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The Aseptic Revolution: Three Hygienic Benefits to Rapid Recovery

18 August 2022

Picture your top-selling high-value dairy, yogurt or plant-based chocolate dessert. We won’t name names. Keep that creamy treat in mind, then think of its key characteristics. Are you thinking of an ambient, long shelf-life product? Can it be commercially stored at room temperature?

Ambient dairy and plant-based products are becoming increasingly popular across fresh product categories and introduced in regions with taste preferences. Keeping dairy and plant-based products at ambient temperature while also maintaining their long shelf-life qualities requires special processing throughout and before packing, leaving no room for post-contamination. Given the amount of time and attention given to a process like this, none of the product should be wasted during water flush after the production cycle is over.

Every drop counts. It adds to the top and bottom line of your business.

Introducing the APV Aseptic Rapid Recovery System (ARRS).

A one-of-a-kind aseptic pigging system that’s reducing product waste, slashing water usage and time- especially for sensitive, neutral pH, long shelf life and ambient products.

“When we talk about new products, the first thought is often that it will simply be a new version of an existing solution. What is exciting here is we will really offer innovative solutions to our customers by opening pigging technology to new processes,” says solution maker Sebastien Ferre, Fresh and Fermented Dairy Manager.

Revolutionize Your Plant:

What makes it an aseptic system?

Once the production cycle is over, the process line is cleaned-in-place (CIP) and sterilized-in-place (SIP). This is imperative for products such as ambient products and yogurts or dessert creams and cosmetics because cross-contamination can lead to product recalls and harm consumers. After each production cycle commences, the entire production cycle, including the pig, pipeline and receiving station are kept at a higher pressure than atmospheric pressure. This ensures the entire product line is sterilized and leaves full sanitation control to the operator.

How does it maximize productivity?

The short answer: the pig. A rubber, tight-fitting projectile, forced through the process pipeline, that cleanly scrapes and recovers residual product to limit waste. It leaves less than 0.5% in the line and offers 87% in product savings in the product pipes between valve manifolds.*

After scraping, the pig is returned to the launch station by compressed air, maintaining aseptic conditions and keeping the line clear for the next cycle. One customer, when calculating the benefits of the Aseptic Rapid Recovery System, found it recovered a million dollars’ worth of residual product by year end.

What’s the sustainability angle?

Oftentimes, increased productivity means increased CIP cycles. With the ARRS, this isn’t necessarily the case. Because the pig recovers much more product, there’s less waste left to rinse. From chemical usage, reduced waste volume and treatment costs to water usage, cleaning time and changeover time, expect 60-70%* in ARRS water savings.

The ARRS in Action:

Not long ago, we brought you APV’s six benefits of Rapid Recovery, an innovative pigging system that also recovers viscous product from process piping. What makes the ARRS unique is its ultra-hygienic twist, especially for those ambient and long shelf-life products.

Time is money. With each CIP cycle, sanitation check and changeover, you lose a bit of both. Trust the pioneers of homogenizers, heat exchangers and UHT Infusion technology with your entire dairy line. We have solutions.

Because your product is too valuable to waste.

*Figures are indicative and dependent on actual running conditions

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The Author

Pranav Shah,Process Category Director

Pranav Shah is Process Category Director for Fresh and Fermented Dairy and Plant-Based, striving to achieve superior value-propositions for the customers and decrease the overall life-cycle costs of the processing lines.

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