify the UDCM in the first
instance of the equipment and then copy-and-paste the procedure/equipment pair before you
use it elsewhere in your process. Additionally you may also deposit the UDCM from an
equipment in the database and then import it back into the process to which ever equipment
of the same type it is needed.
For more information on the user-defined cost model interface see User-Defined Cost Model Dialog.
Also all of the above choices and parameters including the UDCM interface can be viewed and/or edited
through the Equipment Data Dialog: Purchase Cost Tab.
Pasteurization: Inactivation/Degradation Tab Page 1 of 2
Pasteurization: Inactivation/Degradation Tab
Variable Definitions, Ranges and Default Values

The following table shows a brief description of the variables appearing in this tab. The table also
displays their default values and their generally acceptable range:
Variable Default Range

Value
○ Decimal Reduction Time at Ref. 0.1 Positive

Temperature. (min)
The decimal reduction time of the microorganism of
interest at a reference tempearure.
○ Reference Temperature (oC) 64 Positive

The temperature corresponding to the above
decimal reduction time.
○ Thermal Resistance Factor (oC) 0.0 Positive

The thermal resistance factor for the selected
microorganism.
● Decimal Reduction Time at Pasteur. 0.0 Positive

Temperature(min)
The decimal reduction time of the microorganism of
interest at the pasteurization tempearure.
● Reduction Exponent log(N0/N) 0.0 Positive
● Inactivation 0.0% 0 - 99%
The % inactivation of the microorganism during

the pasteurization process.
Pasteurization: Inactivation/Degradation Tab Page 2 of 2
○ Decimal Reduction Time at Ref. 50.0 Positive

Temperature. (min)
The decimal reduction time of the nutritious food
component of interest at a reference tempearure.
○ Reference Temperature (oC) 75.0 Positive

The temperature corresponding to the above
decimal reduction time.
○ Thermal Resistance Factor (oC) 8.0 Positive

The thermal resistance factor for the nutritious food
component of interest.
● Degradation 0.0 Positive
The % percentage degradation of the nutritious

food component during the pasteurization process.
Symbol Key: ○ User-specified value (always input); ● Calculated value (always output); ◙ Sometimes input, sometimes output
By providing appropriate values for the microorganism inactivation and food component
degradation kinetics, the user is able to estimate the impact of the pasteurization process to the
quality of food. In that sense, different pasteurization policies can be simulated (i.e., w.r.t to the
pasteurization temperature and residence time in the holding tube) in order to perform a trial-and-
error optimization of the pasteurization process.
Operations Dialog_ Labor_ etc Tab Page 1 of 2
Operations Dialog: Labor, etc Tab

This dialog tab is common to all operations’ I/O simulation data; it allows you to set the following:
• Labor Amount...
This is the labor coefficient for the operation. It specifies how many operator hours per operation
hour are required. Essentially, this coefficient allows you to specify how many operators need to
be occupied while this operation is being carried out. Fractional values are meaningful in the
sense that perhaps an operator needs to spend only a fraction of his/her time during the
progress of this operation (while he/she is supervising the execution of another operation).
• Auxiliary Utilities...
Auxiliary utilities (Heating/Cooling/Power) are amounts of utilities that are not normally being
calculated as part of the simulation model of the operation. If significant amounts are being
consumed, then you should specify their rate of consumption in this dialog. Note that rates are
required as amounts / h where h refers to operation hour (i.e. time during which the operation is
being carried out). When you specify an auxiliary heating, cooling, or power requirement for a
specific operation, the resulting values are not used in heat balances. The values are only used
in calculating the operating cost of the equipment associated with that unit procedure and for
adding to the consumption levels of that resource. The agents of the auxiliary utility are selected
from the heat transfer agents databank. If the desired agent is not defined, you can add it to the
heat transfer agents databank.
Operations Dialog_ Labor_ etc Tab Page 2 of 2
• Size Utilization for Throughput Analysis...

