Particulate Filling

December 2017

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Key elements for particulates filling

What impacts particulates filling capability

Quality Control

Product characteristics

Processing Filling machine& settings

Package

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Product characteristics

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Hardness and dimension are crucial for the characterization

Wide varieties of particulates in the market

CITRUS VESICLES / SACSCollapsed / whole vesicles

SOFT / GELATINOUS PARTICLESNata de Coco

Aloe

SOFT / HARD FRUIT PIECES Peach cubes

Pineapple pieces

FIBERSTomato peels

fruit wires

HARD PARTICLESSeeds

cereal / nuts / grains

stone cells

Note: Definition may differ from country to country or from customer to customer / 4

How do particulates impact filling capability?

► It is critical to understand the following:

− Size, content and physical properties of particulates

− Property of carrier

► Before performing filling trials it is very important

to characterize products to be able to execute

filling process in the best possible way.

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Processing for Particulates Filling

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Processing line critical process parameters

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HEAT / HOLD TIME PARTICULATES

DISTRIBUTION

PARTICULATES

INTEGRITY

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…particulates might need different heat/hold profile

Heat/Hold time depends on particulate types…

6.000 lph, 95C / 15s, 15% particulates 6x6x6 mm

120º C

100º C

80º C

60º C

40º C

20º C

0º C

400 SEC350 SEC300 SEC250 SEC200 SEC150 SEC100 SEC50 SEC0 SEC

Liquid

Particulates

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Particulates distribution

Aseptic tank and agitator design are crucial to control particulates

distribution and ensure particulates integrity

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Particulates integrity

► Pumps need to be designed for gentle

handling of sensitive products

► Heat exchanger to be selected according

to the product type

► Pipe diameter in the heat exchanger needs

to be matched to the size of particulates

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3 typical particulates processing layout design

► Aseptic single line – single stream

► Aseptic single line with in-line dosing of particulates

► Aseptic dual line – double stream

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Aseptic single line – single stream

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Pulp

particulates

Carrier

Mixing

tanks

Aseptic

storageFillingSterilizer

ADVANTAGES

• Traditional design

• Simple operation

• Lower investment level

LIMITATIONS

• Particulate size

• Long holding time for juice

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Aseptic single line with in-line dosing of particulates

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Pulp

particulates

Juice

Mixing

tanks

Aseptic

storageFillingSteriliser

Mixing

tanks

ADVANTAGES

• Effective deaeration of juice

• Improved particulate integrity

• Cost efficient line

LIMITATIONS

• Extended holding time

for juice

• Medium investment level

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For superior product quality

Aseptic dual line – dual stream line

Aseptic

storage

Aseptic

mix/storageFilling

SteriliserMixing

tanks

Pulp

particulates

Aseptic

storageSteriliser

Mixing

tanksJuice

ADVANTAGES

• Good particulate integrity

• Effect deaeration of juice

• Optimal holding time for juice

LIMITATIONS

• Higher investment level

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Processing investment level

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ASEPTIC SINGLE LINE FOR HOMOGENEOUS

NON PARTICULATES PRODUCT: 100%

ASEPTIC SINGLE LINE – SINGLE

STREAM FOR PARTICULATES: 150%

ASEPTIC SINGLE LINE WITH IN-LINE

DOSING FOR PARTICULATES: 175%

ASEPTIC DUAL LINE – DUAL STREAM

FOR PARTICULATES: 300%

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Tetra VertensoTM

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Tetra Pak design for optimal processing solution

Tetra Vertenso™ is the integrated solution for particulates

Tetra Therm® Aseptic DrinkPre mix tanks Tetra Alsafe®

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Roll fed filling equipment for particulates filling

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Two elements are crucial for particulates filling

What enables particulates filling on roll fed machines?

