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The Ultimate Guide to Mocktails and Tunnel Pasteurization

Sponsored by PRO Engineering / Manufacturing Inc.

Table of Contents

Mocktails & Tunnel Pasteurization: Ensuring Safe, Fresh Non-Alcoholic Beverages

Introduction

Mocktails, or non-alcoholic cocktails, have become a popular alternative to alcoholic beverages, offering a sophisticated and enjoyable experience for those who prefer to avoid alcohol.

Whether it’s for health reasons, personal preferences, or simply a desire for a refreshing drink, mocktails provide a range of flavors that can satisfy any palate. To ensure these beverages maintain their quality, taste, and safety, producers often use pasteurization methods, specifically tunnel pasteurization, which helps preserve freshness without sacrificing flavor.

In this guide, we’ll dive deep into what mocktails are, why pasteurization is essential for their quality and safety, and how tunnel pasteurization by companies like PRO Engineering / Manufacturing Inc. enhances the production process for optimal results.

Understanding Mocktails and Their Appeal

Mocktails, derived from “mock” and “cocktail,” are drinks designed to replicate the look and feel of traditional cocktails without the inclusion of alcohol. They’re crafted with the same attention to detail as alcoholic cocktails, often combining fruit juices, syrups, herbs, and spices to create complex and layered flavors.

The Rise of Mocktails in Social Culture

Mocktails have gained traction across various demographics and cultural contexts. Here’s why they’re increasingly popular:

  • Health-Conscious Trends: Many people are becoming more mindful of their alcohol consumption. Mocktails provide a way to enjoy a sophisticated beverage without the potential drawbacks of alcohol.
  • Inclusivity: Offering mocktails ensures that social gatherings are more inclusive, allowing everyone to have an enjoyable drink option regardless of their drinking habits.
  • Creative Flavors: Mocktails allow bartenders and mixologists to experiment with ingredients, leading to unique and flavorful combinations that can rival any alcoholic cocktail.
  • Suitable for All Ages: Because they contain no alcohol, mocktails can be enjoyed by a wider audience, including young adults and older individuals.

The Importance of Pasteurization in Beverage Quality

When producing mocktails at a commercial level, maintaining consistent quality and safety is crucial. Since mocktails are often made with fresh ingredients like fruit juice, herbs, and spices, they are susceptible to microbial contamination. Pasteurization is a reliable solution to eliminate harmful microorganisms and prolong the beverage’s shelf life without compromising taste.

Types of Pasteurization for Beverages

There are several types of pasteurization methods used in the beverage industry, including:

  • High-Temperature Short-Time (HTST): This method rapidly heats and cools the beverage, killing pathogens but requiring rapid processing.
  • Flash Pasteurization: Involves heating the liquid at high temperatures for a few seconds, often used for dairy and fruit juices.
  • Tunnel Pasteurization: Ideal for bottled and canned beverages, this method subjects the packaged product to a gradual heating and cooling process.

What is Tunnel Pasteurization?

Tunnel pasteurization is a technique where the entire bottle or can of beverage passes through a tunnel with controlled zones of heating and cooling. It’s a gradual process that heats the product over a specified time, ensuring that every part of the drink reaches a temperature sufficient to destroy harmful microbes.

How Tunnel Pasteurization Works

  • Step 1: Heating: The beverage containers enter the tunnel where they are exposed to progressively higher temperatures. This gradual heating helps reduce thermal shock and preserves the container’s integrity.
  • Step 2: Holding Zone: Once the desired temperature is reached, the beverage stays in a “holding zone” for a set amount of time. This allows the heat to penetrate uniformly, ensuring thorough pasteurization.
  • Step 3: Cooling: The beverage then passes through cooler zones that bring the temperature down gradually, minimizing the risk of overheating or flavor alteration.

For businesses producing mocktails, using tunnel pasteurization can be highly advantageous, as it is specifically designed for bottled and canned beverages and ensures consistency in quality and safety.

