Injection UHT Systems | Direct UHT Processing for Dairy & Beverages

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Injection UHT Systems

The APV® Injection UHT Systems are high-efficiency direct UHT processing solutions that use steam injection to rapidly sterilize products with minimal thermal damage. They are ideal for aseptic processing of milk, cream, flavored beverages, custard and other sensitive liquid foods. These systems help ensure long shelf life without compromising taste, color, or nutrition, all with reliable, consistent performance.

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Direct UHT Technology Designed for Product Integrity and Processing Flexibility

In the dairy and beverage industries, delivering shelf-stable products with clean taste and strong visual appeal takes more than high heat, it takes the right kind of heat. SPX FLOW’s Injection UHT Systems use direct thermal processing to achieve exceptional quality and efficiency. They are ideal for milk, flavored beverages, custard, cream and other low- to medium-viscosity products.

Today’s food and beverage processors need to overcome critical challenges:

Avoiding heat damage that can impact flavor, color, or nutritional value
Maximizing runtime by reducing fouling and CIP frequency
Running diverse product lines with consistent results and easy changeovers

Why APV® Injection UHT Systems?

Built on decades of thermal processing expertise, APV Injection UHT systems are designed for rapid, gentle processing that maintains product quality while minimizing operational downtime. They deliver:

Fast heating (~300°C/sec) for optimal taste and minimal degradation
Instantaneous flash cooling for flavor and aroma preservation
Precise thermal control with uniform product treatment
Efficient spore kill with very low C values* for excellent shelf stability
Low fouling and extended CIP intervals for increased uptime
Energy-efficient operation with lower total cost compared to indirect systems
Broad product compatibility of low- to medium-viscosity products from milk, plant-based to specialty beverages, ice cream mix, flavored drinks and custards
Operator-Friendly Design with usability in mind, the system features intuitive controls and automated cleaning functions, ensuring easy day-to-day operation and simplified maintenance.
Pre-assembled and factory-tested for fast deployment
Available with compliance options including ASME, PMO, and 3-A
Low on maintenance and energy costs, supporting long-term operational efficiency
Supported by pilot UHT plants for testing and product development
Backed by SPX FLOW’s global service network, including training, preventive maintenance, spare parts, and remote diagnostics, ensuring ongoing performance, uptime and ROI.

Distinctive Advantages

At the core of the Injection UHT System is the APV Steam Injector — a purpose-built component engineered for thermal precision and reliability.

Key advantages include:

Advanced Processing: Innovative automation and controls deliver high food safety and process consistency
PEEK Nozzle Technology: Prevents direct contact between metal and product using specialized nozzles, reducing fouling and burn-on risk
Simplified Design: High mixing efficiency ensures rapid and even heat transfer
Stepless Steam Gap Adjustment: Allows real-time adjustment for precise heating control and greater flexibility
Silent Operation: Uniquely designed for the lowest noise levels in its class

This injector technology supports longer run times, better product protection and simplified maintenance — reinforcing the system’s performance edge.

Product Applications

UHT milk and flavored milk
Cream, coffee creamers and custards
Plant-based beverages (oat, almond, soy)
Ice cream mix and milkshake base
Nutritional and specialty drinks

Theory of Operation

Designed for high throughput and reliable aseptic processing, this UHT system meets rigorous standards for product quality and food safety in low- to medium-viscosity products, including milk, flavored milk, cream and plant-based beverages.

The Injection UHT System operates on the principle of direct UHT processing. During the process:

Culinary-grade steam is injected directly into the product through a specially engineered nozzle. The steam is free from any off-flavors that could alter the taste of the product.
The product is instantly and evenly heated to sterilization temperatures (~138–142°C), achieving a high microbial kill rate.
It is then transferred into a flash chamber where the injected steam is rapidly evaporated, cooling the product back down and removing excess moisture.
The result is a commercially sterile product that retains its natural taste, color and nutrients — making it ideal for aseptic food processing applications.

This precise thermal control enables a gentle process with maximum efficiency and minimal degradation, perfectly suited for sensitive applications like UHT processing milk, flavored dairy drinks and premium beverages.

Our APV Injection UHT Systems are engineered to deliver precision, efficiency and versatility in ultra high temperature (UHT) processing. Below is an in-depth look at the system’s specifications that make it ideal for aseptic processing:

Processing capacity:	2,000 – 30,000 L/h (550 – 8,000 U.S. gal/h)
Product temperature profile:	5–75–142–75–25°C (41–167–288–167–77°F)
Viscosity range:	Low to medium viscosity
Heat regeneration:	~85%
Pressure tolerance:	Up to 60 bar

Our APV Injection UHT Systems come with a range of premium options to further customize and optimize your aseptic processing operations:

Designed according to ASME, PMO and 3A
The system is optionally designed to comply with ASME, PMO and 3A accommodating regulatory requirements for global markets
Energy Efficiency
The system is equipped with advanced energy-saving features:
- Non-Aseptic Cooler (NAC)
  This patented design achieves up to 67% energy recovery during sterilization and cleaning processes, significantly reducing operational costs.
- Insulation:
  The infusion chamber
- Condensers with Energy Recovery
  A set of condensers enables an additional 12% energy recovery, which can be reused internally or externally within the UHT plant, enhancing overall energy efficiency.
- Sterile Water Unit:
  This feature produces sterile water for the homogenizer, eliminating the need for condensate and contributing to resource optimization.
- Hibernation Mode
  During waiting times, the intelligent energy reduction mode saves over 50% in energy consumption, making the system extremely efficient even when not in active production.
Run Times and Product Integrity
- Aseptic Pulsation Dampener
  The aseptic pulsation dampener reduces pressure fluctuations within the system, ensuring steady product flow and maintaining an aseptic system and product integrity. By stabilizing pressure, this option enhances product safety and consistency, especially when dealing with delicate or high-viscosity products.