PARTICULATES SEALING KITTransversal sealing

PARTICULATES FILLING KITRegulating valve

Counter pressure flange in the filling pipe

assembly

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2

1 2

* Please note that once the kit is installed, the equipment can work with homogenous product. / 18

PAPER TUBE WITH PRODUCTα

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Mandatory for all particulates products

Particulates sealing kit

β TRANSVERSAL SEALING PARTα

β

β

Dollies Radius 15 “Mushroom”

Installation of Radius 15 dolly to apply effective pressure and push the product out from the sealing area

*Not needed for homogeneous products

Flat Dolly Mushroom dollies*

J CUTTING RAIL

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Required for specific particulate dimensions

Particulates filling kit

PRODUCT REGULATING VALVE

Servo valve

Shuttera

b

a

COUNTER PRESSURE FLANGE c

c

New shutter

wider opening section

wider longitudinal section

b

Standard shutter

Standard flange

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Tetra Pak Particulates packing capability

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Wide range of packages

► Particulates sealing Kits are available for all packages except:

Tetra Brik® Aseptic 80 Slim, Tetra Brik® Aseptic 100 Base and Tetra Brik® Aseptic

125 Slim (due to Transversal Sealing – 6mm fin height too narrow – geometrical

design constrain)

► Particulates filling kits are available for all packages except:

Tetra Brik® Aseptic 80 Slim, Tetra Brik® Aseptic 100 Base and Tetra Brik® Aseptic

125 Slim (due to Transversal Sealing – 6mm fin height too narrow – geometrical

design constrain) + Tetra Brik® Aseptic 500Base, 500Edge, 500 Slim,1000

Base,1000 Mid,1500 Slim, 2000 Slim, Tetra Gemina® Aseptic 1500 Square.

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Package portfolio with particulates

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Filling and sealing kits can be installed on:

Tetra Pak® TBA/19

0100, 0200, 0300, 0400, 0500

Tetra Pak® A3/CompactFlex

0100, 0200, 0300, 0400

Tetra Pak® A3/Flex

0200, 0300, 0400

Equipment portfolio for particulates

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Sealing kits (only for citrus sacs up to 3%) can be installed on:

Equipment portfolio for particulates

Tetra Pak® A3/Speed

0200, 0300, 0400

Tetra Pak® TBA/22

0500

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Selection of the right material and opening for each product

► The package material should be selected according

to the product content

► Straws, caps should be selected according

to the particulate dimensions

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Importance of package functionality

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For aseptic roll fed systems

Tetra Pak particulates capability

Light Green / Green

Feasible

Orange

To be assessed

Hard particles

< 0.2 mm

up to 3% ww

Nata de Coco

& Grass jelly

7 mm

up to 8% ww

Orange

vesicles

up to 20 mm

up to 8% ww

Passata / Tomato Frito

(no or small particles, no seeds)

Peach 6 mm

up to 5% ww

Orange vesicles

>8% Soft cereals

2x2x2 mm

Tomato Sauce

with garlic/basil

(small particles)

Apple 4 mm

up to 5% ww

Carrot smoothies

3 mm

up to 5% ww

Aloe vera

4 mm

up to 2% ww

Grass jelly

4 mm

up to 5% ww

Peanuts

4 mm

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With particulates sealing kit

Light green zone

ElementMaximum

Dimension

Particulate

HardnessWet weight

Nata de coco &

Grass Jelly*7 mm Gummy and slippery Up to 8%

Grass Jelly* 4 mm Gummy and slippery Up to 5%

Tomato Passata / Tomato

Frito (no or small

particles, no seeds)

Seeds: 0.2mm

Skins: 3x3mmMedium Up to 3%

Orange Vesicles

(collapsed)

20 mm (length)

randomly distributedSoft Up to 8%

Aloe vera 4 mm Soft Up to 2%

Please note: this product is borderline between light green and green zone. Product characteristics have to be evaluated on a case by case basis. / 27

Light green zone applications

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Filling Machine availability:• Tetra Pak TBA/19 all dev steps

• Tetra Pak A3/Flex 0200, 0300, 0400

• Tetra Pak A3/CompactFlex 0100, 0200, 0300, 0400

Assumptions in order to successfully pack particulates: • Homogeneous distribution inside the product

• Installation of sealing kit

Packages:Almost all packages can be fulfilled with particulates except for:

• TBA 80 Slim/ TBA 100 Base/TBA 125 Slim (due to TS – 6mm fin

height too narrow – geometrical design constrain)