 Ensure the highest quality and safety for your mocktail production with tunnel pasteurizers from PRO Engineering / Manufacturing Inc.

How Tunnel Pasteurization Enhances Mocktail Quality

Tunnel pasteurization is an ideal method for mocktail production, as it combines effective microbial control with gentle processing that retains flavor integrity. Mocktails often use fresh fruit juices and natural ingredients, which can be sensitive to heat. Tunnel pasteurization allows these beverages to be safely processed without degrading the natural flavors.

Retaining Freshness and Flavor

Mocktails are known for their vibrant and refreshing taste, largely due to their fresh ingredients. Tunnel pasteurization offers a gentle yet effective heat treatment that preserves the nuanced flavors of fruits, herbs, and spices, allowing consumers to enjoy a fresh taste with each sip.

Extending Shelf Life

By eliminating bacteria and other pathogens, tunnel pasteurization significantly extends the shelf life of mocktails. This benefit is especially important for producers and retailers, as it reduces spoilage, waste, and financial loss while ensuring that consumers receive a safe product.

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“Want to ensure safe, delicious, and long-lasting mocktails? PRO Engineering’s tunnel pasteurizers are designed for the beverage industry’s most demanding needs. Perfect for high-volume production, our pasteurizers are built to provide consistency and efficiency, ensuring that each bottle and can meets the highest standards.

Give your mocktail brand a competitive edge with the best in pasteurization technology. Learn more about our Slimline tunnel pasteurizers today and see how PRO Engineering can support your production goals.”

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Benefits of Using Tunnel Pasteurization in Mocktail Production

For businesses involved in the production of mocktails, tunnel pasteurization presents several benefits, which we’ll explore below.

Consistent Quality and Safety

Tunnel pasteurization is one of the most reliable pasteurization methods available, providing consistent quality control across batches. This consistency is particularly vital for brand reputation, as consumers expect the same taste and freshness with every purchase.

Scalability for High-Volume Production

Tunnel pasteurizers are designed for continuous operation, making them ideal for large-scale production environments. With the ability to process hundreds to thousands of bottles or cans in a single cycle, this method is highly efficient and well-suited for businesses aiming to meet high demand.

Environmental and Economic Efficiency

Unlike some other pasteurization methods, tunnel pasteurization can be more energy-efficient, as it uses a controlled and steady heating and cooling process. Additionally, the gradual heat exposure reduces the likelihood of container damage, helping to minimize waste and operational costs.

 Discover how PRO Engineering / Manufacturing Inc. can help you implement efficient tunnel pasteurization for your mocktail production needs. Learn more here.

Why Choose PRO Engineering / Manufacturing Inc. for Tunnel Pasteurization Solutions

For mocktail producers seeking to incorporate tunnel pasteurization, partnering with a reliable and experienced provider is crucial. PRO Engineering / Manufacturing Inc. specializes in developing high-quality tunnel pasteurizers tailored to the specific needs of beverage producers.

Expertise in Beverage Pasteurization

PRO Engineering / Manufacturing Inc. has extensive experience in the pasteurization industry, offering a range of tunnel pasteurizers that meet the unique requirements of various beverage types. Their systems are designed to provide optimal temperature control and energy efficiency, ensuring a balanced and effective pasteurization process.

Customizable and Scalable Solutions

Whether you’re a small-scale producer or a large beverage manufacturer, PRO Engineering offers customizable tunnel pasteurizers that can be scaled to fit your production needs. Their technology accommodates varying production volumes, providing flexible solutions for growing businesses.

Cutting-Edge Technology and Reliable Support

In addition to providing high-quality equipment, PRO Engineering / Manufacturing Inc. offers support throughout the implementation process. This includes initial consultations, equipment customization, installation, and ongoing maintenance to ensure uninterrupted operation.

 Ready to elevate your mocktail production process? Contact PRO Engineering / Manufacturing Inc. to explore customizable tunnel pasteurization options. Get started today!

