Tunnel pasteurized

Types of Tunnel Pasteurizers

A tunnel pasteurized is an industrial equipment used to control the temperature of products in a tunnel through heating or cooling. It is widely used in various industries such as food and beverage, pharmaceutical, chemical, and cosmetics, among others. The main function of the tunnel pasteurizer is to ensure the safety of the products and extend their shelf life by eradicating harmful microorganisms.

There are different types of tunnel pasteurizers based on the method of heating and cooling, the direction of flow, and the kind of product they handle, among other features.

• Based on the method of heating and cooling: The water spray tunnel pasteurizer is the most common in the food and beverage industry. It uses heated water to change the temperature of the product that is being processed in the tunnel. This tunnel can also use cold water to cool down the product immediately after pasteurization to avoid re-heating. Another type is the hot water recirculation tunnel pasteurizer, which uses hot water that is pumped through the tunnel. This type of tunnel pasteurizer is common in bottling and canning industries. A steam tunnel pasteurizer uses steam and ventilation ducts to heat the product. This steam tunnel is ideal for products with high acidity or those that require high-temperature processing.
• Based on the flow direction: An up-flow tunnel pasteurizer has products flowing upwards, which is ideal for solid particles and liquids with large solids. It uses a spray or dribble method to apply the heating and cooling medium. On the other hand, a down-flow tunnel pasteurizer has the products flowing downwards, which is ideal for liquids and semi-liquids.
• Based on the kind of product being handled: The liquid tunnel pasteurizer is designed specifically to handle liquids such as juices, dairy drinks, and sauces. It features a system that controls the flow rate and ensures even pasteurization. On the other hand, the solid and semi-solid tunnel pasteurizer is used to handle products such as meat, poultry, and dairy products like cheese. It has conveyor systems that move the products through the heating and cooling zones.

Other than the above-mentioned types of tunnel pasteurizers, there are also size variations. The small-sized pasteurizers are common in small-scale industries, whereas the large-sized pasteurizers are used in industrial-scale facilities.

The efficiency of the tunnels is categorized into three main types: non-efficient, semi-efficient, and efficient. An efficient machine ensures even heat distribution and uniform pasteurization. In contrast, semi-efficient and non-efficient systems are less effective and may fall short of the safety standards required for certain products.

Specifications and maintenance of tunnel pasteurized

Specifications

• Sizes:

  Tunnel pasteurizers can be enormous, with lengths reaching up to 20 meters (65 feet) and widths of up to 2 meters (6.5 feet). This is due in part to the fact that they have to fit entire production lines inside of them. They also have to accommodate multiple product lanes, which allows for higher outputs per hour.

• Max temperature:

  Tunnel pasteurizers are designed to heat food to a wide variety of different temperatures depending on what kind of food is being processed and what type of pasteurizer is being used. Generally speaking, the heat used in these machines is around 60°C (140°F) to 85°C (185°F).

• Heating method:

  Tunnel pasteurizers can be heated in many different ways, including steam, hot water, electric heating elements, or a hot water spray. The method used to heat the food will usually determine the flavor of the final product and may also affect the shelf life of the food being pasteurized.

• Cooling method:

  Similar to how the heating method can vary, the cooling method used in a tunnel pasteurizer may also differ. It can be cooled down using ice water, ambient water, water spray, or air.

• Material:

  Tunnel pasteurizers are usually made out of stainless steel 304 or 316L, which makes them rustproof. The SS304 is adequate when there are no harsh environmental factors. On the other hand, the SS316L offers greater resistance to corrosion and durability in more extreme situations.

Maintenance

• Regular Cleaning:

  This is perhaps the most important part of maintaining a tunnel pasteurizer. Whatever product lanes/gooey things have been left from the processed food, they need to come out as ASAP. Regularly cleaning the machine will prevent any build-up of bacteria, mold, fungus, or anything else yucky that could have accumulated.

  Always carefully read the manufacturer's instruction manual on how to clean the machine properly, and make sure to use products that follow safe food handling practices.

• Weekly Inspections:

  Depending on how often the machine is used, pasteurizers should be checked at least weekly. Inspect all parts for any signs of wear, damage, or leaks. Pay close attention to belts, rollers, gaskets, pumps, valves, and other important components. Make sure to tighten any loose parts that are fastened and oil any parts that need lubrication.

  Replace anything damaged or particularly worn out to ensure the smooth function of the machine.

