Tubular UHT

The indirect UHT platform from DS Triple enhances the added value to the customer when compared to all other indirect plants on the market.

The new tubular heat exchanger (THE) is designed to be extremely durable and with its modular base it also restricts loss of energy to the environment.

Furthermore, the THE also provides full access to inspect the inside of all tubes in every bundle.

Along with the new design of the THE, DS Triple also introduces the SATIC control system (Patent pending) which enables a continuous automatic control of the temperature balance in the plant. This secures that both the runtime of the plant is optimized, but also that the energy consumption remains at its lowest.

Customer Benefits

  • Robust performance with a solid record for uptime and low maintenance demand.

  • Very low changeover losses due to double balance tanks system as well as the design of the plant.

  • Inline pulsation dampers allow for multiday production runs.

  • Fully effective ACIP warrants long continuous runs without losing time on re-sterilization.

  • An innovative SATIC system that provides:

    • The lowest heat load on the product when compared to any other plant in the market.
    • The lowest environmental impact for this type due to the class leading monitored heat recovery system.
    • Very low consumption of cooling water

Capacity

1.000 – 35.000 kg/h

Product Media

  • Cow and buffalo milk with demanding long shelf life
  • Flavoured milks
  • Evaporated milk
  • Vla and other traditional puddings.
  • Stabilized Creams
  • Plant-based drinks, coffee drinks, tea etc.

Details

The DS Triple type ‘UHT-I’ based on tubular heat exchanger technology is designed with the product quality and the environment in mind

The temperature treatment of the product is a unique design, optimized and cultivated based on deep understanding of the UHT process and its effects on the milk.

The plant is not only designed to have the best environmental footprint in its class but also supplied with the new SATIC system (Patent Pending) which is constantly monitoring and correcting the energy exchange in order to ensure that quality and environmental concerns are addressed.

The UHT-I THE

The plant consists of various heating sections:

U1
The first section in which the product initially enters and is preheated to be homogenized at, importantly, a specific temperature.

Homogenization
The process of conditioning the product through high pressure homogenization has a major importance on the long-term stability of the product.

U2
In which the product is tempered to enter the pre-denaturation Holding tube.

W2
The trim cooler assists in keeping the pre-denaturation and homogenizing temperatures constant irrespectively of the run length.

Pre-denaturation Holding Tube
The product is held at a particular temperature to pre-denature the whey proteins and to ensure that the plasmin inactivation is done in time by the sulphur-containing proteins. The temperature must not exceed 93°C.

U3
The product is heated in the critical temperature range where the whey proteins are denaturing at a higher pace. The design and energy balance in this section is critical to the plant performance.

U4
The product is heated to its final temperature where it is led to the UHT holding tube in a energy balanced section.

UHT Holding Tube
The holding tube ensures the required decimation of the target spores.

The SATIC system (Patent Pending)

The SATIC system is an intelligent system which monitors and corrects the exchange of energy with the aim of keeping it constant to preserve key processing parameters.

Most modern UHT plants rely on water as the medium to exchange heat in the regeneration of heat.

The control of the medium and product balance is very important. In most cases, it is set according to a recipe or simply a setting that is decided upon at commissioning, often, never to be revisited.

DS Triple has developed our SATIC system to ensure a balanced flow of energy throughout the UHT plant.

This means that a DS Triple plant maintains the correct settings, not just as flow of water against a typical product, but  instead it keeps the plant to the set parameters using energy transfer as the setpoint, and thereby provides accurate control without having to go through endless corrections based on trial and error.

Importantly, the parameters are kept stable through-out the run irrespective of changes in the heat-transfer caused during extended runs.

The parameters of the process can be decided by the user and could be homogenization temperature, maximum control of plasmin/pre-denaturation as well as best possible regeneration profile for the plant.

Example 1: SATIC
A DS Triple system equipped with SATIC, where the energy balance is managed and the parameters are preserved. (Note the trim color). The result is control of product quality and energy consumption along with longer, stable runtimes.

Example 2: Non-SATIC
The non-SATIC system, managed. The parameters have slipped, the predenaturation holding tube is no longer effectively helping runtime or plasmin destruction. The energy consumption both for heating and cooling are high due to poor regeneration.

Double Balance Tank System

Setting the standards for low product losses and high productivity:

  • with long duration of runs, CIP is saved and the plant becomes more effective.
  • with aseptic CIP being as efficient as a normal CIP, the need for sterilizations after CIP is considerably lowered allowing for highly increased productive access to the plant.

By choosing our double balance tank system, it will enable the shortest mixing zone possible.

Our Newly Designed Tubular Heat Exchanger

The hygienic design of the THE including all connections and executions is in compliance with and even exceeds the EHEDG standards.

The design provides unhindered access to all tubes in the heat exchangers for visual inspection.

Built-in compensation for the thermal expansion is standard in the design, which allows for a prolonged service life.

With the insert and body being separated it is possible to exchange the tube bundle without having to change the shell.

The THE is designed to fit seamlessly into our contemporary rack system, providing protection against excess heat losses to the atmosphere.

Sterile Water System – reducing the consumption of steam and water to approx. 15% compared to condensate systems

The self-contained sterile water production system sterilizes the lubrication water for the homogenizer:

  • Saves 90% of both water and steam consumption when compared to condensate-based generation of lubrication water.
  • Due to the colder lubrication temperature the piston seals will last much longer in our systems, in some case up to 1800 hours of production before service is needed.
  • Internal pressure and flow control ensure that the system is resistant to variations in water pressure.
  • Integration in the CIP of the plant is available in case of soft water supply not available.

Inline pulsation dampers – allowing for weeklong up-time

A setup with pulsation dampers lends itself to multiple days of up-time:

  • Is cleaned in-line by CIP, no manual cleaning required.
  • Self-contained with no need for complicated systems or make up functions.
  • Positive leak detection with possible use of steam as flush medium.
  • Low maintenance cost based on simple design.