The Science Behind Tunnel Pasteurization: Ensuring Safe and Flavorful Mocktails

PRO Engineering tunnel pasteurizer ensuring mocktail quality and safety

Tunnel pasteurization operates on principles of microbiology and thermal processing, making it an efficient solution for sterilizing beverages without diminishing their quality. To understand its role in mocktail production, it’s essential to break down the science behind the process.

Microbial Control and Food Safety

Fresh ingredients, such as fruit juices and herbs, are prone to contamination by various microorganisms, including bacteria, yeasts, and molds. Consuming beverages with these microorganisms can lead to foodborne illnesses or unpleasant changes in taste and odor. The thermal treatment provided by tunnel pasteurization effectively destroys these harmful microbes by exposing the beverage to controlled heat over a designated period. The result is a mocktail that is not only safe but also has an extended shelf life.

Heat Sensitivity and Mocktail Ingredients

One of the unique challenges in mocktail production is that many ingredients are heat sensitive. Tunnel pasteurization addresses this issue by applying gradual and precise heating and cooling phases. This controlled process ensures that volatile compounds (which often contribute to the aroma and taste of fresh fruits and herbs) are preserved, allowing mocktails to retain their intended flavors and characteristics.

Consistency in Quality

The science of tunnel pasteurization also ensures batch consistency, which is critical for brand reliability. Every batch of mocktails passes through the same heating, holding, and cooling phases, guaranteeing that every bottle or can has been treated equally. This consistency reinforces consumer trust, as they know they can rely on the product’s taste and safety with each purchase.

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“Take your mocktail production to the next level with PRO Engineering’s advanced tunnel pasteurizers. Offering unmatched control over temperature and process, our tunnel pasteurizers ensure your mocktails are pasteurized to perfection. Safe, fresh, and flavor-preserving, our equipment is the ideal solution for modern mocktail brands aiming to stay competitive.

Discover how our custom solutions can fit seamlessly into your production line. Don’t wait—explore PRO Engineering’s pasteurization solutions and secure the quality of your non-alcoholic beverages.”

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Consumer Perception and Brand Loyalty: The Pasteurization Advantage

In the competitive beverage industry, consumer perception and brand loyalty are key to success. Mocktails, being a premium, health-conscious product, attract consumers who value quality and safety. By incorporating tunnel pasteurization, brands can demonstrate their commitment to producing high-quality, safe beverages, enhancing consumer trust and brand loyalty.

Meeting Health-Conscious Demands

Today’s consumers are more informed and selective, often preferring products that prioritize health and safety. By clearly communicating the use of pasteurization, brands can appeal to health-conscious consumers who seek transparency in the production process.

Mocktail brands that emphasize their use of safe, high-quality production methods are likely to foster a loyal customer base that values these attributes.

Shelf Stability and Reduced Waste

Extended shelf life means that mocktail products can reach a broader market and stay fresh for longer, reducing product spoilage and waste. For retailers, this translates to fewer losses due to expired products, and for consumers, it means a reliable, fresh-tasting product even weeks after purchase.

This reliability can significantly boost a brand’s reputation and customer loyalty, as buyers know they are investing in a product that maintains its quality over time.

 Ready to boost your brand’s reputation with safe, consistent mocktails? Explore PRO Engineering’s tunnel pasteurization solutions today.

Environmental and Economic Benefits of Tunnel Pasteurization

Tunnel pasteurization is not only beneficial for beverage quality and safety but also presents several environmental and economic advantages.

Energy Efficiency and Sustainability

Compared to other forms of pasteurization, tunnel pasteurization is designed for efficiency. The gradual heating and cooling zones are optimized for energy use, and the equipment can operate continuously, reducing the energy required for start-stop cycles. This efficiency translates to lower utility costs and a reduced environmental footprint.

Minimizing Packaging Waste

With tunnel pasteurization, beverages are pasteurized in their final packaging, reducing the need for additional handling and minimizing the risk of contamination. This process reduces waste associated with damaged or compromised packaging, as each bottle or can undergoes a gentle thermal process.

