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CFB20504 Food Process Engineering

Laboratory 2: Thermal Processing of Food

Ultra-High Temperature (UHT) Sterilisation by Steam Infusion

Objectives

1. Familiarise the boiler operation as energy supply for UHT equipment

2. Quantify the UHT process parameters
3. Analysing the effect of UHT on physical properties of food

Introduction

Thermal treatment is an approach to preserve food products. Pasteurisation is one technique of thermal treatment
which is widely being used to prolong the shelf life of food product. The aim of pasteurisation is to reduce the
microbial numbers to a safe level and not to kill it. Pasteurisation inactivate enzymes and kill relatively
heat-sensitive microorganisms that cause spoilage with minimal changes in food physicochemical properties. The
purpose of thermal treatment mostly relies on the pH of the food. For low-acid foods (i.e pH>4.5) pasteurisation is
for destruction of pathogenic bacteria. Other purposes of pasteurisation in relation to pH of food are given in
Table 1.

Table 1: Purpose for pasteurisation for different foods (Handbook of Food Preservation, 2 nd Edition)

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Generally, to achieve desired pasteurisation conditions involves a combination of time and temperature such as
heating foods to relatively lower temperature at a longer time. Alternately, pasteurisation can be done through
higher temperature and shorter time. Test to evaluate effectiveness of pasteurisation process include colorimetric
tests, rapid enzymatic assay (Alkaline phosphatase, ALP) and determination of redox potential (in citrus juices).
Common type of pasteurisation are:

1. In-package pasteurisation- heating to sterility level is not required. Gradual change in temperature is
preferred in some containers.
2. Pasteurisation prior to packaging- preheating. Suitable for heat-sensitive foods.
3. Batch pasteurisation- low temperature short time process
4. Continuous pasteurisation- high-temperature-short-time (HTST) process

Ultra-High-Temperature Pasteurisers (UHT)

UHT pasteurisation takes place at ultra-high temperature as high as 131oC compared to the normal pasteurisation
that is achieved at 72oC for 15 seconds. In order to arrive at such a high temperature in short time, high temperature
and pressure steam is either injected or infused into the food mass. The food is then flashed in a vacuum vessel
such that the same amount of water as the amount of steam infused is removed. UHT treatment is desirable
because of its efficiency to reduce greater amount of microbial growth even its effects on ice-cream texture.

Although pasteurisation is a mild heat treatment, deterioration of pasteurised food is inevitable. Quality of
pasteurised foods may reduce in flavour, aroma and vitamins. Colour changes in juices and milk are not because
of pasteurisation but because of enzymatic browning or homogenisation. Figure 1 to Figure 3 are the schematics
for the UHT unit.

Materials and Equipment

1. Milk powder 5. UHT Pasteurisation unit

2. Water 6. Boiler
3. Tintometer
4. Viscometer

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Procedures

A (Boiler operation)

1. Open the steam valve and all valves in the water feed line (ensure the feed water pump is primed).
2. Switch the door isolator to the ‘ON’ position.
3. Ensure the boiler selector and all tank elements are ‘ON’. Turn the feed water pump to the off position.
4. Open the boiler blowdown valve and lower the water level in the boiler until the low water alarm reset button
illuminated and triggered (sound).
5. Close the blowdown valve. Turn the feed water switch to ‘ON’. The feed water pump should start and restore
the water level to the normal position and stop.
6. Press the low water level reset button. The illuminating light should disappear and the audible alarm should
cease. Elements should re-energise. The elements selector switches should illuminate.
7. Boiler is now ready for use. The on/off steam pressure controller will control the on/off cycle of the elements
once the boiler is operating.
8. The low water relays, automatically maintain level of water in the boiler (and tank if fitted) and will immediately
shut off the power to the elements should the water level fall to an unsafe level.
9. The element switches situated on the control panel enable elements to be switched on/off independently to
meet steam requirements.
 When the low water level alarm sounds, elements that are energised should de-energise and the element
selector switches should disappear.

