THERMAL PROCESSING

TRAINING

Module 10. Continuous Rotary

(Agitating) Retorts
Thermal Processing for Meat and Poultry
Products Training

USDA
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1
 Introduction

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 Uses steam as the heating medium

 Continuous container handling
 Intermittent product agitation
 At least two shells
 Configuration will vary

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 Typical Arrangements of Continuous Rotary
Retorts

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• ATMOS. COOLER
•
ATMOS. ·COO.Lf-R
_ _ _ _....,..,, 1 t,,II- -
A MtJS. OR PRESS.
COOl.fR PRESS., fl'~ESS.
COOLER COOLB!
PRESS. COOKER
OVERHEAD
fEEl> ELEVATOR PRESS. COOKER

cvP FEEt>

• •
I

TWO SHELL LINE ARIMNGEMENT 'TH~f,ESKBU. llNE ARRANGEMENT THREE SHEU. LINE ARitiiNGEMEN

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THERMAL PROCESSING
transfer valve
TRAINING

discharge
valve

shell
reel Inlet valve
spiral T

4
steps
THERMAL PROCESSING STE:RILMATIC
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INFEEO

DISCH.t;FIGE

CANS IN CARRIER STEPS

ARE FORCED THROUGH
RETORT BY SPIRAL T’S
5 WELDED TO RETORT
SHELL IN
 End View of Continuous Rotary Retort

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 Retort Description

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 Rotating reel with steps to hold containers

 Spiral T attached to shell to move containers
through

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 Spiral T

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 The Reel

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 Number of Reel Steps for Can Diameters

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Steps Per Turn of

Can Size Reel
211 56

300-303 47

307-401 42

404 35

603 24

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 In-Feed

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- ___ - .~
I
.J~
~

.......

~~ ·
CUP FEED DIRECT -
T9 FEEiD
(Wl,Il:LEREE RO LLER VALVE
FEED.
ER)

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 Transfer Valve

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 Retort Description

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 Advantages:
• Short process time
• Continuous input
 Disadvantages:
• Extra critical factors
• Container size limits
• Larger investment than a still steam retort
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 Retort Installation/Operation - Steam Inlet

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 Multiple feeder lines to trough at bottom of

shell
 Must be large enough for proper operation

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 Retort Operation - Condensate Removal

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 Required to remove it
 Condensate interferes with container rotation
 May reduce product agitation leading to under
processing

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 Retort Operation - Condensate Removal

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Must:
 Open drain for sufficient time during venting
 Provide for continuous or intermittent removal
 Have bleeder arranged for observation
 Be observed and recorded frequently

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 Retort Operation - Pressure Cooling

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 May be needed to prevent container distortion

 Cooler pressure should be slightly below
cooker pressure so water does not enter
cooker

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 Rotational Speed and Process Timing

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 Reel speed must be set as stated in process

schedule before containers enter retort

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 Rotational Speed

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 Determines process time

 Affects product agitation
 Faster than calculated time results in shorter
process time
 Slower than required minimum speed reduces
agitation

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 Rotational Speed

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The rotational speed must be:

 Specified by process authority in the process
schedule
 Checked and adjusted when the retort is
brought up to temperature and determined
and recorded at intervals not to exceed 4
hours

Notice to prevent unauthorized changes

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 Rotational Speed

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FREE
Ir\
~
0
CONTAINER CARRIED
ROTATION SLIDING BY REEL
21 ROTATION
 Intermittent Agitation

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Process Considerations:
 Intermittent agitation provides more rapid
heating and cooling when compared to no
agitating
 Container rotation is divided into carried,
sliding and free phases

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 Intermittent Agitation

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 Product and headspace bubble mix during

rotation
 Solid pack items like beef stew and chili do
not benefit from agitation
 Brine-packed items, soups and sauces may
benefit by faster heating and shorter
processes
 Dependent on headspace, consistency, reel
speed and fill-in weight

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 Important Critical Factors

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 Condensate build-up
 Headspace
 Consistency
 Reel speed

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 Headspace

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 Area not occupied by product

 Critical factor for agitation
 Net or gross headspace

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 Consistency

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 Measure of product thickness

 Thicker product may reduce agitation
 Measure consistency at location specified in
the process schedule and in accordance with
a written procedure, e.g., at the cooking kettle
of filler at 160 F or higher temperature

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 Reel Speed

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27 RETORT REEL TIMING

 Reel Speed

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 For reel speed calculation you need:

• Process time
• Total container capacity of processing shells
• Number of reel steps

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 Reel Speed

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Steps Per Turn of

Can Size Reel
211 56

300-303 47

307-401 42

404 35

603 24

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 Reel Speed

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Calculations
• Reel Speed

RPM = capacity/reel steps x process time

• Cans Per Minute

CPM = capacity/process time

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 Reel Speed

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Seconds for 10 Revolutions of Reel =

10 revs x 60 sec/min x reel steps x process time
Shell Capacity

10 x 60 sec/min x 47 x 14 min = 39.48 secs

10, 000 (303 diameter)

10 x 60 sec/min x 24 x 10 min = 28.8 secs.

5,000 (603 diameter)

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 Initial Temperature (IT)

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 Critical heating parameter specified in the

process schedule
 Measured on containers taken from line prior
to inlet valve

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 Recordkeeping Requirements

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 Critical factors and IT must be measured and

recorded in accordance with the method and
frequency in the written procedure
 Must include reel speed checks

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 Handling Process Deviations

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Retort Jam or Reel Breakdown In-Process:

 Must reprocess, repack and reprocess, or
destroy all containers
 May use emergency still process before
retort is cooled

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 Handling Process Deviations

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Emergency Still Process:

 Obtained from a processing authority, if not
process must be reviewed by a processing
authority
 Must reprocess, repack and reprocess or
destroy containers in inlet and transfer valves
 Records must be kept of actions including the
time the retort stopped and the time retort was
used for the still process
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 Handling Process Deviations

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Alternative Procedures in Case of Temperature

Drop in the Retort:
 < 10°F drop
• Stop reel and use emergency still process on file
• Stop container entry and use emergency
agitating process on file
• Have process evaluated by processing authority
• Empty retort and reprocess, repack and
reprocess, or destroy all containers
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 Handling Process Deviations

THERMAL PROCESSING
TRAINING

Alternative Procedures in Case of Temperature

Drop in the Retort:
 ≥ 10°F drop
• Stop reel and use emergency still process on file
• Have process evaluated by processing authority
• Empty retort and reprocess, repack and
reprocess, or destroy all containers
• Records must be kept of actions
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THERMAL PROCESSING
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THERMAL PROCESSING
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Twin spira ls (Tr11
1
ple available)

Dedicated 1:ine system for high speeds, or sepa­

rated multiple products/can sizes. In addition
delicate products can be run at high speed with
hatf the agitatlon of a single sp'iral.

Different can sizes or products can be introduced into

custom reels. Spirals can be custom designed to handle
different length cans or can be designed to provide
39 different thermal process times to different cans.
 Questions?

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TRAINING

Questions?

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