2019 Adue SYRUP ROOM PROCESS PLANT FOR JUICE PRODUCTION

SYRUP ROOM PROCESS PLANT SUITABALE FOR JUICE PRODUCTION  Check PDF on website to download infos

4000 liter an hour - There are 2x Plants available (so 8000 liters an hour of juice production)

there is a water treatment plnt (12.000 liter/hour)

At the end of the line there is a Flash pasteurizer.

CIP also included.

Can produce yoghurt , ice cream, any beverage.

TO BE HOT FILLED, CAPABLE TO FEED nr. 4 FILLING LINE WITH FLOW RATE 1.500 l/h EACH FOR A TOTAL FLOW RATE OF 6.000 l/h OF FINAL BEVERAGE

Product specification 

In case of ordering, detailed specification of all products are immediately required, if possible together with  products samples. 

The nominal outputs of the proposed plants and machinery are based on the so-called non-problematic  products without major foaming such as fruit juices, fruit juices drinks, milk based products. High viscosity products or strongly foaming products may require reduction of the nominal output of the  proposed plants and machinery. 

Project planning 

The installation of the proposed plants and machinery is done on the basis of an installation plan made by  ADUE in close cooperation with the Customer, and which requires the Customer’s final approval. ADUE will supply the required documentation for the planning stage. 

In case of considerable layout changes, requested after the Customer’s final approval, ADUE reserves the  right to invoice the additional costs to the Customer. 

Room Temperature 

Parameter min. max. Unit  

Temperature 15 35 °C 

Humidity 30 70 % 

If temperature is higher, all control boards must be equipped with Air Conditioning Units against extra cost. 

Ambient Temperature 

Parameter min. max. Unit  

Temperature -15 50 °C 

Humidity 30 90 % 

Commissioning and Start up 

The proposed plants and machinery will be commissioned by ADUE with 3 test productions, together with  fillers, immediately after the completion of erection. 

As soon as laboratory results are available, the start-up phase will be done with products and capacities  specified by the Customer in a 10 – shift production, each shift consisting of 8 hours ( 1 shift / day ).

SUGGESTED WATER CHARACTERISTICS  

1. Drinking water (mains water) 

The drinking water should also be used as cleaning water and product flush water 

The quality should meet the WHO guidelines (stated below) or European EC drinking water directive 

Taste none 

Smell none 

Turbidity max 3 NTU 

Colour max 20 mg/l Pt 

Oxygen demand max 20 mg/l KNnO4 

Total dissolved solids max 500 mg/l 

pH (M,S) 7-8.5 

Total hardness (M,S) 4-7 dH 

Ammonium traces 

Ammonia max 0.5 mg/l NH4 

Iron max 0.1 mg/l Fo 

Manganese max 0.05 mg/l Mn 

Nitrate max 30 mg/l NO3 

Nitrite max 0.02 mg/l NO2 

Sulphate max 100 mg/l SO4 

Chlorine (M,S) max 0.2 mg/l Cl2 

Chloride (M,S) max 30 mg/l Cl 

Aggressive corbon acid max 0 mg/l CO2 

Corbon acid (M,S) 

Total amount of bacteria max 100/ml 

Total amount of 35°C coliform bacteria max 1/100 ml 

Total amount of 44°C coliform bacteria 0/100 ml 

Copper max 0.05 mg/l Cu 

Zinc max 1.0 mg/l Zn 

In addition: 

Design pressure 300 kPa 

Temperature 15°C 

Capacity m3/h: AS PER QUOTATION 

2. Product water is used for reconstitution of product concentrates. 

Product water may not affect the essential characteristics of the product and its minimum requirement should  follow the EC drinking water directive. 

The reference temperature is 20 - 30°C  

This means for example: 

Conductivity max 400 us/cm 

Chloride max 25 mg/l Cl 

Sulphate max 25 mg/l SO4 

Calcium max 100 mg/l Ca 

Sodium max 20 mg/l No 

Nitrate max 25 mg/l NO3

3 Service water to be used as cooling water, sealing water, tower water and boiler feed water. 

There are different requirements for all the different types of service water. 

Special attention must always be taken to hardness (CaCO3), chlorine, chloride and pH. The service water shall be without solid particles. 

