Manufacturer: GEA
Model: 6500/215
Type of Machine: UHT System
Purpose: Indirect heating treatment system for milk (3.8% fat)
Specifications:
- Capacity: 15,000 – 21,500 l/h (adjustable)
- Product: Milk (3.8% fat)
- Heating System: Tube bundle heat exchangers with indirect heating
using hot water and steam
- Max Heating Temp: Up to 139°C
- Cooling System: Regenerative cooling with water
- Holding Tube: Stainless steel, 1.5 sec @ high-temp, and 120 sec @
90–95°C for protein stabilization
- Sterilization: Fully closed product and water circuits, sterilizable
with automatic programs
- Control System: Siemens S7-400 PLC with recipe management (up to 100
recipes)
- Flow Metering: Inductive
- Pump Systems: Various frequency-controlled centrifugal pumps for
product and water circuits
- Construction Materials: AISI 316Ti for product-contact parts; AISI
304 elsewhere
- Extras: CIP compatibility, magnet float switch, safety interlocks
UHT System Type 6500/215
as product treatment system with indirect heating system designed
according to the latest technological findings
Capacity: 15,000 – 21,500 l/h FQ controlled
Product: Milk 3.8% fat
The heating and cooling of the product occur indirectly by heat
exchange with water in counterflow in TDS shell-and-tube heat
exchangers. Their favorable ratio of heat exchanger surface area to
product volume ensures an optimized product quality with high heat
recovery, i.e., low steam and cooling water consumption.
The pressure- and temperature-stable shell-and-tube heat exchangers
have simple, secure seals. Straight, smooth product flow paths ensure
easy inspection.
All product-carrying lines and heat exchangers including the filling
line (ring line) are switched into a closed circuit and sterilized
during the program step Sterilization.” Thus, the system offers a
maximum level of safety for aseptic production.
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Specification of delivery scope:
1 shell-and-tube heat exchanger system, divided as follows:
- 1 heating system from approx. 6°C to 123°C through regenerative
heat exchange with water in counterflow, with inlet and outlet to the
homogenizer at 70°C and inlet and outlet to the holding section at
approx. 90°C.
- 1 high heating system from 123°C to 139°C through regenerative
heat exchange with hot water in counterflow.
- 1 recooling system from 139°C to approx. 25°C through regenerative
heat exchange with water in counterflow.
- 1 heating system for the hot water circuit: the hot water is heated
to the required temperature by heat exchange with steam before it
enters the high heating system.
- 1 cooling system for the regenerative circuit. The water (heat
exchanger medium) is, if necessary, cooled by heat exchange with
cooling water before entering the recooling system, so that the
product outlet temperature does not rise above the specified maximum
value even during extended standstill.
- 1 holding section made of pipe DIN 11850 approx. 1.5 seconds dwell
time at high heating temperature
- 1 holding section made of pipe DIN 11850 approx. 120 seconds dwell
time at approx. 90–95°C for stabilization of whey proteins
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Operating platform
1 feed tank
- standing, round, closed design, with manhole (200 mm)
- made of material no. 1.4301 (AISI 304)
- with spray cone for CIP
- level monitoring via float and magnetic tube switch
Through a special valve configuration during production start/stop and
end, mixing of product with water in the feed tank is avoided.
- 1 expansion vessel for closed product circuit during system
sterilization
- 1 expansion vessel for closed water circuit (regenerative
circuit)
- 1 centrifugal pump as product transfer pump
- 1 high-pressure centrifugal pump as transfer pump for the water
circuit (frequency-controlled)
- 1 centrifugal pump as transfer pump for the hot water circuit (high
heating system) (frequency-controlled)
- 1 set of valves, ball valves, fittings and accessories for all
program sequences within the system
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Measuring and control devices
- 2 conductivity probes for checking the cleaning agent concentration
and product monitoring
- 1 electronic pressure measuring device for monitoring the pressure
in the system
- 1 temperature control for the heating temperature
- 1 temperature control for the water cooler
- 1 multi-channel line recorder for monitoring the measuring points
described in the flow diagram as well as marking the process states:
sterilization, production, cleaning, and non-sterile
- 2 float-type flow indicators for the regenerative circuit and high
heater circuit (water side)
1 inductive flow meter on product side
1 stainless steel control cabinet
Inside equipped with mounting plates, on which, among others, the
following components are installed:
- Programmable logic controller type Simatic S7 400
- Power supply
- Fuses
- Terminal strips
- Pilot valves
- Compressed air preparation unit
On the front door of the control cabinet, the following components are
installed:
- Operating panel for visualization of program sequences with up to
100 recipes that the operator can enter and modify
- Electronic control devices
- Multi-channel line recorder
The control cabinet is completely wired up to the connection terminals
and tested.
Using the programmable logic controller, the following programs are
implemented:
- Sterilization of the system
- Production
- Production interruption
- Cleaning
The following messages are signaled as alarms:
- Product shortage
- Undershooting of the high heating temperature
- Drop in compressed air
- Increased system pressure
- Conductivity limit exceeded during production
- Error message homogenizer
1 stainless steel control cabinet
Including air circulation cooling unit
Inside equipped with mounting plates, on which, among others, the
following components are installed:
- Power section (motor protection switches, contactors)
- Frequency converter
All product-contacting parts of the shell-and-tube heat exchangers are
made from material no. 1.4571 (equivalent to AISI 316 TI), all other
product-contacting parts are made from material no. 1.4301 (equivalent
to AISI 304).
The shell-and-tube heat exchangers are sealed with PTFE rings.
The outer surfaces of all shell-and-tube heat exchangers, frame
structures, and piping are treated with synthetic mineral blasting
media in compressed air blasting according to DIN 8200.
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Homogenizing unit type Niro Soavi
- Capacity: 15,000 – 21,500 l/h
- Max. operating pressure: 200 bar
- Inlet pressure: 2–3 bar
- Max. product temperature: 80°C
- Motor power: 160 kW
- Motor voltage: 400 V / 3 PH / 50 Hz
Machine design:
- Frequency-controlled
- Aseptic
- Homogenizing pressure gauge
- Homogenizing valve 1-stage as nano valve version
- Pistons in ceramic design
- Pressure head made of stainless special steel
- Gear housing in cast steel
- Oil lubrication system
- V-belt drive
- Housing made of stainless steel
- Three-phase motor
- Stainless steel control cabinet, including electrical equipment to
control and protect the main motor and all auxiliary circuits
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