Specify how the equipment capacity utilization factor is to be calculated in the Throughput
Analysis Report. The equipment capacity utilization factor indicates how much of the available
equipment capacity (e.g. volume) this operation is using up. This factor is employed heavily in
the throughput analysis performed by SuperPro Designer. SuperPro Designer has its own logic
for computing these factors for every type of operation. The user may allow the computed value
to be used in the throughput analysis, or he/she may overwrite the computed value to either
extreme: 100% (thus increasing the likelihood that the program will consider this operation and
its equipment as potential bottlenecking candidates) or 0% (thus removing this equipment from
the list of potential bottlenecking candidates). For more details, see Debottlenecking.
Operations Dialog: Description Tab Page 1 of 1
Operations Dialog: Description Tab

This dialog tab is common to all operations’ I/O simulation data; it allows you to do the following:
a) Specify whether to use a built-in template (either short or long version of it) when including a
description of the operation, or use a user-supplied overwrite text.
b) Type (for bookkeeping and documentation) comments for each operation (if necessary).

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Pasteurization Page 1 of 1

Host Equipment Pasteurizer

SPECIAL INPUTS / OUTPUTS

Costing Variable Overall Heat Exchanger Area, Holding

Costing Variable Overall Heat Exchanger Area in m2

A Pasteurizer is used to represent an equipment resource typically used to host a Pasteurization

Pasteurizer: Equipment Tab

Variable Definitions, Ranges and Default Values

Variable Default Value Range

◙ Max Throughput 100,000.0 L/h Positive

◙ Rated Throughput 3600.0 L/h Positive

The rated volumetric throughput.

◙ Holding Tube Diameter 10.0 cm Positive

◙ Holding Tube Length 1.0 m Positive

● Holding Tube Volume 7.85 m

○ Is Regenerator Available? Yes Yes/No

SIZING: DESIGN MODE

SIZING: RATING MODE

Equipment Data Dialog: Equipment tab

DESIGN VS RATING SIZING MODE

UNIT PROCEDURE AVAILABILITY

PASTEURIZATION: MODELING CALCULATIONS

● Ux is the overall heat transfer coefficient (W m-2 K-1)

Inactivation and Degradation Kinetics

The Scheduling Group of Variables

The process time can be dictated from a master-slave realationship.

The Master-Slave Relationship Dialog

After the above setup, the Gantt chart will be as follows:

2b. Exact Operation Match: Keep Number of Cycles of Slave Procedure to 1

Procedure Data Dialog: Scheduling Tab

Procedure Cycle and Cycle Time

Equipment Data Dialog: Purchase Cost Tab

Variable Default Range

◙ Purchase Cost 0.0 Positive

◙ Purchase Cost Reference Year Varies 1990 -

○ Purchase Cost Estimation Mode Built-in 1 of 3

Specification Choices / Comments

• User-Defined Cost Model

THE USER-DEFINED COST MODEL (UDCM)

Pasteurization: Inactivation/Degradation Tab

Variable Definitions, Ranges and Default Values

Variable Default Range

○ Decimal Reduction Time at Ref. 0.1 Positive

○ Reference Temperature (oC) 64 Positive

○ Thermal Resistance Factor (oC) 0.0 Positive

● Decimal Reduction Time at Pasteur. 0.0 Positive

● Reduction Exponent log(N0/N) 0.0 Positive

● Inactivation 0.0% 0 - 99%

The % inactivation of the microorganism during

○ Decimal Reduction Time at Ref. 50.0 Positive

○ Reference Temperature (oC) 75.0 Positive

○ Thermal Resistance Factor (oC) 8.0 Positive

● Degradation 0.0 Positive

The % percentage degradation of the nutritious

Operations Dialog: Labor, etc Tab

Specification Choices / Comments

• Size Utilization for Throughput Analysis...

Operations Dialog: Description Tab

Specification Choices / Comments

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