If unclear requirements, we recommend to use the same quality demands as for mains water. 

Boiler feedwater 

Hardness max 0.1 dH 

Rest aluminium max 0.2 mg/l 

pH 8.5-9 

Silicon acid max 30 mg/l SiO2 

Tower water 

Design pressure 300 kPa 

Capacity m3/h: AS PER QUOTATION 

Temperature °C: AS PER QUOTATION 

Cooling water 

Design pressure 300 kPa (e) 

Capacity m3/h: AS PER QUOTATION 

Temperature °C: AS PER QUOTATION 

Ice water 

Design pressure 300 kPa 

Capacity m3/h: AS PER QUOTATION 

Temperature °C: AS PER QUOTATION 

4 Suggested steam characteristics  

Main advices: 

• Steam has to be of good quality and dry. 

• Steam feeding piping has to be equipped with a pressure regulator in order to keep a constant feeding  pressure.  

• Steam piping has to be insulated in order to avoid to hurt people. 

The main features are the following: 

- Pressure: min 3 bar – max 8 bar  

- Quality: dry saturated steam 

- Humidity : max. 5% of condensate 

- Max pressure of condensate recovery: 0,5 Bar 

5 Suggested electricity characteristics  

The following network has to be distributed in the factory: 

- Voltage : 230/ 400 V. 

- Frequency : 50 Hz 

- Voltage variation : max. ± 5% 

- Frequency variation: max. ±-2% 

- Phases : 3 + neutral 

- Auxiliary : 24 V – AC/DC 

Environment information  

The factory is located in Lagos - Nigeria, altitude on sl less than 400 m. 

Rules and Standards 

Electric principle IEC (International Electrotecnic Commission) 

Measurement SI (Unit International System) 

Mechanic EN and UNI norms 

Electric EN 60204 

Tank under pressure 97/23/CE 

Equipment protection degree proposed: IP 54

A DUE SRL OFFER N.0315.13.ML Rev.3 DU 27.03.20135 

6 Suggested compressed air characteristics 

The main characteristics are the following ones : 

- Pressure : 6 - 8 bar 

- Quality : dry and non-oiled air 

- Water content : none 

- Oil content : max. 10mg/l 

- Dew point : min. 10°C less than ambient temperature 

- Solid particles : max. 0.01

A DUE SRL OFFER N.0315.13.ML Rev.3 DU 27.03.2013 6 

SUPPLY DESCRIPTION 

SUGAR - THICKENERS - MINOR COMPONENTS & LIQUIDS INGREDIENTS PREPARATION SECTION  

POS.1 N.2 MAGNETIC FLOW METER 

Magnetic flow meter suitable to control the process water quantity transferred to the  blending tanks, the dissolving tank and to the acid and minor ingredient  

storage/dissolving tanks. 

Minimum conductivity > 50 µS/cm. 

POS.2 N.2 DISSOLVER DR 10  

Suitable to dissolve sugar & powders, completely built in stainless steel, 

 equipped with: 

• Stainless steel skid in Aisi 304 tickness.40/10; 

• n° 04 adjustable stainless steel supporting feet; 

• Hopper capacity 70 Lt.; 

• Removable bag holder;  

• Suction regulation manual butterfly valve Dn50 with 9 postions; 

• Inlet/Outlet of the liquid with connection Dn50 F; 

• Mixing chamber type “Double Vacuum”; 

• Pump 4 Kw; 

• Carter to cover the pump body; 

• Stainless steel hopper supporting frame 

• Switch control system with termic to protect the motor. 

• Overall dimension: 1000x800x H=900 mm 

• Weight: Kg 95;

A DUE SRL OFFER N.0315.13.ML Rev.3 DU 27.03.2013 7 

 Technical Features: 

• Pump capacity: 15 m³/h  

• Product Viscosity: ± 100 CPS ; 

• Specific gravity: 1,2; 

• Product Temperature: +2°/+80°C; 

• Dissolution capacity: 1000 Kg/h *; 

• Power supply: Multi-voltage Volt 380/660 Hz. 50; 

• Injector : Made in non-toxic resin; 

• Vacuum degree: -0,7 Bar 

N.B.: All the parts in contact with the product are in stainless steel AISI 316 L,  

the other parts are in stainless steel AISI 304. 

