Choosing an Industrial Autoclave: What to Look For
Industrial Autoclave is a device designed for large-scale production of canned goods. These systems can handle both glass and metal cans, as well as products in flexible packaging.
What is the Purpose of an Autoclave?
How Does an Autoclave Work?
The sterilization process occurs through the principle of a steam bath. What does this mean?
In a hermetic vessel filled with water, the necessary product is placed. Increased pressure is then created within the vessel. As a result of this process, the boiling temperature of the liquid increases from 100°C to 120-130°C. It is important to note that the temperature throughout the chamber is uniform.
This allows all pathogenic bacteria to be killed while simultaneously cooking the product. The sterilization time in the autoclave depends on the technological process and user settings.
After this, the power is turned off and the product is naturally cooled to the specified parameters.
Safety Measures
Since servicing and operating industrial autoclaves involves high-risk tasks, all servicing personnel must have the appropriate certifications (work with pressure vessels, electrical safety group, operation of pressure equipment, etc.).
Technical and organizational measures must include the following:
1.
All manometers and thermometers must be calibrated.
2.
Insulation resistance measurements, “phase-neutral” loops, and grounding circuit checks must be performed.
3.
All metal parts must be grounded.
4.
The room where the autoclave is installed must be equipped with an automatic fire suppression system.
5.
The installation site of the autoclave must be well-ventilated, and in case of a fire, all air conditioning and ventilation systems must be turned off.
To ensure continuous operation of the autoclave production line, it is better to supply power from two independent sources (e.g., a generator and a centralized power supply).
The installation and commissioning of the equipment should be carried out by a specialized installation organization with the appropriate certificates and permits.
Design Features.
An industrial sterilizer for jars consists of the following components:
- Programmer (control panel). Used for setting temperature, pasteurization time, and pressure readings.
- Basket (container) for loading the product.
- Automation system for the production process
- Automation system for the production process
- Electric motors designed to move (pump or rotate) the prepared product.
- Temperature sensor (automated temperature control).
- Pressure sensor (automated pressure control).
- Heat exchanger for regulating the temperature mode.
- Water supply system. Provides water circulation in the system
These devices are also categorized by loading type into vertical and horizontal.
Advantages of Industrial Sterilizers
- Structural Execution. High-alloy stainless steel up to 10 mm thick is used for the walls and up to 20 mm thick for the lid and bottom in the production of industrial autoclaves.
- Compliance with European Quality Standards. Each unit undergoes a series of tests after manufacture, including weld seam leak testing using ultrasonic and radiographic diagnostics, compliance with temperature, pressure, and time parameters as programmed.
- Convenience of Design. Due to the special design of the lid, equipped with a rotating mechanism, loading and unloading of the product can be done without additional special equipment.
- Safety. All industrial autoclaves, in addition to program control of temperature, pressure, and cooking time, are equipped with additional protective means—mechanical safety valves that release pressure in the system in case of automatic control failure.
- Automation. The entire canning process is controlled by an intelligent system, the parameters of which are set during installation.
- Economy. Since the sterilization autoclave operates in a semi-automatic mode, besides saving from producing large batches of finished products, it is possible to minimize the number of service personnel.
- High Level of Control. Some models are equipped with recorders and loggers that allow process monitoring in real-time from any mobile device. It is also worth noting that particular attention is paid to the power of the installed heating elements during the production of the autoclave, as per some GOST standards, the sterilization process must take a strictly specified time at a constant temperature.
What to Consider When Choosing an Industrial Autoclave?
- Type of products being processed (fruits, fish, meat, sauces, etc.).
- Type and volume of packaging.
- Production volume planned per unit of time.
- Operation mode of the facility (shift-based, continuous).
- Presence or absence of a steam production source (boiler room, steam generators).
- Size of the production space.
- Availability of a constant water source and its quality (if high metal content, a water purification system may be needed).
What Types of Industrial Sterilizers Are There?
It is very important for products being pasteurized to move during the process. This helps to more effectively combat pathogenic bacteria and cook the product evenly.
Based on this factor, there are 2 main types:
- Tilting;
- Rotating.
In Which Sectors Is a Sterilizer Indispensable?
Autoclaving is most widely used in the food industry because this technology allows for the preparation of:
- Canned fish;
- Meat pâtés;
- Juices;
- Mayonnaise;
- Canned vegetables and fruits;
- Sauces, etc.
However, this technology is also frequently used in other industries, such as:
- Medical (e.g., sterilization of instruments);
- Chemical (e.g., production of antiseptics);
- Rubber and derivative production (vulcanization);
- Research, etc.
Application in the Chemical Industry
With these boilers, it is possible to carry out:
- Combustion and oxidation reactions;
- Production of cement mixtures;
- Production of aerated concrete blocks;
- Polymer formation;
- Hydrothermal interactions with metals and non-metals;
- Hydration reactions involving catalysts, etc.
Conclusions
After reviewing the advantages, design features, and application areas of industrial autoclaves, it can be said that these devices from “Ukrpromtech” are used in almost every industry.
They significantly accelerate the canning process both in industrial and household scales. The only difference is the output of finished products.
Sterilization in an autoclave allows:
- Canning products in their own juice;
- Cooking compotes, jams, preserves;
- Producing both canned goods and baby food;
- Storing more juice due to the presence of vacuum during the production process;
- Reducing the production time by half.
Buy an industrial autoclave for large-scale canning production on our website. Our managers will help you choose the model you need.
Also read:
- Autoclave Operating Modes
- What is an Autoclave
- Hydraulic Testing of Autoclaves
- How to Use an Autoclave
- How to Choose an Autoclave
