Sterilizers
- High temperature, high pressure retort sterilizer
- There are three types of retort sterilizers that hot water spray type, hot water storage type and steam type.
We offer the best system for the customers depend on the product type and container shape, production volume and automation correspondence, etc.
- Hot water spray type retort sterilizer(RCS)
- No variation in temperature, and possible to adapt for air-containing container.
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- Hot water spray type retort sterilizer(RCS)
- No variation in temperature, and possible to adapt for air-containing container.
The sterilizer has very high temperature uniformity during the process of warming, heating and cooling, and no variation in temperature.
By performing indirect heating/cooling with a plate type heat exchanger, we prevent contamination from steam and cooling water and safely handle important products.
Features
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1. Heat sterilization by a four-way spray nozzle with uniform and high dispersion.
A four-way spray nozzle placed on each product tray enables heating and sterilization with the same quality at all up/down, right/left and back/forth tray positions.
The direction of the nozzle is clear, and uniform diffusion of hot water is achieved up to the center of each tray.Ideal system minimizes temperature variation inside the processing tank even in large size equipment
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2. Suitable for air-containing containers and glass bottles.
No influence of water pressure due to buoyancy or liquid depth, and even large size equipment can adapt for air-containing containers and glass bottles.
The retort foods in air-containing containers can be sterilized without deforming the container by the air-containing container processing system. -
3,1. Economical in energy saving and water saving type
The amount of holding water is 1/6 to 1/7 of hot water storage type, and the running cost is reduced by using the cooling tower which is standard in the plate heat exchanger.
The use of a hot water recovery system (optional) in large size equipment enables further energy saving and water saving. -
3,2. No secondary contamination
Since circulating water is sterilized with a plate heat exchanger, there is no secondary contamination in the cooling process and no pre-treatment of coolant is required by chlorine or the like. Also, there is no need to worry about contamination from heated steam.
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4. Can be installed anywhere
No hot water tank is required, and because of its lightweight and compact design, it can be freely laid out such as installing on the second floor. It also improves the working environment by reducing noise levels which is difficult to achieve in direct heating.
Dimension, weight and utility
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5. Experienced control technology
Adopting AMMU (Pattern setting instrument) to set and register the planned sterilization conditions for food sterilization (HACCP-compatible). The ideal system to prevent the mistake of the setting operation by calling up the best sterilization condition by the pattern card by one touch, it is possible to correspond from one sterilizer unit to the unmanned operation in the factory (FA System).
Standard functions
Next-generation air-containing container processing system
Air-containing containers are processed with an advanced system.
- Patented next-generation air-containing container processing system (GGG).
A pioneer in the field of air-containing container processing system, Hisaka has been highly praised for a preparation and sterilization achievements of a wide variety of air-containing containers.
Adopting a thermal calculation theory formula based on actual data from further evolved processing systems, and by calculating the temperature of product in the air-containing container, we have been able to simulate subtle changes in the container air pressure, making possible accurate and highly repeatable pressure control.
Features
- Preparation and sterilization without deforming a variety of air-containing containers.
- Software application technology based on heat transfer cultivated from a lot of achievements and data.
Correspond to HACCP
Employing optimal operations to ensure HACCP system is implemented in a rational and efficient way.
Features
Uniform temperature distribution
Demonstration of uniform temperature distribution by FDA registration of Temperature Distribution Studies (Full-load of product).
As shown in the figure below, the sensors are placed on the center of the top, middle and bottom, also in two places of the each corner of the stacked trays, and the temperature is measured at a total of 24 locations in four columns.
Optional
Rolling type
Rolling allows the food in the pouch to be stirred and uniformly heated and cooled in a short time, greatly reducing the processing time and minimizing food quality degradation.
Features
Processing volume (pouch)
Equivalent size of pouch
- Case of stationary type
130 x 170 x 20mm
- Case of rolling type (3kg)
270 x 400 x 50mm
F-value computer
The best solution for the sterilizers.
FVAC-VI is a software and sensor exchanger unit that gathers the data of real time temperature and F-value from product heating sterilization. It is ideal for sterilization management and for the development of new and high quality products.
FAM (Flavor Ace Master)
A comprehensive system that provides improvements in productivity and creativity, as well as quality assurance.
