State-of-the-art heat treatment of beverages
GEA ECO-FLASH® Flash Pasteurization System
The GEA ECO-FLASH® flash pasteurization system meets the growing needs of beverage producers for the best possible quality of their final products through pasteurization while ensuring maximum process safety and resource conservation. It is, not least, the result of the extensive technological know-how that GEA has built up together with global beverage producers, sometimes over decades.
Beverage manufacturers face a tremendous risk if microbiologically unstable products are filled and delivered to the end consumer. Potential carryovers of unwanted microorganisms from the production process into the final product remain initially undetected and can only be detected with a significant time delay. This risk can be minimized.
The best method to achieve microbiologically stable product quality while maintaining full flavor is continuous or flash pasteurization. Flash pasteurization systems improve the microbiological stability of liquid products such as beer, beer mixes, cider, hard seltzer or soft drinks by thermal inactivation of unwanted microorganisms (pasteurization) in a controlled, continuous process. The flash pasteurization process is equally suitable for filtered and unfiltered products, which represents a significant advantage over cold sterile filtration, which can only be used with clear filtered products.
In addition to microbiological stability, flash pasteurization can also increase the chemical-physical stability of the product (e.g., filtered beer). Another positive side effect of flash pasteurization is the inactivation of enzymes.
State-of-the-art heat treatment of carbonated and non-carbonated beverages with the focus on process safety, efficiency and sustainability
The ECO-FLASH® is a fully automated, modular, frame-mounted flash pasteurization system that masters a wide range of pasteurization conditions. Its design and functionality are precisely engineered to match with the type of products to be treated. The use of proven hygienic equipment and advanced process software are fundamental conditions for high microbiological safety, taste stability and system efficiency. The system is widely adjustable according to its task and operates within tight tolerances. In addition to the basic configuration, there are numerous options available that further improve product safety and minimize the lifecycle costs of the system.
All functions of this fully automated flash pasteurization system are implemented in its own decentralized control system. The risk of malfunctions is minimized due to standardized process software.
ECO-FLASH® flash pasteurization module
The ECO-FLASH® flash pasteurization module enables efficient heat treatment and stabilization of liquid products by inactivating unwanted microorganisms. The product is processed at controlled, continuous flow and exposed to the desired temperature for a defined time (holding time). Precise control of the applied Pasteurization Units is an essential safety factor. The well-engineered combination of different control loops ensures high accuracies of ± 1 PU or ± 2 %, depending on the control range.
A three-stage plate heat exchanger ensures high operating efficiency. In it, the previously pasteurized hot product heats the untreated, cold product in counterflow and cools down in the process. Thanks to this recuperative design, more than 90 % of the introduced thermal energy can be recovered. This makes flash pasteurization the most economical of all heat treatment processes today.
ECO-FLASH® buffer tank module for pasteurized product
The ECO-FLASH® buffer tank module completes the flash pasteurization system when it is, for example, located upstream of a filling line. In this case, the integrated buffer tank for pasteurized product ensures hydraulic decoupling of the flash pasteurization and the downstream process. Despite of a standstill of the downstream process, interruption-free operation of the system is still possible until the available buffer tank capacity is depleted. The necessary buffer tank capacity is determined by the plant operator's requirements. A vacuum-resistant design of the buffer tank allows the omission of a vacuum valve, which excludes potential recontamination of the buffer tank by ambient air.
Features
- Precise control of the Pasteurization Units as an essential safety factor
- Consistent pressure regime prevents outgassing and ensures a positive pressure gradient
- Efficient recuperative design with high heat recovery
- Consistent use of mix-proof valves prevents contamination
- Fully integrated cleaning concept for highest hygiene standards
- Integrated standby operation to maintain steady-state control
- Carefully considered responses to interruptions and errors ensure maximum process safety and minimized product losses
- Integrated hot water recirculation at production start and after critical errors or emergency stops ensures microbial integrity
- Level-dependent flow control increases buffer capacity and reduces product losses
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