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With particulates sealing & filling kits

Green zone

ElementMaximum

Dimension

Particulate

HardnessWet weight

Peach 4x4x4 mm Gummy and slippery Up to 5 %

Apple 4x4x4 mm Slippery Up to 5 %

Carrot Smoothies 3 mm Soft Up to 5 %

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Green zone applications

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Filling Machine availability:• Tetra Pak TBA/19 all dev steps

• Tetra Pak A3/Flex 0200, 0300, 0400

• Tetra Pak A3/CompactFlex 0100, 0200, 0300, 0400

Assumptions in order to successfully pack particulates: • Homogeneous distribution inside the product

• Installation of sealing kit & particulates kit

Packages:Almost all packages can be fulfilled with particulates except for:

• Tetra Brik® Aseptic 80 Slim, 100 Base and 125 Slim (due to TS –

6mm fin height too narrow – geometrical design constrain) + Tetra

Brik® Aseptic 500 Base , 500 Edge, 500 Slim,1000 Base,1000

Mid,1500 Slim, 2000 Slim, Tetra Gemina® Aseptic 1500 Square.

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Installation time required - Carton Value - Continuous filling

Example of particulates kit capability

Machine

Down time

Filling kit Sealing kit Total

Lig

ht

Gre

en Tetra Pak TBA/19

Tetra Pak A3/CompactFlex

Tetra Pak A3/Flex

Not required

30 mins

10 mins

10 mins

30 mins

10 mins

10 mins

Gre

en

Tetra Pak TBA/19

Tetra Pak A3/CompactFlex*

Tetra Pak A3/Flex 0200 and above

20 hours

16 hours

1 hour

30 mins

10 mins

10 mins

20h 30 mins

16h 10 mins

01h 10 mins

Please Note: exception for the Tetra Pak A3/CompactFlex 0400, which requires less than 30 minutes installation time. / 31

How can we support you in developing new product recipes

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The concept and new

product formulation is

taken to the customer to

trial in real commercial

production

Understanding

customer need and

product characteristics

A particle size analysis

(PSA) performed by

aseptic performance

specialists to define

product characterisation

and feasibility

A Tetra Pak expert

would visit customer

site to verify current

installation based of

both processing and

packaging equipment

This step consists of a

package performance

data analysis to

understand production

and package

performance

Commercial production

is continued monitored

to assure the

performance of the line

From customer need to commercial production

Initial

question

Product

Charaterization

Processing,

Packaging,

Assessment

Feasibility

evaluation

Industrial

Qualification

Production

Scale up

PD

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Initial

question

Product

Charaterization

Processing,

Packaging,

Assessment

Feasibility

evaluation

Industrial

Qualification

Production

Scale up

PD

C

Light green and green zone product development process

From customer need to commercial production

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Initial

question

Product

Charaterization

Processing,

Packaging,

Assessment

Feasibility

evaluation

Industrial

Qualification

Production

Scale up

PD

C

Orange zone product development process

From customer need to commercial production

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Customer interaction and PDC key competencies

Product Development Centre

Validation

Production

set-up & criteria

Formulation

and production

Analysis

Food

technologists

Laboratory Production

facility

Production

operators

Customer

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Customer Innovation Centers (CIC): global support in processing and packaging of particulate products

DENTONCapability: particulate up to10mm.

Particulate filling / sealing kit for:

Tetra Pak A3/CompactFlex 330ml

DreamCap

LUNDCapability: products up to 20mm.

Particulate filling / sealing kit

TBA/19 (TBA250B)

PUDONGCapability particulate up to 3mm.

Particulate filling / sealing kit

Tetra Pak A3/CompactFlex

(TBA 200E Sq)

GOTEMBACapability: particulate up to

4mm.

Particulate filling / sealing kit

TBA/19 (TBA200S)

SINGAPORECapability:particulate products up

to 3mm.

Particulate filling / sealing kit

TBA/19 (TBA250E)

PUNECapability:

particulate up to

3mm.

Particulate sealing

kit TBA/19

(TBA250E)

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Tetra Pak® particulatesCapabilities evolution

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