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Truly, a great plant with small dimensions…

DS TRIPLEUHT PILOT PLANT

Ideal for:

• manufacturers (dairy, juice and specialty products)

• recearch institutes

• universities

• ingredient suppliers to the food and dairy industry

DS Triple offers unique and flexible pilot UHT systems for manufacturers (dairy, juice and specialty products), research institutes, universities as well as ingredient suppliers to the food and dairy industry.

The plant can be supplied with all current thermal treatment using both indirect as well as direct heating. The plant can be set up for treatments covering the ranges of HTST, ESL and full UHT of low acid and high acid liquid food products ranging from: milk, cream, desserts, puddings, soups and sauces, ketchup, plant based drinks and juice and beverage products.

The objective of the plant is to simulate the industrial production of liquid products using the various technologies to provide best possible scale-up information. The simulation and the data collected is meant to provide manufactures with effective means to ensure repeatability in pilot scale and reliable scalability.

TRULY, A GREAT PLANT WITH SMALL DIMENSIONS

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Through its modular design, the DS Triple UHT pilot plant has been constructed to operate inside as well as outside of a standard plant de-sign, so that a new product can be tested with the plant ‘as is’ and in case of need, in alter-native setups, mostly without having to make physical changes to the plant.

Contrary to common practice, where the pro-cess setup is rigid, this allows development of products that involves changes to the process, creating high value products with very specific functionalities.

Particular effort has been made to ensure that the key elements, such as the tubular heat ex-changer, reflect the physical functionality of the commercial plants.

This has been obtained by a careful balancing of the design of the tubular heat exchanger itself, endeavouring to match the production characteristics in large scale designs by exploit-ing the possibilities varying the flow of media and product in order to calibrate the heat ex-change capacity of the individual sections.

Once the temperature profile has been deter-mined, possible product changes due to heating or cooling conditions can be determined and a root cause analysis can narrow down margins to be designed into the process, be it ingredient parameters or process related parameters.

The four heating sections are designed with in-dividually controlled heating circuits to allow for maximum operation flexibility and correctional interference in the initial runs. This will, in turn, allow for optimization by analysing and making use of the collected data.

The cooling sections are similarly designed with individual circulation circuits that enable close repeatability of any commercial UHT plant as well as freedom to alter capacities.

All water circuit flows and temperatures are individually and automatically controlled.

It is important to notice that the final cooling section is made with recirculation of the me-dia in order to facilitate a gentle and effective cooling of high viscous products to avoid the detrimental effect of ‘freezing’ the product on the cooling surfaces of the heat exchanger.

The A-platform of the DS Triple UHT pilot plant is based on the tubularheat exchanger principle with further ability to add additional process options such as but not limited to:

• Holding cell module (30 – 300 seconds holding)

• Deaerator module with flavour recovery technology

• Plate based HTST and UHT capability

• Steam Infusion for temperatures up to full UHT treatment

• Steam Injection UHT temperatures up to full UHT treatment

The plant is as default designed for a capacity from 100 – 150 l/h. However, to provide users the ability to resemble flow conditions, veloci-ties, turbulences and plant residence times as they typically exist in commercial tubular milk UHT plants, the pilot plant capacity can be ad-justed to operate at up to 250 l/h.

The homogenizer is in aseptic designed, which allows for both upstream and downstream ho-mogenization. The machine is equipped with a two-stage homogenization arrangement, capa-ble of providing up to 350 bar pressure.

FLEXIBILITYSHOWS THE WAY

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All individual plant sections are connected to the centrally positioned flow plate, which allows for an extensive range of configurations where switching from one setup to another is simple and easily achieved by its logical and concise design.

To counter the issue of thermal losses the flow plate is shielded from heat loss, as it is inte-grated with the tubular heat exchanger and enclosed on the front side once it has been set up.

The plant consists of a significant number of heat exchanger modules in 3 m. length. A specific re-quired heating surface area can be freely selected at any of the 7 individual tubular plant sections to match any unique heating surface area require-ment.

The plant is equipped with two balance tanks, each holding 30 litres of product. The two tanks, both fitted with a small agitator, provide virtually loss free transition from water to product and reverse. An eccentric screw pump ensures high-pressure capability and reliable/stable flow for both high and low viscosity products with a minimum of shear.

PLANT OPERATIONAND FUNCTIONALITY

Balance Tanks

Infusion Chamber

Steam Injection

Flowplate

Flash Chamber

Tubular Heat Exchanger Modules

Homogenizer

Multi-touch Screens

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PLANT CONTROL SYSTEM

The plant is based on automatic control, en-abling full reporting from recipe throughout log-ging of all process parameter of each test run.

The management of the plant is facilitated by an unique dual intouch operator station mount-ed strategically at the pilot plant panel to pro-vide the perfect ‘cockpit experience’. This allows a close monitoring and effective management of the plant during runs with even the most complex products.

The PLC software provides for fully automat-ic control and monitoring of all instruments and actuators at the pilot plant. The software consists of pre-tested modules for automatic operation, regulation, monitoring, alarming and operator dialogue. The software is tested and tailored for optimal commissioning and opera-tion of the plant.

The software includes:

• PPE Events for MIS system (PPE: Production Performance Events)• Automatic modules control• Monitoring procedures• Interlocks

The operator software for the system is developed in a user-friendly manner which ensures an effec-tive operator dialogue during operation as well as monitoring of the plant at two large 21,5” multi-touch screens.

The following operator dialogue facilities are avail-able:

• Detailed mimic displays showing all “controlled” items in the process plant • Process overview displays • Operator displays for start/stop of process programs • Component status in pop-up window faceplates • Alarm monitoring displays

Having two monitors at hand will provide the oper-ator with a perfect platform for easy and fast plant control while at same time providing an amazing overview on all process parameters.

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Focus on SafetyDesigning a plant which is safe and easy to operate whilst simultaneously truly complying to all relevant European safety regulations and guidelines

is a primary focus point and driver for DS Triple.

Optimized for Service and MaintenancePractical easy and safe access to the plant for service and

maintenance has been an equal important focus point during the design phase.

Innovative plant designDS Triple has come up with a new design that reverses the

traditional way of building pilot plants, by installing the service circuits and pumps along with the relevant valves col-lectively at the back allowing safer, better and easier access

to all important parts of the plant. This ensures that the plant truly adheres to CE marking and provides for a favourable working environment for both operators and technicians.

FUNCTIONAL DESIGN/ SERVICE ACCESSIBILITY

Through innovative designs, detailed understanding of process needs, and precise engineering; our systems will simply deliver more to your business:

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• Offers the highest possible level of flexibility regarding plant configura- tion

• Provides a test production of a very wide range of products from low acid to high acid, from low viscous to high viscous

• Easy and reliable to operate with an automatic control system. A high level of repeatability

• Dual operator station with 21,5” multi-touch screens

DS TRIPLE UHT PILOT PLANT BENEFITS

Remarks in regards of general component standard

As a free independent provider of UHT sys-tems from pilot to commercial UHT units to manufactures all over the globe, DS Triple™ may select any type of pumps, valves, ho-mogenizers and instruments in accordance with the preferences of the end-user.

DS Triple A/S · Frichsvej 178600 Silkeborg · Denmark

Tel: +45 87 221 111mail: sales@dstriple.dk

• Automatic monitoring and display of all process data in a user-friendly manner

• Nominal flow capacity 100 l/h with the ability to process up to 250 l/h on liquid milk products

• Skid mounted and tested unit with a very fast installation and commis- sioning at site

• AISI 316L on all product contact surfaces

• Danish quality throughout! From design to construction and commissioning.