POS. 3 N.2 STORAGE/DISSOLVING TANKS  

Storage tanks, cap. 2.000 L. each on vertical axis, closed shape, equipped with agitator,  suitable for Sugar, Thickeners, powders & liquids dissolution 

built in AISI 316 stainless steel. 

equipped with: 

• n.4 adjustable stainless steel supporting feet; 

• High efficiency Turbo Emulsifier agitator group on vertical axis. 

• service connections; 

• spray washing ball group with DN 40 connection. 

POS.4 N.1 BAG FILTERS 

Bag filters, flow rate 6.000 l/h for sugar syrup at 50°Bx and 25°C.

A DUE SRL OFFER N.0315.13.ML Rev.3 DU 27.03.2013 8 BLENDING SECTION 

POS.5 N.4 BLENDING TANKS 

type S, cap. 6.000 L each one, on vertical axis, closed shape 

built in AISI 316 stainless steel. 

The tanks are used to prepare the juice concentrate to feed the Blending Thanks. 

Each tank is equipped with: 

• conical type bottom and lid; 

• electro stirrer group, on vertical axis  

• n.5 adjustable stainless steel supporting feet; 

• DN 400 quick-locking inspection manhole placed on the top; 

• service connections; 

• spray washing ball group with DN 40 connection; 

• stainless steel air vent; 

• level probe. 

Finishing: 

• welds executed in Argon inter gas atmosphere with the TIG method; 

• inner welds ground and satin; 

• outer welds ground and satin; 

• cold rolled with 2B finishing externally; 

• cold rolled with 2B finishing internally.

A DUE SRL OFFER N.0315.13.ML Rev.3 DU 27.03.2013 9 

POS.6 N.2 SWING BEND PANELS 

To serve the two above mentioned Blending Tanks, suitable to load the ingredients into the blending tanks, to feed the product to the Premix, for washing solutions recovery  The swing bend panels includes : 

• frame built in AISI 304 stainless steel . 

• Automatic butterfly valves in AISI 316 stainless steel.  

• connections 

• connection to the tanks 

POS.7 N.2 CENTRIFUGAL ELECTROPUMP 

to feed the Pasteurizer, built in AISI 316 stainless steel, flow rate 3.000 l/h each. 

POS.8 N.2 SELF-PRIMPING CENTRIFUGAL ELECTROPUMP  

for washing solutions recovery, built in AISI 316 stainless steel, flow rate 20.000 l/ each. 

POS.9 N.1 SERVICE LADDER 

To serve the two Blending Tank in case of maintenance and inspections.

A DUE SRL OFFER N.0315.13.ML Rev.3 DU 27.03.2013 10 

TUBULAR PRE HEATER / COOLER SECTION 

POS.10 N.2 HOT FILLING TUBULAR HEATER / COOLER FOR STILL DRINK,  FLOW RATE 3.000 L/H EACH FOR A TOTAL OF 6.000 L/H OF FINAL BEVERAGE.. 

EACH MACHINE IS CAPABLE TO FEED NR. 2 FILLERS AT THE SAME TIME  

FOR A TOTAL RUNNING OF 4 FILLERS SIMULTANEOUSLY. 

The Plant Is Composed By: 

N.1 MULTI-PIPE HEAT EXCHANGER, TWO STAGE suitable to pasteurise with the  following cycle:  

• pre – heating stage from +20°C to +85°C by means of hot water circulation 

• cooling stage from 85 to 45°C for the product recycling from the filler  

by means of tower water  

The equipment is composed by: 

• stainless steel supporting frame for tubular elements;  

• multi-pipe tubular exchanging elements, sanitary type with pipe for product  passage in AISI 316 L, equipped with expanding compensator; 

• thermometers and PT100 for working temperature control 

Stainless Steel Piping 

Including: pipes, fittings, valves, manual and automatic valves, deviating valves, etc