For brands focused on sustainability, this efficiency aligns well with eco-friendly initiatives, as it supports both energy savings and waste reduction.

Long-Term Cost Savings

While initial setup costs for a tunnel pasteurizer might seem substantial, the long-term savings often outweigh these costs. Tunnel pasteurization’s continuous operation and minimized waste contribute to a more economically viable production process, helping companies maximize profit margins in the long run.

Market Demand for Mocktails: Capitalizing on a Growing Trend

The market for non-alcoholic beverages is booming, with mocktails leading the way as one of the fastest-growing segments. This popularity is driven by several factors, including the wellness trend, an increase in sober socializing, and a growing preference for sophisticated flavors without alcohol. Let’s examine why mocktail producers can benefit from this trend by ensuring their products are pasteurized effectively.

Mocktails for Health and Wellness

As people become more health-conscious, many are choosing to reduce their alcohol intake, seeking alternatives that align with their wellness goals. Mocktails offer a solution with fewer calories, no alcohol-related health risks, and often, added health benefits from natural ingredients.

Tunnel-pasteurized mocktails are able to retain these fresh, healthy ingredients longer, appealing to consumers who prioritize quality and nutrition.

A Suitable Beverage for All Occasions

Mocktails provide a versatile option for social gatherings, corporate events, family celebrations, and more. They offer inclusivity, allowing everyone to enjoy a beautifully crafted drink without alcohol. By ensuring safety and shelf stability through tunnel pasteurization, brands can meet the demand for a product that fits every social occasion, season, and demographic.

Competing in a Crowded Marketplace

The non-alcoholic beverage market is becoming increasingly competitive, and brands need unique selling points to stand out. By highlighting the use of tunnel pasteurization as part of their production process, mocktail brands can set themselves apart.

This method provides a reliable means of delivering a fresh, safe product that consumers can trust, offering an edge over competitors who may not use such advanced quality assurance techniques.

 Gain a competitive edge in the booming mocktail market with top-quality tunnel pasteurization from PRO Engineering / Manufacturing Inc..

Choosing the Right Pasteurization Partner: PRO Engineering / Manufacturing Inc.

Implementing tunnel pasteurization requires specialized equipment and expertise. Selecting a trusted partner like PRO Engineering / Manufacturing Inc. can make all the difference in achieving seamless, efficient pasteurization for your mocktail production.

Proven Expertise in Beverage Pasteurization

PRO Engineering / Manufacturing Inc. has been at the forefront of pasteurization technology for decades, offering solutions that have been tested and trusted by beverage companies worldwide. Their experience ensures that your mocktail production will benefit from industry-leading technology and reliable equipment.

Customizable Solutions for Your Brand’s Needs

No two beverage brands are alike, and PRO Engineering understands this. Their tunnel pasteurizers can be customized to meet specific production volumes, temperatures, and packaging requirements, giving you a solution that aligns with your unique production goals. Whether you’re a small brand scaling up or an established producer seeking to optimize your process, PRO Engineering provides solutions that fit.

Commitment to Quality and Support

Implementing new equipment can be daunting, but PRO Engineering supports their clients every step of the way. From installation and training to ongoing maintenance and troubleshooting, they ensure that your tunnel pasteurizer operates at peak efficiency. This commitment to service means that you can focus on producing high-quality mocktails without worrying about equipment downtime or inefficiencies.

As the beverage industry continues to evolve, advancements in technology are likely to shape the future of mocktail production and pasteurization.

Automation and Smart Technology in Pasteurization

As automation becomes more prevalent, many modern tunnel pasteurizers incorporate smart technology that allows for real-time monitoring, data collection, and remote control.

This technology helps producers maintain precise control over pasteurization conditions, enhancing consistency and quality. As these advancements continue, brands can expect even greater efficiencies and improved product outcomes.

Innovative Ingredients and Formulations

The mocktail industry is increasingly experimenting with functional ingredients such as adaptogens, botanicals, and probiotics. These ingredients add complexity and appeal but also present new challenges for pasteurization. Tunnel pasteurization offers the gentle processing necessary for handling sensitive, high-value ingredients while maintaining their efficacy.

