Tetra Alex

Homogenizers &
high pressure pumps

Internal
LGO/0908
CHP - The Organisation

Anders Karlsson
General Mgr

Nicole Uvenbeck
Marketing Mgr

Nils Wendestam
Johan Tihof
Technical Mgr
Production Mgr
CHP Marketing

Nicole Uvenbeck Marcus Heinecke Emilie Sellman Lars Göran Olsson

Marketing Mgr Area Marketing Mgr Area Marketing Mgr Technical Sales Mgr&
Area Marketing Mgr
 CHP Engineering & Development

Christer Andersson Tomas Carlsson Tommy Petersson Lars-Göran Persson Jozo Valencuk
Claim & Tech. Order Handl Tech. Order Handl. Product Support Product Support
Tech. Support Tech. Support Technical Sales
Tech Sales Technical Support
CHP Engineering & Development

Pavlos Kouroutsidis Jenny Jonsson Rikard Hansson Fredrik Johansson

R&D R&D R&D, System Supp. R&D
Application Specialist General Product Valves Piston & Seals
Homog Efficiency Platform
 CHP Production

Niklas Lärka Anders B Karlsson Jan Inge Malmström Sten Inge Karlsson
Order Purchase & Order Handling Order handling Order Handling
Logistics

Leif Svantesson
Team Leader
Component Stock
A constant development
over 80 years

1920 1930 1940 1950 1960 1970 1980 1990 2000

 Creating value

From pilot to high capacity

55 l/h 45.800 l/h

50 000

40 000

30 000

20 000

10 000

Tetra Alex S05 Tetra Alex 150 Tetra Alex 200 / Tetra Alex 25 Tetra Alex 30 Tetra Alex 350 Tetra Alex 400
Tetra Alex 2
Tetra Alex® design
Drive end
- Gear box / Direct drive
 Main components

Drive end

Crank house

Piston/seals
Wet end
H-Device
Pump block

Hydraulic system

Cooling system
 Drive unit

Crankcase

wetend

Frame

Hydraulic unit

Homogenizing heads
 Main components

Cooling system

Drive end

Wet end Pump block

Hydraulic system

Crank house
TWO-STAGE HOMOGENIZING HEAD HD100
Homogenization
of dairy products
Milk • Avoiding a cream line
• Avoiding sedimentation

Recombined milk • No separation of fat

Cream • Raising viscosity and

improving
mouth-feel and taste

Yoghurt • Avoiding separation of whey

in product
• Increasing viscosity
Ice-cream mix • Making the emulsion of fat
stable and uniform
Improving product shelf-life
for milk

► Stokes’ relation

► Rising velocity is given by

► g x particle size2 x (dens. SM- dens. fat)
► 18 x visc. milk

► 3.2 micron

► 0.8 micron

► 0.2 micron

Weeks
 Definition:
Homogenization is a process to achieve a homogeneous
distribution of the disperse phase in a dispersion
The process is a combination of
the unit operations

size reduction
and
contacting
working
simultaneously

PSD.TPPC.Tetra Alex, MR No.13, JI05

 Effects of size reduction

Fat globules
• 2000 times increased
numbers
• 10 times increased surface
• 20 times decreased distance
Process in the homogenizing device

Homogenized product
Pressure 5 – 80 bar (75–1 200 psi)

Unhomogenized product
Pressure up to 400 bar
(5 800 psi)

PSD.TPPC.Tetra Alex, MR No.16, JI05

Pressure profile

Distance mm
PSD.TPPC.Tetra Alex, MR No.17, JI05
Homogenization in action
 Nizo – homogenizaton efficiency

Application Average Recommended Average Approx

shelf life, min. NIZO value particle homogenisation
days size, pressure, bar
micron

Past. 7-10 70% ~1 120

ESL 20-30 80%

UHT, indir. min 30 85%

250*
UHT, dir. min 30 90%
<0,2

* Homogenised 1 time
Effect of the 2nd stage

TA 25 PARTIAL HOMOGENIZATION; 4100 L/H; 18 %F;P1=100;

► Constant & controlled counter 85 140; 200 BAR

pressure to 1st stage

80
► Reduce vibrations & noise
► Break up clusters formed 75

H-EFFECT (NIZO%)
directly after homogenisation
70

200 Bar
140 Bar
100 Bar
65

60

55
0 10 20
P2 % of P1
USP Standard
Analysing methods
Laser Diffraction Instrument
Size distribution

NIZO Method

PSD.TPPC.Tetra Alex, MR No.14, JI05

Using detailed analysis tool
to verify accuracy
Wet end
Suction stroke
Pump stroke
Aseptic cooling system
 Pump block with mushroom valves