Effectively supporting the production and quality control of food producing systems, the management of operation data of sterilizers, and the document preparation, and useful for the food processing methods, data analysis, and management for the development of the sterilization conditions.
This consists of two types of systems that gathering, monitoring and reporting of processing data and managing standard recipes such as operational and control conditions.
Parameter And Simulation System (PASS)
[Patent No. 6142040/6163590]
Prediction calculation system for product temperature and numerical information
Support for testing and product development
Product analysis
- Analyze product temperature data
Simulating product temperature
- Based on the data, the temperature of the product is predicted from the set ambient temperature.
Calculation of F- and C-values
- Predict the F-value (sterilization) and C-value (component attenuation value) from the predicted product temperature.
- Hot water storage type retort sterilizer(RCS)
- Uniform sterilization is possible in a short time.
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- Hot water storage type retort sterilizer(RCS)
- Uniform sterilization is possible in a short time.
This is a highly versatile sterilizer that not only minimizes temperature variations by changing the direction of water flow, but also can select a rotating type (optional) that can be applied for large size cans and commercial pouches.
Features
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1. Dispersion of uniform water flow
By switching the water flow direction in the sterilization tank, uniform water flow to all directions is achieved.
The ideal system to disperse the water flow to the center of each product tray provides uniform sterilization. -
2. High temperature and rapid processing
By preparing hot water in advance and the heat sterilizing from the high temperature, enable high temperature sterilization in a short time.
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3. Support for the large size cans and commercial pouches by rotating type (optional)
In case of the stationary type, high viscosity foods using large size cans and commercial pouches are difficult to heat sterilize to the center in a short time. By stirring with rotational motion, high viscosity food can be uniformly heated to the center in a short time, and efficiently sterilized.
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4. Compatible with air-containing containers
For the air-containing container, processing with optimal conditions including the preparation temperature of the hot water tank, processing temperature, temperature curve and pressure curve (air-containing container processing system).
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5. Experienced control technology
Adopting AMMU (Pattern setting instrument) to set and register the planned sterilization conditions for food sterilization (HACCP-compatible). The ideal system to prevent the mistake of the setting operation by calling up the best sterilization condition by the pattern card by one touch, it is possible to correspond from one sterilizer unit to the unmanned operation in the factory (FA System).
Dimension, weight and utility
Standard functions
Next-generation air-containing container processing system
Air-containing containers are processed with an advanced system.
- Patented next-generation air-containing container processing system (GGG).
A pioneer in the field of air-containing container processing system, Hisaka has been highly praised for a preparation and sterilization achievements of a wide variety of air-containing containers.
Adopting a thermal calculation theory formula based on actual data from further evolved processing systems, and by calculating the temperature of product in the air-containing container, we have been able to simulate subtle changes in the container air pressure, making possible accurate and highly repeatable pressure control.
Features
- Preparation and sterilization without deforming a variety of air-containing containers.
- Software application technology based on heat transfer cultivated from a lot of achievements and data.
Correspond to HACCP
Employing optimal operations to ensure HACCP system is implemented in a rational and efficient way.
Features
Optional
F-value computer
The best solution for the sterilizers.
FVAC-VI is a software and sensor exchanger unit that gathers the data of real time temperature and F-value from product heating sterilization. It is ideal for sterilization management and for the development of new and high quality products.
FAM (Flavor Ace Master)
A comprehensive system that provides improvements in productivity and creativity, as well as quality assurance.
Effectively supporting the production and quality control of food producing systems, the management of operation data of sterilizers, and the document preparation, and useful for the food processing methods, data analysis, and management for the development of the sterilization conditions.
This consists of two types of systems that gathering, monitoring and reporting of processing data and managing standard recipes such as operational and control conditions.
Parameter And Simulation System (PASS)
[Patent No. 6142040/6163590]
Prediction calculation system for product temperature and numerical information
Support for testing and product development
Product analysis
- Analyze product temperature data
Simulating product temperature
- Based on the data, the temperature of the product is predicted from the set ambient temperature.
Calculation of F- and C-values
- Predict the F-value (sterilization) and C-value (component attenuation value) from the predicted product temperature.
