How to start Aseptic Bag in Drum Paste Unit?

How to Start an Aseptic Bag in Drum Pasteurization Unit: A Detailed Guide

Aseptic processing is a critical technology in the food and beverage industry, ensuring the preservation of products without compromising their taste, texture, or nutritional value. A key component in this process is the aseptic bag in drum pasteurization unit (ABDU), which is widely used to pasteurize liquid food products such as juices, dairy, and sauces. Understanding the proper startup procedure for this system is essential to ensure safety, efficiency, and product quality. In this blog, we will learn about the steps required to successfully start an aseptic bag in drum pasteurization unit, including safety measures, equipment checks, and process monitoring.

 

What is an Aseptic Bag in Drum Pasteurization Unit?

An aseptic bag in drum pasteurization unit is a specialized equipment designed to sterilize liquid food products by heating them to a specific temperature for a specified period of time before sealing them in sterile containers (usually aseptic bags) under sterile conditions. The primary goal is to kill any harmful micro organisms without altering the essential properties of the product, such as taste, color and nutrients. The unit operates by filling large drums with aseptic bags, heating the contents to a predetermined pasteurization temperature and then cooling it rapidly to ensure that the product remains safe for a longer period of time.

 

Steps to Start Aseptic Bags in a Drum Pasteurization Unit

Starting up aseptic bags in a drum pasteurization unit requires careful attention to detail and a systematic approach. Follow these steps to ensure proper operation.

1. Pre-Startup Checks

• Before starting the pasteurization process, perform the following pre-startup checks:

A. Inspect the Equipment

• Visual Inspection: Check the entire system, including piping, valves and drums, for signs of any damage or leaks. Make sure there are no blockages in the system that could affect flow or pasteurization.
• Check the Aseptic Bag: Inspect the aseptic bag for any holes or defects that could compromise the sterility of the product.
• Sterilization Chamber: Confirm that the sterilization chamber and related components are clean and free of contaminants.

B. Verify System Settings

• Temperature and Time Settings: Ensure that the temperature and time settings for the pasteurization process are correctly configured for the product which will be in the process. Different products may require different pasteurization profiles.
• Pressure Settings: Check that the system pressure is set correctly for the type of product and packaging to ensure uniform pasteurization.

C. Verify Utility Connections

• Steam Supply: Confirm that the steam supply is active and give proper pressure to achieve the required pasteurization temperature.
• Water Supply: Ensure that the cooling system has an adequate water supply for cooling after pasteurization.
• Power supply: Check that the unit is connected to a stable power supply, and ensure that all electrical systems are operational.

 

2. Loading aseptic bags into the drum

• Once the pre-startup checks are complete, load aseptic bags into the drum pasteurization unit.

A. Insert aseptic bags

• Carefully insert the sterilized aseptic bags into the drum. Ensure that the bags are at the correct place and there is no chance of tearing or contamination during loading.
• The number of bags which will take place in each drum should be as per the manufacturer’s guidelines to ensure uniform heating during pasteurization.

B. Check for proper sealing of Aseptic Bags

• After loading the aseptic bags, check that the bags are securely sealed, as any leakage or improper sealing can cause contamination during pasteurization.
• Ensure that the sealing mechanisms in the unit are working correctly, as these will prevent contamination and maintain the integrity of the sterile environment.

 

3. Start the Pasteurization Cycle

A. Activate the Pasteurization Process

• Once after loading all the bags, start the pasteurization cycle by activating the ABDU’s control system.
• The system will gradually increase the drum temperature, heating the product inside the aseptic bags to the preset pasteurization temperature.

B. Monitor Temperature and Pressure

• Continuously monitor both the temperature and pressure in the system during the pasteurization process.
• Ensure that the temperature rises to the preset pasteurization point (typically between 85°C and 95°C for liquid foods) and remains stable for the time period necessary to achieve effective pasteurization.
• Check pressure levels to ensure they are within safe operating limits. Pressure fluctuations may indicate bag malfunction or improper sealing.

C. Process Time

• Pasteurization time is critical in ensuring that harmful microorganisms are destroyed. Generally, pasteurization time ranges from 30 seconds to several minutes, depending on the characteristics of the product and the temperature requirement. The control system should alert operators when the time which will require for pasteurization reaches the operators.

 

4. Cooling the product in Aseptic Bag

• Once the pasteurization process is complete, the product will be in low temperature. Rapid cooling is important to prevent the product from overcooking or spoiling.

A. Activate the Cooling System

• Immediately activate the cooling system after the pasteurization cycle is complete. This usually involves circulating cold water or using a chilling process to rapidly reduce the temperature of the product.
• we should perform cooling in compliance with the manufacturer’s guidelines to maintain the safety and quality of the product.

B. Monitor the Cooling Process

• Monitor the cooling rate to ensure that the product reaches the desired storage temperature as quickly as possible. Typically, the temperature should get down to 30°C or below before storage.

 

5. Final Inspection and Packaging

• Once the product has cooled, the final inspection and packaging process begins.

A. Inspect Bags for Integrity

• After the cooling process is complete, inspect the aseptic bags to ensure they are sealed and have not been compromised during the pasteurization or cooling process.
• Perform an integrity check on the bags, such as a vacuum test, to confirm that no contamination has occurred.

B. Labeling and Storage

• Once the integrity of the bags is confirmed, label them with the required batch information, including pasteurization date, product description, and storage conditions.
• Store the pasteurized product in a sterile environment to maintain its aseptic state until ready for distribution.

 

6. Post-Startup Monitoring and Maintenance

• Even after successfully starting up the ABDU and completing the pasteurization process, it is necessary to maintain a regular monitoring and maintenance schedule:

A. Regular Monitoring

• Continuously monitor the system during operation, ensuring that pasteurization temperature, pressure, and cooling rate remain within acceptable limits.
• Perform regular audits of aseptic bags and drums to ensure they are functioning correctly and without defects.

B. Cleaning and Sanitation

• After each batch, thoroughly clean and sanitize the entire pasteurization unit, including all drums, pipes, and valves, to prevent cross-contamination and ensure the integrity of future batches.

C. Record Keeping

• Document all parameters such as temperature, pressure, pasteurization time, and product batch number. This documentation is important for traceability and regulatory compliance.

 

Conclusion

• Introducing aseptic bags into a drum pasteurization unit is a critical process that requires careful planning, equipment checks, and process monitoring to ensure both product safety and quality. By following the steps outlined, operators can effectively pasteurize food products while maintaining product integrity and preventing contamination. Regular maintenance, vigilant monitoring, and adherence to guidelines are essential for the continued success of the pasteurization process. Whether you’re operating a small unit or a large industrial system, ensuring each step is carefully followed is the key to producing high-quality, safe food products for consumers.

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