Cover
• Easily removed, providing
Solid block wall quick access to all valve parts
• Complete inspection made in
• No penetrating holes
less than ten minutes
Maximised strength
• High corrosion resistant
material as standard Cylinder bushing
• Separate from pump block
Mushroom valve
• Large flow area Piston
• Smooth design gives steady
flow and low pressure drop
• Low weight means extremely
short opening/closing time Valve seat
• Symmetric design resulting in
• No dead ends for two wear surfaces
Suction/inlet channel
optimised cleaning – for double lifetime
• Large inlet area for smoother
running and less wear and tear

PSD.TPPC.Tetra Alex, MR No.06, JI05

Suction/discharge valves
& homogenizing devices
 General design – Valve and seat, ø55, 65 & 110mm
Mushroom valve Cone valve TD valve

Cover
Spacer

Valve Cage
Valve
Valve seat

Valve guide

Pump block
 Valves

Mushroom valves Cone valves TD Valves

Cobalt carbide Cobalt carbide Cobalt carbide
Seats
Stainless steel Available in ø55mm & 65mm
Cobalt carbide
Reversible
Tetra Alex
– Valves and seats

► Mushroom Cone TD*

► Valve body
– Cobolt carbide

► Valve seats
– Stainless steel or Cobolt Carbide*

►
General design – Piston cartridge, Basic
Support ring
Piston seal - basic
Compression ring
Guide band Piston seal - basic
Compression ring
Spacer ring
Guide band
Guide band
Guide band

Rear piston Rear piston

seal - basic seal - basic
General design – Piston cartridge, Basic
Support ring
Piston seal - basic
Compression ring
Guide band Piston seal - basic
Compression ring
Spacer ring
Guide band
Guide band
Guide band

Rear piston Rear piston

seal - basic seal - basic
P Piston cartridge basic
i
s
t
o
n
General design – Piston cartridge, Aseptic
Piston seal - aseptic
Support ring
Compression ring
Spring
Guide band Guide band

Rear piston
seal - basic
Produktseite
- Kolben / Dichtungen, aseptisch
Piston cartridge aseptic
 Wet end
- Pistons / Seals

Non-aseptic Aseptic

Water Condensate

≤ 315 bar ≤ 400 bar, cond. temp = 110°C

 Tetra Alex
– Piston and seals

► Pistons, 4 types
Wear resistance

– Stainless steel
– Chromium plated
– Case hardened piston
– Tungsten carbide coated
– Solid Ceramic

► Seals, 3 types

PSB1 PSB2 PSA1, (V-ring)

Basic Basic Aseptic
NBR PU PTFE/Nomex
Hydraulic system
General design – Homogenization device

Hydraulic end

Housing

Homogenized
Forcer shaft product
Forcer disc .
Seat

Unhomogenized
product
Forcer with reversible disc
 Tetra Alex
– Homogenization device

► HD100, 3 types

– Cobolt carbide

– Cobolt carbide, Wide gap

– Sintered Carbide, Wide gap

Homogenization device, diameter

Constant capacity/pressure for a small vs. a big device

“small diam.” “big diam.”

“big gap”
Internal
“small gap” BoJ/0308
 Dairy products

Efficient homogenization

Flow m3/h

Homogenization device HD 100

offers:
HD 100
► Lower pressure for same
homogenization effect
– 70% NIZO at 120 bar
for pasteurised milk

► Lower energy cost

► Longer lifetime of wear parts Conventional
device

Based on homogenization of 19,000 l/h consumption milk in a Tetra Alex 350 homogenizer

Homogenization pressure, bar

Tetra Alex
– Homogenization device, Wide gap
Tetra Alex 2

► Highly standardised
► No gearbox, 6 pole motor
► Built in one speed starter
► HD21 homo.device
TA 400 HD100
Homogenizing pressure

► Definition of homogenizing pressure

P1 P2
200 bar 30 bar

1st 2nd
Piston pump homogenizing Homogenizing
stage stage

► Tetra Pak = P1 (200 bar)

► Other definitions that can be found on the market

► P1 + P2 (230 bar)
► P1 - P2 (170 bar)
BASIC
DAMPER
ASEPTIC
DAMPER
LOW FLOW SPEED

INLET PIPE 51MM; 1.6 M/S INLET PIPE 76MM; 0.7 M/S

4 4
PRESSURE (BAR)

3 3

2 2

1 1

0 0
0 0,1 0,2 0,3 0,4 0,5 0 0,1 0,2 0,3 0,4 0,5
TIME (SEC) TIME (SEC)
Capacity & pressure guide
Product model Pressure step Piston diam. Capacity range (l/h)
(bar) (mm) Min. Max.