- Steam type retort sterilizer(RCS)
- Direct steam sterilization reduces running costs
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- Steam type retort sterilizer(RCS)
- Direct steam sterilization reduces running costs
The energy-saving equipment that is very high in temperature uniformity and can reduce running costs by sterilizing directly with steam. It has been adopted a lot in the processing of canned products, and can be applying to the air-containing pouch by installing the fan.
- Liquid continuous sterilizer
- Applicable to a wide variety of liquids sterilization such as beverages, milk, seasonings and alcohols.
Selecting the optimal method from plate, tube, spin-injection, and joule for heat transfer elements in order to improve yields and quality, and stable operation.
- Plate type sterilizer(RMS : Liquid continuous sterilizer)
- Preparation, sterilization, extraction and reaction of the food
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- Plate type sterilizer(RMS : Liquid continuous sterilizer)
- Preparation, sterilization, extraction and reaction of the food
The positive pressure operation is performed to increase the pressure on the sterilizing liquid side, and the safety measure against plate cracking is possible.
Features
- Stainless steel, super stainless steel and titanium, etc. are available for the plate material.
- Plate for food use improves yield and allows for long-term operation.
- The use of fluorine resin cushion gasket reduces foreign matter contamination, residual fragrance, and the frequency of gasket replacement.
Applications
| Beverages | Bottled water, water, tea, juice, coffee, soda (syrup), milk, cream, condensed milk, jelly, yogurt, mayonnaise, etc. |
|---|---|
| Brewings | Soy sauce, noodle soup, sake, cloudy sake, amazake, liqueur, wine, whisky, shochu, etc. |
- Tube type sterilizer(RMS : Liquid continuous sterilizer)
- Multi-product production with a wide range of lineup
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- Tube type sterilizer(RMS : Liquid continuous sterilizer)
- Multi-product production with a wide range of lineup
Sterilizers corresponding to the multi-product production for water soluble liquid, high viscosity liquid, solids or fiber containing liquid, etc.
Depending on the conditions such as liquid properties and processing amount, they are supported by a rich lineup of single tube, multi tube, shell & tube, and triple tube.
Features
- Many types of liquid are applicable, and it can be applied to products from low to high viscosity (~10,000 mPa・S), containing solids and fibers.
- Excellent liquid replacement is best for a wide variety of products.
- Easy maintenance due to limited use of gaskets.
- The small wetted area of the gasket reduces the flavoring and residual fragrance.
- Uniform flow realizes excellent detergency, allowing for long-term operation even for products that are easy to burnt.
- Double tube type
- Multi tube type
- Triple tube type
Applications
| Seasonings | Barbecue sauce, dressings, mayonnaise, sauces, ketchup, mash vinegar, amino acids, sesame sauce, miso sauce, noodle soup, pot soup |
|---|---|
| Beverages | Fruit juice, juice, soy milk, juice, tea, sports drink, coffee, amazake |
| Milks | Milk, coffee milk, cream, pudding, jelly |
| Extracts | Meat extract, seafood extract, vegetable extract, soup |
| Others | Health drink and health food |
- Spin-injection type sterilizer(RMS : Liquid continuous sterilizer)
- Direct steam heating system provides high uniformity and efficient heating
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- Spin-injection type sterilizer(RMS : Liquid continuous sterilizer)
- Direct steam heating system provides high uniformity and efficient heating
It is a sterilizer of the direct steam heating system type developed independently.
The system improves the problem of a conventional direct heating system, and it is effective in the liquid that gets the scale easily.
Features
- Instant supply of direct steam while stirring to achieve high uniformity and efficient heating.
- High quality continuous operation without burning or over-heating.
- Self-pressurization enables operation with low-pressure steam.
- The flow rate and pressure can be numerically controlled by controlling the rotation speed facilitating a wide variety of processing.
- Simple structure with excellent cleaning and high maintainability.
Applications
Dessert, soy milk, blue juice, cream, collagen, gelatin, fruit juice, tea beverage, vegetable juice, liquid diet, sesame sauce, raw milk, cheese, etc.
*By flash cooling, it is effective for the flavor improvement.
- Other sterilization equipment
- By using our plate heat exchanger, we contribute the quality and yield improvement of the customer's product that achieves low cost operation through a lot of experiences and reliable technology.