Sustainability in Mocktail Production

Sustainability remains a priority for both producers and consumers. Tunnel pasteurization supports sustainable practices by reducing waste and minimizing energy use. As the industry moves toward greener practices, tunnel pasteurization will continue to play a significant role in eco-conscious production.

Conclusion: Elevate Your Mocktail Production with Tunnel Pasteurization

In a market driven by quality, safety, and sustainability, tunnel pasteurization offers mocktail producers a distinct advantage. This method not only guarantees a consistent, safe, and fresh product but also aligns with the industry’s shift toward eco-friendly and health-conscious production. By choosing tunnel pasteurization through a trusted provider like PRO Engineering / Manufacturing Inc., brands can confidently meet consumer demands for premium, non-alcoholic beverages.

Embrace the power of tunnel pasteurization to elevate your mocktail production, delivering a superior product that resonates with today’s mindful, discerning consumers.

 Get in touch with PRO Engineering / Manufacturing Inc. today to explore how tunnel pasteurization can enhance your mocktail production! Contact us here.

ABOUT PRO ENGINEERING / MANUFACTURING INC.

Trusted | Knowledge | Quality

We have been involved in pasteurizers since 1977.

PRO Engineering / Manufacturing Inc. has developed a range of small, medium, and large-sized tunnel & batch pasteurizers to fit the needs of BrewMasters and Beverage Makers. When our customers asked for more compact as well as full-size tunnel pasteurizers, PRO developed models to fit our customers’ needs. Then our customers needed a batch pasteurizer. We now provide batch pasteurizers; PRO is a business that continually innovates to meet customer needs.

For more than 40 years, we have been delivering solutions for beverage product shelf stability and consumption safety.

Edward A. Michalski CEO

Ed Michalski started his career in the beverage industry by designing stainless steel, higher flow, spray headers for Pabst Brewing. Along with the header design he also developed a process to produce the new headers.

Ed, along with his brother David, formed PRO Engineering / Manufacturing Inc. Based on what they learned by re-designing and refurbishing other manufacturers’ pasteurizers, Ed and PRO started to offer the pasteurizer marketplace superior new pasteurizers. PRO Engineering / Manufacturing Inc. has been designing and manufacturing great pasteurizers for over four decades.

For more information on tunnel and batch pasteurization contact PRO Engineering / Manufacturing, Inc. at [email protected] or call (414) 362-1500 and ask for Ed Michalski, CEO.

Partner with a PRO!… PRO Engineering / Manufacturing Inc.

Internal Resources:

Inside the Pasteurization Process: How PRO Engineering’s Tunnel Pasteurizers Maintain Beverage Quality

Introduction to Tunnel Pasteurization 

  • Overview of the pasteurization process
  • Importance of maintaining beverage safety and quality
  • How PRO Engineering’s technology excels in this process

The Science Behind Tunnel Pasteurization 

  • Explanation of microbiological principles behind pasteurization
  • How tunnel pasteurization works (heating, holding, cooling)
  • PRO Engineering’s role in ensuring consistent results

How PRO Engineering’s Tunnel Pasteurizers Preserve Taste and Quality 

  • Challenges in balancing microbial safety and sensory qualities
  • Key features of PRO Engineering’s tunnel pasteurizers (precision control, customizable settings, cooling systems)
  • How these features ensure the preservation of taste and texture

Custom Features of PRO Engineering’s Tunnel Pasteurizers 

  • Overview of different models: Slim/Line™, PRO/Line™ series
  • Advanced spray technology and energy efficiency
  • Easy maintenance and hygiene considerations

Benefits of PRO Engineering’s Tunnel Pasteurizers 

  • Consistent quality, extended shelf life, custom solutions
  • Efficiency and cost-effectiveness

Conclusion 

  • Importance of investing in tunnel pasteurizers for beverage safety and quality
  • Call to action for contacting PRO Engineering for customized solutions

Ensuring Flavor and Safety: The Science Behind PRO Engineering’s Tunnel Pasteurizers in Pasteurization

Introduction to Tunnel Pasteurization

Tunnel pasteurization is a crucial process in beverage manufacturing, designed to eliminate harmful microorganisms without compromising taste or quality. The method involves heating beverages to a specific temperature for a set period to kill pathogens, followed by cooling to preserve flavor and shelf life. This process is particularly important for beverages like beer, juices, and kombucha, where maintaining taste is as essential as ensuring safety.