A DUE SRL OFFER N.0315.13.ML Rev.3 DU 27.03.2013 11 

N.1 OVER-HEATED WATER PREPARATION AND CIRCULATION SYSTEM  at 98÷100°C, servicing the pasteurisation stage, fully built in stainless steel, including: • heat exchanger water/steam without direct injection of steam in water; 

• circulation centrifugal pump for water built in stainless steel; 

• modulating pneumatic valve for the regular inlet of dry saturated steam at 4 Bar • pressure reducer, steam filter, manual on/off valve, pressure gauges, steam trap • hot/over-heated water connecting pipes between water preparer and tubular  

elements including expanding small tank, safety valve, pressure gauge,  

thermometer 

N.1 CONTROL PANEL AND INSTRUMENTS including: 

• PLC SIEMENS S7 to control the pasteurisation cycles equipped with software  

and operational keyboard TP270 - Siemens; 

• Panel in stainless steel, hinged front door, waterproof, equipped with  

external air conditioner; 

• Electrical part for protection and control, auxiliary circuits 24V; 

• Deviation circuit for low pasteurisation temperature with alarm, silent key,  

light alarm, auto/manual deviator; 

• Working circuit to select production/washing/sterilisation; 

The panel is placed on the en bloc base; 

INSTRUMENTS 

for an automatic control, recording of the pasteurisation temperature including: 

• Temperature regulator range 10÷140°C, stainless steel probes, and equipped  

with intervention contact in case of low temperature; 

• Filter/reducer for instruments service compressed air with fittings and pipe for  

reduced compressed air distribution; 

• Reducer for service compressed air; 

• Solenoid valves for air. 

Process Description 

The pasteurizer start up is with product. When the pasteurization temperature is  

reached, the system gives to filler the readiness signal. In case of line stop after a  settable time, the pasteurizer stops the steam feeding keeping the product in  

recirculation with cooling section on, to cool down the product avoiding cooking and  related damages. 

When filling line is ready, the pasteurizer start feeding steam till the pasteurization  temperature is reached again. When product from one batch tank is finished, the  

pasteurizer stops giving indication to operator (alarm) to change the swing bend  

panels. To go back to production the operator confirm operation done. 

A DUE SRL OFFER N.0315.13.ML Rev.3 DU 27.03.2013 12 SANIFICATION SECTION 

POS.11 N.1 “CIP UNIT 3 x 2.000 L” SANITIZING EQUIPMENT Automatic running,  equipped with n°1 washing manifolds composed by: 

N.1 Insulated section for the preparation of soda solution capacity 2.000 l. 

cylindrical shape, built in AISI 304 stainless steel, equipped with: 

• insulation on the cylindrical band;  

• level probe group; 

• inspection manhole; 

• stainless steel adjustable supporting feet; 

• safety overflow pipe outside the tank with a minimum diameter of 80 mm; 

• service connections; 

• finish: internally and externally 2B rolled with ground and satin welds; 

N.1 Insulated section for hot water capacity 2.000 l. 

cylindrical shape, built in AISI 304 stainless steel, equipped with: 

• insulation on the cylindrical band;  

• level probe group; 

• inspection manhole placed on the lid; 

• stainless steel adjustable supporting feet; 

• safety overflow pipe outside the tank with a minimum diameter of 80 mm; 

• service connections; 

• finish: internally and externally 2B rolled with ground and satin welds;

A DUE SRL OFFER N.0315.13.ML Rev.3 DU 27.03.2013 13 

N.1 Not insulated section for water recovery capacity 2.000 l. 

cylindrical shape, built in AISI 304 stainless steel, equipped with: 

• level probe group; 

• inspection manhole placed on the lid; 

• stainless steel adjustable supporting feet; 

• safety overflow pipe outside the tank with a minimum diameter of 80 mm; 

• service connections; 

• finish: internally and externally 2B rolled with ground and satin welds; 

• n°1 on-line conductivity meters to automatically recover the soda solution  

with a % data readout & to control the washing solution recovery temperature; 

• n°1 PT 100 to control the washing solution delivery temperature; 

• n°1 thermometers to control the washing solution delivery temperature; 

• n°1 pressure gauges to control the washing solution delivery pressure; 

• Inlet valves of 20,000 l/h of cold water at 7/8 bar to rinse directly the utilities  

to be washed cold water SUPPLIED BY THE CUSTOMER; 

• n°1 centrifugal pump sanitary type for washing solution feeding  

flow rate 20.000 l/h - 2,5 bar, equipped with frequency converter; 

• n°1 diaphragm electro pump to dose/transfer the caustic soda concentrate;. 