B (UHT operation)

1. Ensure that all on/off valves are closed initially. Open valve (29) to allow compressed air to the pressure
regulating valve (20). Adjust the pressure on gauge (P4) until it reads 5 bar.
2. Feed tank (A) can accept a batch of 2.0 litres of process fluid. Start by using de-mineralised water so that the
running conditions can be approximated. Pour water into the feed tank after removing the filler plug. This plug
must not be removed if vessel is pressurised as indicated on pressure gauge (P1). Valve (16) is designed to
exhaust any pressure in (A) when moved to allow the plug to be lifted out. Make sure the plug is firmly replaced
before operating valve (16) to re-apply pressure. The air pressure on this vessel determines the throughput
rate and this is varied using hand wheel on regulating valve (22). The initial setting will be 1 bar above the
pressure required in the steam vessel (C).
3. Carefully open valve (28) which will admit steam to the pressure control valve (27). The steam pressure in
the vessel (C) determines the process temperature and valve (27) will be adjusted to suit requirements but this
can be set initially at 3 bar (gauge P2). Steam will enter the vessel (C), some will vent through orifice (K)
making hissing sound and the pressure will gradually rise to the adjusted value.

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4. Open valve (2) using MANUAL SELECT button on the control console. Steam will pass through orifice (E) to
the vacuum chamber (F).
5. Open valve (19). Check the water is flowing into liquid ring vacuum pump and switch on the pump. Valve (19)
should be carefully adjusted to allow a reading of approximately 100mbar on gauge (P3). Carefully open
valve (8).
6. Set the process timers on the control console to:
HOLDING TIME- 0.40
PROCESS TIME- 010 sec
DRAIN TIME- 05.0
Close valve (2) before initiating cycle. Press the PROCESS START button to begin the process.
7. Samples are collected in vessel (F) and this can be disposed of by first closing vacuum valve (8) then open
valves (12) and (9) then open valve (3) and carefully (4)-the sample will pass through the cooling coil and out
through valve (4) to waste.
8. Close all on/off valves again except (19), (28) and (29). Release any pressure in (F) through the discharge
system valves (3) and (4) before opening valve (8) to reintroduce vacuum to vessel (F).
9. Using MANUAL SELECT switch open valve (2). This will push out any condensate that has collected in sight
glass (D) and steam will continue to push any condensate vacuum vessel (F). This is the STANDBY condition
and now it is possible to regulate the air flow rates. Ensure air pressure of valve (20) is reading approximately
2.0 bar above the process vessel pressure (P2). Open valves (13) and (15) then open valve (17), air will
pass through V13 and V15. Temperature will fall and fall steady. If temperature DECREASED during run,
open valve (18) slowly. Closed valve (17) sufficiently to return the temperature to its original value. Do the
opposite it the temperature INCREASED during run.

C (Analysis of sample)

1. Take a volume of sample and test for colour changes and viscosity.

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Fig 1: UHT/ Aseptic unit

A- FEED CHAMBER J- PTFE FILTER

B- ATOMIZING NOZZLE K- ORIFICE PLATE
C- STEAM VESSEL L- STERILE AIR FILTER
D- SIGHT GLASS M- STERILE AIR FILTER
E- ORIFICE PLATE N- ELCB SWITCH
F- VACUUM CHAMBER P- PRESSURE GAUGE
G- COOLING COIL T-TYPE K THERMOCOUPLE
H- STEAM DRIER V- AIR FILTER
W- DRAIN VALVE NO 1-32: VALVES

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Fig 2: UHT/ Aseptic unit

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Fig 3: PID UHT/ Aseptic unit

Data Analysis and Questions

Using recorded data:

1. Determine the steam temperature used, heated temperature of products and holding time.
2. Compute the mass and energy balance for the process.
3. Evaluate and discuss the effects of thermal treatment onto the physical properties of sample.
4. Elaborate on the efficiency of boiler.

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