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The pilot retort is a multifunctional test sterilization retort, which can realize sterilization methods such as spray (water spray, cascade, side spray), water immersion, steam, rotation, etc. It can also have any combination of multiple sterilization methods to be suitable for food manufacturers' new product development laboratories, formulating sterilization processes for new products, measuring FO value, and simulating the sterilization environment in actual production.
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1. Put the product into the sterilization retort and close the door. The retort door is secured by triple safety interlocking. Throughout the whole process, the door is mechanically locked. Use the knob or operation screen to select the sterilization method, and download the recipe to the PLC. After checking, start the sterilization program, and the whole process will automatically follow the sterilization recipe.
2. Equip the spiral-tube heat exchanger for the sterilization retort and at the heating and cooling stages, process water in the retort passes through the shell side, while steam and cooling water pass through the tube side, so that the sterilized product will not directly contact the steam and cooling water to realize aseptic heating and cooling.
3. Throughout the whole process, the pressure inside the retort is controlled by the program by feeding or discharging compressed air through the automatic valve to the retort.
4. When the sterilization process is finished, an alarm signal will be issued. At this time, the door can be opened and unloaded. The triple safety interlock ensures that the retort door will not be opened when there is pressure in the retort, thus ensuring safe operation.
5. The uniformity of temperature distribution in the retort is +/-0.5ºC, and the pressure is controlled at 0.05Bar.
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1. Spiral tube heat exchanger
DTS patented tube heat exchanger. Inside tube material is stainless steel 316L, no need to replace the rubber gasket, no need maintenance, corrosion resistance, long service life.
2. Safety interlockManual swing open door with safety interlock.
Option: Space-saving gullotine door with hydraulic driven.
Retorts have intrinsically safe door locking mechanisms with electrical switches interlocked with the internal vessel pressure.
3.Maintenance cycle and time alarm
For main valves, we set the maintenance cycle and time in the PLC, when it arrives, there will be alarm appear to notice.
4. Full automatic linear control systemDTS self-studied patented technology D-TOP system can be sensitive to temperature. It can automatically calculate the pressure changes inside the container according to the temperature. And then automatically adjust the pressure inside the retort to get the pressure balance between container internal and external. So it can prevent the package's deformation, keep the package shape. Pressure was controlled in + / - 0.05 bar with compressed air intake valve and exhaust valve.
5. Double pressure control
Two pressure sensors work at the same time, contrast each other, for real-time monitoring of pressure. When there is a failure, another work automatically, to ensure normal operation of equipment.
6.Heat distribution and Heat penetration (Optional)Good heat distribution result is the basis of the retort, before using the retort for sterilizing the product, heat distribution must be carried out. And as for the product process, we need to do the heat penetration to find the exact sterilization process instead of cooking too much or less. It means we can find the F0 according to the logger's data. DTS has the loggers to do these tests, we bought from America TMI, we can send engineers for this service.
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| Model | Effective diameter | Effective length | Dimension | Qty of food baskets | Design Temperature | Design Pressure | ||
| L | W | H | ||||||
| DTSE/07-1 | 700 | 500 | 2204 | 1706 | 2045 | 1 | 147ºC | 3.5bar |
| DTSE/09-1 | 900 | 600 | 3323 | 1800 | 2584 | 1 | ||
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1. Accurate temperature control, excellent heat distribution
The temperature control module (D-TOP system) developed by DTS has up to 12 stages of temperature control, and the step or linearity can be selected according to different product and process recipe heating modes, so that the repeatability and stability between batches of products are maximized well, the temperature can be controlled within ±0.5ºC.
2. Perfect pressure control, suitable for a variety of packaging forms
The pressure control module (D-TOP system) developed by DTS continuously adjusts the pressure throughout the whole process to adapt the internal pressure changes of the product packaging, so that the degree of deformation of the product packaging is minimized, regardless of the rigid container of tin cans, aluminum cans or plastic bottles, plastic boxes or flexible containers can be easily satisfied, and the pressure can be controlled within ±0.05Bar.
3. Highly clean product packaging
The heat exchanger is used for indirect heating and cooling, so that the steam and cooling water are not in contact with the process water. The impurities in the steam and cooling water will not be brought to the sterilization retort, which avoids the secondary pollution of the product and does not require water treatment chemicals (No need to add chlorine), and the service life of the heat exchanger is also greatly extended.
DTS has experienced thermal verification experts and is a member of IFTPS in the United States. It fully cooperates with FDA-approved third-party thermal verification agencies. The experience of many North American customers has made DTS familiar with FDA/USDA regulatory requirements and cutting-edge sterilization technology.
4. Energy saving and envirnmental protection
A small amount of process water is quickly circulated to quickly reach the predetermined sterilization temperature.
Low noise, create a quiet and comfortable working environment.
Unlike pure steam sterilization, there is no need to vent before heating, which greatly saves steam loss and saves about 30% of steam.
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1. How to install and maintain the machine?
The retort will be tested at the factory, and will try to ship without disassembly. All pipeline have number and identification, as shown in the picture. Also, we will provide remote service system, through which our engineers can guide and train in real time.
2. Are you a factory or a trader?
DTS is one of the most influential suppliers for food and beverage sterilization manufacturing industry in Asia. We have highly experienced and talent mechanical engineers, design engineers and electrical software development engineers to provide the best products and services as well as excellent working environment for our customers
3. What shall we do if breakdown occurs?
Please inform us once the breakdown occurs. During warranty period, if breakdown occurs, we shall respond in time after receiving the notification of the buyer. We shall handle failure over the telephone/real time video according to the buyer's requirements.