FOOD & BEVERAGE INDUSTRIES
HORIZONTAL STEAM AIR RETORT STERILIZER
STEAM AIR RETORT TECHNOLOGY FOR PRESERVATION OF FOOD AND BEVERAGES
- This Technology Helps In Preserving Food, Without Adding Any Additives Or Preservatives, And Increasing The Shelf Life Of Products By At Least 1 Year. There Are Different Varieties Of Retorts Available In The World, But One Of The Most Successful And Cost-effective Variant Is The Steam Air Retort. Steam Retorts Are Perfect For Processing Food Since It Is An Excellent Medium For Heat Transfer. In These Retorts There Is A Mixing Of Steam And Air To Induce An Even Pressured Environment Which Would Be Suitable For Processing Pressure Sensitive Containers Such As Jars, Pouches, Cans, Tins, Plastic Bottles Etc. The Steam Air Retort Works By Ensuring That The Mixture Of Steam And Air Is Mixed In A Uniform Way So As To Ensure Complete Sterilization.
- To Ensure Uniform Temperature Distribution All Around The Chamber, Hospharma Provides A Rotating Fan Inside The Chamber Which Guarantees Uniform Mixing Of Steam & Air & Ensure Proper Circulation & Complete Sterilization. Steam Air Retorts Are Energy Efficient. The System Is Also Provided With A Post Sterilization Water Spray Cooling Facility To Reduce The Product Temperature For Easy & Safe Unloading Process. IT IS A CYCLIC PROCESS COMPRISING OF BELOW GIVEN PHASES :
Venting Phase - In this phase the steam is automatic injected and evenly distributed. The fan agitating air efficiently enables the circulation of uniform steam/air in the retort chamber, which guarantees the correct temperature during the holding period.
Temperature Come-up Phase - In this phase the Set Sterilization Temperature is attained with the continuous injection of Steam inside the chamber & after a certain temperature is reached, the counter pressure Air is injected gradually in the chamber with respect to temp which is controlled by our inhouse developed automated technology. The steam-air mixing fan circulation guarantees uniform steam/air in the chamber.
Holding Phase - In this phase the Set Sterilization Temperature & Counter pressure is attained with the PLC automated injection of Steam & compressed Air inside the chamber. Once the set temp is attained, the holding phase begins where the product is subjected to the set temp for a time period as set by the user. The steam-air mixing fan circulation guarantees uniform steam/air in the chamber & correct temperature during the holding period.
Temperature Reducing Phase - In this phase the Steam injection is stopped & the chamber is allowed to cool naturally & keeping the Pressure intact by addition of counter pressure air. This phase continuous till the temp reaches the mark as set by the user.
Cooling Phase - Cooling in the chamber is facilitated by spraying cool water inside the chamber to reduce the product temp gradually. The addition of cold water is automatically obtained in order to eliminate the possibility of thermal shock and control temperature for ramping down. The PLC Automation maintains and monitors the temperature and pressure inside the retort chamber.
End of Cycle - On completion of the cooling phase the residual pressure is released. The end of a cycle signal assures the operator that the door can now be opened.
FEATURES
- The Counter Pressure Retort reliably kills all commonly occurring microorganisms preventing it from spoiling. Shelf life of Retort products will be 12 months to 24 months in ambient conditions without refrigeration.
- Available in small capacities also based on scale of production and requirement. Compact Design, Portable & Plug & Play system
- Adaptable to treat all kinds of Meats, Fish and seafood, Ready meals, Pet food, Baby food, Milk and dairy products for Food Industries
- Adaptable to treat IV solute injections, Blood derivative in plastic pouches / blood bags, Etc for Pharmaceutical Industries.
- Adaptable to all kind of packaging like Pouches PP/PE/PVC, Metal Cans, Glass Bottles/Jars, Plastic Bottles, Glass Ampoules & Vials Etc.
- Packaging integrity is respected, even for the most fragile.
- Inhouse developed program & with PLC technology to control the sterilization temp & counter pressure air inside the chamber.
- Steam -air mixing & circulation by specially designed bladed Fan provided inside the chamber with mechanical sealing system.
- The Automated system ensure there is no thermal shock to the product & its packaging.
- Inbuilt Electrically Fired Steam Generator provided with all models
- Hygienic design & high-quality finish.
- Highly customized to user requirements.
- HMI & PLC controlled, one touch operation with Minimal operator intervention. Operator only needs to select the right Parameters.