- Plate heat exchanger for food(FX series)
- Food dedicated plate to solve the problem of food production line
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- Plate heat exchanger for food(FX series)
- Food dedicated plate to solve the problem of food production line
Smooth and product-friendly liquid flow through the plate provides uniform heating and quick liquid replacement characteristics.
The electrolytic polishing plate prevents from the scales and burnt, and can be cleaned with CIP.
Features
- Uniform and smooth liquid flow realizes uniform heating and cooling of products, reducing the amount of holding liquid.
- The electrolytic polishing plate reduces the deposition of the scale, allowing long continuous operation.
- Improved cleanability by greatly reducing the number of contact points between plates and preventing from the scales and burnt.
- By realizing the piston flow, the liquid replacement time is greatly shortened, and it contributes to the reductions of the operation time and products loss.
Applications
| Beverages | Bottled water, water, tea, juice, coffee, soda (syrup), milk, cream, condensed milk, jelly, yogurt, mayonnaise, etc. |
|---|---|
| Brewings | Soy sauce, noodle soup, sake, cloudy sake, amazake, liqueur, wine, whisky, shochu, etc. |
Scope of the application
FX series lineup
Note: Please be aware that the dimensions may be changed without notice.
Applicable Material
Plate / SUS316, Titanium
Gasket / EPDM, fluorine resin cushion gasket (TCG), silicon
Development concept
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1.Sanitary
1) No remaining scale after CIP
2) Easy to disassemble and wash -
2.Stable quality and production
1) Ensuring uniform heating history by uniform liquid flow
2) Improvement of liquid replacement efficiency
3) Prevention of scale occurring during Operation -
3.Economical operation costs
1) Complete recovery of residual liquid
2) Reducing Utility load
3) Ease of operation
4) Highly efficient liquid replacement
5) Reducing installation space
Various test data
Introducing the test cases of the liquid sterilizers
- Rapid preparation sterilizer(RIC)
- Sterilizing the food before packaging in high temperature and short time
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- Rapid preparation sterilizer(RIC)
- Sterilizing the food before packaging in high temperature and short time
The foods and its ingredients are rapidly sterilized before packaging (sealing). Selecting either high temperature (above 100°C) sterilization or low temperature (under 100°C) sterilization, the range of applicable products to be very wide and uniformly sterilize any solid food.
Features
- High temperature rapid sterilization (HTST) retains the flavor of food ingredients
- The air which inhibits heat transfer to solids is removed (adopting the original vacuum deaeration system), and applying clean steam directly to the food ingredients, uniform sterilization is achieved in a short time (*patented)
- Dried products can be taken out in dry condition after sterilization
Applications
Marine products such as hijiki (seaweed), spices, boiled/dried young sardines, beans, prepared dishes, etc.
- Lift steamer Z(Fully automated continuous sterilization cooling system)
- Further improvement of quality and work efficiency achieves the costs reduction.
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- Lift steamer Z(Fully automated continuous sterilization cooling system)
- Further improvement of quality and work efficiency achieves the costs reduction.
It is ideal for mass production because uniform heating and cooling of sealed chilled foods can be performed continuously.
Features
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1. Accurate and easy temperature control
The temperature of the heating chamber is precisely and stably controlled by PID control simply setting an arbitrary temperature from 60 up to 100℃ at the control panel.
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2. Significant energy saving
The consumption of steam is about 50% compared with the hot water type, since there is no steam outflow from the equipment and the heat loss is very low.
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3. Shorten warm-up time
Since there is no necessity of boiling water, compared with the conventional hot water type, warm-up time of the equipment is significantly reduced.
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4. Improvement of the factory environment and reduction of equipment and plant maintenance costs
Since there is no steam outflow from the equipment, the temperature and humidity rise in the factory can be prevented even without exhaust fans or ducts, and total cost reduction is possible.
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5. Improvement of the product quality and value
The texture, color and flavor of the product are good compared with the hot water sterilization, and also the surface gloss of the product remains very beautiful.
Applications
Cup containers and vacuum pouches for jelly, steamed egg, egg tofu and boiled beans, etc.
*Main product of Asahi Industry Co., Ltd.