*) Crankshaft speed (rpm)

 Drive motor sizing

Calculation of motor
Q x P /constant* = Effect (kW), Q = flow rate (l/h), P = pressure (bar).

*constant will differ between 1-speed machines and variable

machines
Valid only if ambient temperature is below 40 °C and altitude is below
1000 m.
 Pressure, force

30.000 60.000
N N
200bar 400bar

30.000
N
400bar
Pasteuriser
Milk
Cream
Skimmilk
15 Standardised milk
16 Heating medium
Cooling medium
Diverted flow
Tetra Pak
Tetra Alfast

Tetra Pak
14
12

13 8
17

11
6
9 9 8
3 4
1 7 8
2 10

5
Dairy products

Partial homogenization
Cost savings for pasteurised milk

Full stream homogenization

► Lower energy consumption

Skim
► Less media consumption 3.25% 3.25%

► Lower investment requirement

Cream 40%
Flow: 21,000 l/h (5,500 gph)
► Less costly spare parts Partial homogenization

Skim
18% 3.25%

Cream 40%
Flow: 3,800 l/h (1,000) gph
TA Flex-
aseptic or non-aseptic homogenizer
Pasteur / Erhitzung indirekt
–up- / down-stream Homogenisierung
Pasteur / Erhitzung indirekt
–up- / down-stream Homogenisierung
 VTIS – always aseptic homogenizer

6
5
4
7

14 9 8 11

1
3 10 13 12

Milk Diverted flow

Steam Hot water
Cooling water Vacuum and condensate
Wear & tear exposure
 Products
Standard Semi-abrasive Abrasive Highly Abrasive
Consumption milk Baby food Baby food Tomato ketchup
Egg Apricot beverages
Fermented milk Condensed milk Carrot beverages Tomato paste

Flavoured milk Flavoured milk Guava beverages Tomato sauce

Ice cream mix Ice cream mix Gum arabicum

Juice Oat beverages Mango juice

Nectar Soy products Pear beverages

Recombined milk Calcium enriched milk Soy products

Yoghurt Tomato juice

Calcium enriched milk

Factors influencing Valve wear

►Product
– Relative hardness between particles and valve material
– Size and shape of particles
– Concentration of particles

►Running speed of machine

– Opening and closing frequency of the valve
– Most wear appears during the closing phase of the valve

►Product pressure

►Material used in valve and seat

 Factors influencing piston seal wear

► Product ► Machine
– Abrasiveness – Crankshaft speed
– Air in product (amount of piston strokes)
– Too low feed capacity/pressure – High homogenization pressure
– High temperature
– Damaged pistons
– Low fat content
– Frequent product changes – General machine condition
and frequent water circulation ► Cleaning solution
► Condensate (aseptic) – Too high concentration
– Too high temperature – Too high temperature
– Too low flow
– Cleaning solutions divergent from TP
► Cooling water recommendations
– Too high temperature
– Hardness, impurities
Most common problems causing reduced piston seal
lifetime

Problem Lifetime impact

1) Air in product Medium

2) Worn/damaged pistons High
3) Product related problems High
4) Water/steam quality Medium
5) CIP, solutions, frequency, water circ. Medium

6) Medium impact = 50 – 75% of normal lifetime

7) High impact = 30 – 75% of normal lifetime
Factors influencing wear of homogenizing device

► Product
– Relative hardness between particles and valve material
– Size and shape of particles
– Concentration of particles
– Corrosiveness

► Capacity of machine
– A smaller device in relation to capacity is more wear resistant, but less efficient

► Improper feed
– Too much air in the product may crack the forcer when it hits the seat
Factors influencing wear of homogenizing device

► Homogenization pressure
– Higher pressure means higher speed in the gap and more wear
– Too low second stage pressure will give cavitation damages down stream the
gap

► Material used in valve and seat

– Harder material are more erosion resistant, but cracks easier

► Design
– Wider gap is more wear resistant, but less efficient
Used in various applications

– Dairy products
– Soy-based products
– Juices & Nectars
– Tomato products
– Soups & Sauces
– Egg
Improving product shelf-life
for juice

► Stokes’ relation

► Sedimentation velocity is given by

► g x particle size2 x (dens. fibre- dens. juice)
► 18 x visc. juice
Homogenization
of juice & nectars
– Reduce sedimentation of
the pulp
– Improving mouth-feel, colour
and flavour
Homogenization
of soy-based products

– Breaking up protein particles

– Avoiding sedimentation
in package
– Improving mouth feel
Homogenization
of tomato products
– Raising viscosity
– Improving product appearance
– Avoiding separation in package
 Tomato products

Homogenization for

► product stability
► increased viscosity
► enhanced mouthfeel

PSD.TPPC.Tetra Alex, MR No.22, JI05