- Sterilization Cycle data printing facility which makes processes highly verifiable. Prints all critical data related to the cycle.
- Guaranteed Uniform Sterilization.
- Unique Carriage with trays design configurations to ensure complete sterilization of products & easy handling.
- Onsite Supervision of erection and commissioning plus training of operators by our qualified engineers
- All Safety related to the pressure vessel like pressure switches, safety valves, provided with utmost importance.
Chamber - The material used for chamber is of heavy duty 316 L / 304 L grade stainless steel Sheets for GMP Model & Standard Models
Doors - The doors are constructed of heavy duty 316 L / 304 L grade stainless steel Solid Plate for GMP Model & Standard Models.
Piping - The pipes and fittings are made up of 316 L / 304 L Quality.
Operating Valves – The Branded Manual/Electric/Pneumatic Valves are made up of Heavy-duty S.S 304 Quality for all models
Mounting & Control Panel – The Sterilizer is mounted on a Tabular Stand along with control panel made up of S.S 304 Quality for GMP Model & M.S quality powder coated for Standard Model.
Trolley & Carriage with Trays – This is provided with all the models to assist with the loading and unloading process. The Loading Carriage with trays are made up of 316 L / 304 L Quality & Transfer trolleys are made up of S.S 304 / M.S Quality Powder Coated with heavy duty castor wheels.
Inbuilt Steam Generator - The Retort Sterilizer is provided with an Inbuilt Electrically fired Steam Generator mode up of S.S 304 Quality to generate its own clean & pure steam to be used in the chamber during the sterilization cycle. It comes with all Safety features like Low Water protection system, Safety valve, pressure switch etc.
Direct Steam Heated - If Inbuilt Steam generator is not opted then customer can provide the clean & pure steam from their own Centralized Boiler which will be connected to the Sterilizer via PRV valve, Strainers & Moisture Traps.
Fully Automatic Touch Screen HMI & PLC operating system.
Cycle phases which can be operated automatically includes Venting, Temp Come Up, Holding Phase, Temp Reduction Phase & Cooling Phase
This control system is based on state-of the art technology programmed inhouse to ensure high precision & highly reliable cycle operation. The PLC control unit ensures a fully automatic operation throughout the entire cycle.
Sterilization Cycle Online printing facility is also available with this operating mode. An Epson Branded Dot Matrix printer is provided along with this system which is connected to the Automation Panel. The printer generator a hard copy printout of the Sterilization cycle which includes information concerning the cycle operation such as the Company Name, Manufacturer’s name, date, time, Batch number, Set Parameters, Temperature, Pressure & other cycle phase information.
Outer Cabinet Enclosure - This Optional Outer Cabinet is opted for elegant & aesthetic look of the Sterilizer. The Equipment is mounted on a tubular stand which would be fitted on S.S 304 /M.S Quality Frame & there would be S.S 304/M.S Quality Powder Coated cabinet Enclosure covering the whole machine with maintenance doors on the sides. The S.S Cabinet would be Mirror/Matt Finished as per the customer’s requirements
Air Compressor - This optional Accessory is provided along with the Equipment to provide pressurized compressed air to operate the Pneumatic Valves of the Sterilizer in case the customer doesn’t have a centralized compressed air line available on site. The Compressors are available in many variants like Oil Free, Noise Free, Compact, Reciprocating, Etc.
PRV Line Assembly - This optional accessory is provided along with direct steam heated Sterilizer Sterilizers where the steam is directly provided from the customer’s centralized Boiler. This system includes PRV Valve, Strainers, Moisture Traps & Pressure Gauge.
TABLE SPECIFICATIONS
| MODEL | SIZES & CAPACITIES | DIRECT STEAM HEATED MODELS | |||||
|---|---|---|---|---|---|---|---|
| SAR-36 | SAR-60 | SAR-90 | SAR-135 | SAR-240 | SAR-540 | ||
| Chamber Dim. MM | D | 400 MM | 500 MM | 750 MM | 900 MM | 1000 MM | 1500 MM |
| L | 900 MM | 1200 MM | 1200 MM | 1500 MM | 2400 MM | 3600 MM | |
| Chamber Vol. | Lit. | 100 Liters | 200 Liters | 500 Liters | 900 Liters | 1800 Liters | 6000 Liters |
| CIRCULATING FAN | YES | YES | YES | YES | YES | YES | |
| WATER SPRAY COOLING SYSTEM | YES | YES | YES | YES | YES | YES | |
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