• n°1 diaphragm electro pump for the In-Line dosing of the disinfectant solution; 

• n°1 magnetic flow meter for washing flow rate control; 

• n°1 tubular heat exchangers of 500,000 Kcal/h each (maximum steam  

consumption 1.000 kg/h at 4 bar), built completely in stainless steel Aisi 316,  

equipped with a modulating valve to adjust the steam, a steam trap, pressure  

gauges and a thermo regulator to control the temperature. The exchangers  

are used to heat on recirculation (inside CIP tanks) the caustic soda solution  

(or water) from room temperature to +85°C approx. during the setting the CIP  

unit to optimum working conditions. They are also used to keep the  

washing solution at the temperature of +85°C approx. during the washing  

program.

A DUE SRL OFFER N.0315.13.ML Rev.3 DU 27.03.2013 14 

N.1 Electro-Pneumatic Control Board 

For the automatic management of the section, including SIEMENS S7 ‘PLC’, MP377  Siemens Touch Screen Multi Panel ‘PC’ and the electronic, electric and pneumatic  instruments: 

• to control the processing data; 

• to control and protect the motors; 

• for the signal exchange managing; 

• for the integration with the CIP unit and existing syrup room; 

• cubicle in AISI 304 stainless steel manufacturing; 

• conditioner; 

• with IP.54 protection degree; 

• with auxiliary circuits 24 V. 

Please Note:  

The steam supply piping, the steam reduction unit up to 4 bar, the system for the  

recovery and re-launching of the condensate are at Customer Charge.

A DUE SRL OFFER N.0315.13.ML Rev.3 DU 27.03.2013 15 ANCILLARY SECTION 

POS.12 N.1 PIPING MATERIAL & IN-HOUSE PRE-ASSEMBLY 

Piping material suitable to connect the a.m. equipment inside the syrup room,  

built in AISI 316 & AISI 304 stainless steel. 

The set includes pipes, fittings, valves, manual and automatic valves, gaskets,  

construction material for piping supporting brackets and everything necessary for the  good performance of the plant. 

The processing plant scope of this supply will be in-house pre-assembled  

pre-wired and pre-tested as follow: 

• Ingredients preparation Section (from Pos. 2 to Pos.4). 

• Final beverage preparation Section (from Pos. 4 to Pos.8). 

N.B.: the pre-assembly between the Cip Unit & the above mentioned section 

can be quantified & quoted upon receipt of the Lay Out the Plant. 

Will not be in-house pre-assembled, pre-wired and pre-tested what follows: 

• Washing delivery solution. 

• Washing recovery solution. 

• Process water Pipeline. 

• Loading Lines of all the ingredients from their Storage/Dissolving Tanks 

up to the Blending Tanks (Position 4 of this Offer). 

N.B.: in any case, can be quantified & quoted upon receipt of the Lay Out the Plant. 

POS.13 N.1 MATERIAL FOR THE ELECTRIC AND PNEUMATIC PLANT 

Electric material for the connection of the a.m. equipment inside the syrup room. 

The set includes connecting wires, stainless steel net cable tray, Rilsan pipe 

electric and pneumatic accessories.

A DUE SRL OFFER N.0315.13.ML Rev.3 DU 27.03.2013 16 

POS.14 N.1 ELECTRIC CONTROL BOARD  

For the automatic management of the juice processing section, including SIEMENS S7  ‘PLC’, MP377 Siemens Touch Screen Multi Panel ‘PC’ and the electronic, electric and  pneumatic instruments: 

• to control the processing data; 

• to control and protect the motors; 

• for the signal exchange managing; 

• for the integration with the CIP unit and existing syrup room; 

• cubicle in AISI 304 stainless steel manufacturing; 

• conditioner; 

• with IP.54 protection degree; 

• with auxiliary circuits 24 V.

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Contact us at - sales@ucymachines.com