Technical Information

Main Pasteuriser Construction

Consists of an insulating core (sides and base), surrounded by resin bonded timber sheeting, overlaid with a double 450 gram layerof fibreglass/resin ,with a topcoat of coloured resin to finish.for durability.  The lid consists of resin bonded timber sheeting overlaid in the same manner as the main body of the unit.
 An externally mounted pneumatic ram can be added as an option to hold the lid up, and to allow easier opening and closing.
Removable mesh floor panel covering the heating elements to allow for efficent cleaning.

3 x 3KW heating elements controlled by a thermostatic programmer with safety  trips  in the control box. An alarm and timer module are incorporated which will activate upon reaching the set temperature, and upon completion of the set time of pasteurisation.

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Temperature Controller

A variable timer (from 0- 60 minutes) is used and set inside the control box, so that it cannot be  'accidentally' mis-set. A full guide on how to set the system will be included with the pasteuriser. In short a temperature is set, with a +/- allowance. This can be set up from the factory if required  ready for immediate use. Once the temperature is reached then the timer is set into operation for the required preset time, (the user is responsible for setting  the timer operation for the required period).


Although our temperature probes are very reliable we do however as good practice  advise that the inbuilt temperature prope  is tested against a 'known' temperature probe periodically i.e. testing that both have the same readout just to make sure  that it is functioning correctly.







Electrical System (3 Phase & Single Phase Versions)

A shielded power cable and temperature probe goes from the heating elements to the control box where an isolation switch is located. Power & cabling from  thepasteurisers  control box is to be completed at customer on site by a qualified electrician and is to be wired in to a suitable & protected main board.






  Electrical Requirements

Single Phase Version
Single phase variants are not designed to be used with a domestic plug, but must be hard-wired in to protected circuits at the main-board by  a suitably qualified person.
Three Phase:
These must be connected from the pasteurisers control box to the releveant connection point  by a suitable qualified electrician.
It is the  buyer/users responsibility to ensure that all local electrical compliance and requirements  are appropriate for their own circumstances.

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Wheeled Base

Constructed from 40 x 40 x 5mm angle steel, welded to 40 x 40mm steel legs, painted black.


Lockable wheels for movement and security.


Drainage

A drain is incorporated in to the base of the pasteuriser for removal of water.


Cleaning

Periodically the water should be emptied and changed based on, 
1. Mineral build up (as steam evaporates it will leave behind the mineral deposits which will eventually make the bottles dirty)
2. Contamination (if any product is spilt, or bottles explode in the pasteuriser then it will start to smell)


Tips

NEVER USE THE PASTEURISERS WITHOUT  THE ELEMANTS COVERED IN WATER


When finished pasteurising at the end of a shift leave the lid of the pasteuriser up as this will allow the pasteuriser to cool down. Due to the quality of construction the pasteuriser is extremely well insulated, which means that the pasteurisation water as it cools  is at ‘danger zone’ temperatures for microbiological build up for many hours. In our experience it will take ~12+ hours to drop from 70C to 45C with the lid closed. We would also recommend adding a very small amount of chlorine bleach to the water to kill any microbial growth at the start and end of each shift of use of the pasteuriser.

With the triple unit a power saving tip 
Two of the 3 units can be used to pasteurise while the 3rd is used for peheating and  after cooling  of the bottles thus saving on power usage, and speeding up the time to pasteurise and if 3 are needed they are there to accommodate the extra throughput and not hold up the bottling process!!!







Temperature Rise of Water

50°C rise in 100 litres of water takes 6 hours at 1 kw, therefore if we have a 3 Kw heater to raise the temperature  by 50 degrees it would take 2 hours.
A   40°C rise in 100 litres would take four-fifths the time at 3kw, or 96 minutes.
with the same heater. 50 litres could be heated through 40°C in half this time, 48 minutes, and so on.


Our standard large pasteuriser has 3 x 3 kw water heaters = (kw)


An example with our large pasteuriser from cold start with the pasteuriser holding approximately 120 litres of water at a  temperature at 16º C and with 8 baskets of 750 ml chilled  carbonated bottles (approximately 84 litres of liquid and cold glass bottles!!), with water up to the bottle fill line, equates to approximately 200 litres to heat through plus the cold bottles. This took  100 minutes to reach  over 71 º C .
 A temperature rise of 0.5 degrees per minute were left in for the pasteurisation period, in this case was 20 minutes. Then taken out  and replaced with new baskets of bottles which took just over 30 minutes to reach the pasterisation temperature and stayed in for 20 minutes.

So you can see the initial time for the temperature rise from cold is longer at the start of the day then the time for the temperature to  get to the required  degrees thereafter. Hence the reason why we switch on the pasteuriser before we need it to get it up to  operating temperature.
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Safety in use

During the heating process, the pressures inside the bottles increase. Occasionally due to carbonation/internal pressures, flaws within the bottle or closure, or incorrect handling during bottling, a bottle or closure may explosively fail. To mitigate the risks of this we recommend always keeping the lid closed when bottles are in the pasteuriser with the exception of when adding or removing them.


Proper PPE equipment should be worn by the operator – this should include a chainsaw/strimmer mesh full-face guard, heavy duty insulated waterproof gauntlets and heavy duty rubber apron.

The pasteuriser should never be operated without water covering the elements by 50mm, or you will destroy the heating elements.

Baskets

We use baskets because it makes it easier to load and unload the pasteurisers.

Of course you will get a lot more bottles in the units if placed loose.  It is a trade off against ease of use and maximum capcity, and lets be honest, we all like an easier life!



Useful Links

http://www.redpostltd.com/support/science#PU