Applications of Tunnel Pasteurizers

Food industries mostly use the tunnel pasteurized to process and preserve food products. But they use it in various ways:

• Packaging Preservation: It is mainly used to preserve the integrity of the packaging material of food products. The packaging materials of items like cans, bottles, and cartons are pasteurized using Tunnel Pasteurizers to kill any microorganisms that may spoil the contents or compromise the packaging.
• Packaged Food Pasteurization: Foods like dairy products, juices, sauces, and soups are commonly treated with tunnel pasteurizers. The pasteurization process helps extend shelf life and ensures the safety of consumers.
• Packaged Beverage Pasteurization: Beverages such as fruit juices, soft drinks, beer, and iced tea are often pasteurized using tunnel pasteurizers. The process helps eliminate harmful bacteria while preserving the flavor and quality of the beverage. In some cases, beverages are also subjected to post-packaging pasteurization to ensure product safety and extend shelf life.
• Frozen Food Pasteurization: Frozen food items like frozen fruits and vegetables, frozen ready-to-eat meals, and frozen meat products are also treated with tunnel pasteurizers. The pasteurization process helps maintain the nutritional value and quality of the food products while reducing the risk of foodborne illnesses.
• International Food Export: Many countries require pasteurization of specific food products for international export. Tunnel pasteurizers are commonly used in food processing facilities to meet export requirements and ensure compliance with international food safety standards.

How to choose tunnel pasteurizers

When purchasing a tunnel pasteurization system for food and beverage processing, buyers need to consider important aspects to ensure that it will meet their unique needs.

• Product compatibility and capacity

  Check if the materials the tunnel is made of are compatible with the products being processed. Look for pasteurizer components that can efficiently handle specific production volumes to accommodate growth without causing bottlenecks in the production line.

• Modularity and flexibility

  Consider tunnel pasteurizers with modular designs and adjustable parameters. Such machines allow changes to be made quickly to accommodate different product varieties, packaging formats, and production schedules, thereby reducing downtime.

• Automation and control

  Consider pasteurizers equipped with advanced automation and control systems that enable precise monitoring and regulation of pasteurization parameters such as time, temperature, and pressure. These systems minimize human intervention, enhance process consistency, and ensure compliance with food safety standards.

• Energy efficiency and sustainability

  Look for features like heat recovery systems, energy-efficient burners or heaters, and programmable logic controls (PLCs) for optimal energy utilization. In addition, consider those with recyclable materials to contribute to sustainability initiatives and reduce environmental impact.

• Safety features and compliance

  Check safety features like emergency shutdown systems, safety interlocks, and operator safeguards to minimize the risk of accidents and ensure personnel safety. Also, consider pasteurizers complying with relevant industry standards and regulations. Such machines have certifications indicating adherence to safety and quality benchmarks.

• Maintenance and support

  Consider the maintenance and support requirements of the pasteurizer selected. Research the availability of replacement parts, technical documentation, and training resources. Select machines that have strong after-sales support networks to ensure long-term system performance and reliability.

• Cost-effectiveness

  Consider cost-effectiveness by evaluating the initial purchase cost, operating expenses, and potential return on investment (ROI) from increased efficiency, productivity, and product quality. Conduct a thorough cost-benefit analysis to make an informed decision that aligns with budget constraints and financial goals.

Q&A

Q1: How are tunnel pasteurizers different from other pasteurizers?

A1: Tunnel pasteurizers are distinct from other pasteurizers, such as tubular, plate, HTST, UHT, and batch pasteurizers, because they employ a continual heating and cooling process rather than a batch mode.

Q2: What materials are used to manufacture tunnel pasteurizers?

A2: The primary materials used to manufacture tunnel pasteurizers include food-grade stainless steel, carbon steel, and alloy steel.

Q3: Is customization available for tunnel pasteurizers?

A3: Yes, many manufacturers provide customization options for tunnel pasteurizers. This may include modifying the size, capacity, or configuration of the machine to meet specific production requirements. Manufacturers may also offer additional features or integrate the pasteurizer into existing production lines. Corporations can discuss their unique needs with the manufacturer and explore customization options.

Q4: Can purchasers get a warranty on the tunnel pasteurizer?

A4: Yes, buyers can typically obtain a warranty for the tunnel pasteurizer. The warranty period and coverage details may vary depending on the manufacturer's policies. A warranty may cover defects in materials and craftsmanship, as well as maintenance and repair services during the warranty period.