At the heart of the tunnel pasteurization process is precision—both in temperature control and timing. If not properly managed, beverages can either become unsafe due to insufficient pasteurization or suffer from flavor alterations due to excessive heat. This balance is what makes PRO Engineering’s tunnel pasteurizers a standout solution in the industry.

The Science Behind Tunnel Pasteurization

The tunnel pasteurization process is grounded in microbiological science. Harmful pathogens, including bacteria, yeasts, and molds, can thrive in beverage products if not properly treated. Pasteurization works by heating the beverage to a point where these microorganisms are destroyed, without damaging the overall composition of the beverage.

PRO Engineering’s tunnel pasteurizers apply a controlled, consistent heat treatment across the length of the tunnel. The beverages pass through multiple stages:

  1. Heating: The beverage is gradually heated to the target pasteurization temperature, typically between 140°F (60°C) to 160°F (71°C), depending on the product.
  2. Holding: The product is held at this temperature for a specified period to ensure all harmful microorganisms are destroyed. The holding time varies depending on the beverage type and its particular pasteurization unit (PU) requirements.
  3. Cooling: After pasteurization, the beverage is cooled to prevent over-processing and preserve flavor integrity. A controlled cooling process also minimizes condensation and helps protect packaging.

This gradual temperature increases and controlled cooling, in combination with precise timing, ensure that beverages are both safe for consumption and taste exactly as intended.

How PRO Engineering’s Tunnel Pasteurizers Preserve Taste and Quality

The challenge of tunnel pasteurization is to eliminate harmful organisms while preserving the beverage’s sensory qualities, such as taste, aroma, and mouthfeel. PRO Engineering’s pasteurizers excel in maintaining these characteristics, thanks to several key technological innovations:

  • Precision Control Systems: PRO Engineering’s tunnel pasteurizers are equipped with advanced temperature control systems, which ensure that heat is applied evenly and at the right time. The equipment includes sensors that monitor temperature across different stages of the process, ensuring consistency.
  • Customizable Settings: Not all beverages require the same pasteurization parameters. For example, carbonated beverages like beer or soft drinks may need different settings than juices or kombucha. PRO Engineering allows for customizable settings that adjust the temperature and duration according to the specific beverage type. This flexibility ensures the pasteurization process is tailored to each product’s needs, preserving its unique flavor and texture.
  • Effective Cooling Systems: After pasteurization, rapid and controlled cooling is essential to avoid heat-induced flavor changes. PRO Engineering’s tunnel pasteurizers are equipped with efficient cooling mechanisms that reduce the beverage’s temperature gradually, preventing condensation and packaging issues. This is particularly important in carbonated beverages where pressure can alter if cooling isn’t carefully managed.

Custom Features of PRO Engineering’s Tunnel Pasteurizers

What sets PRO Engineering’s tunnel pasteurizers apart from competitors is their focus on customization and advanced features. Whether a small-scale brewery or a large beverage manufacturer, PRO’s solutions cater to various operational needs.

  • Slim/Line™ Tunnel Pasteurizers: Designed for smaller operations or limited space environments, the Slim/Line™ series offers compact pasteurization solutions without sacrificing performance. Despite its size, it provides the same precision and control as larger units, making it ideal for smaller breweries or niche beverage manufacturers.
  • PRO/Line™ Series Pasteurizers: This series is ideal for large-scale operations that require high throughput and efficient performance. Available in multiple sizes (5, 7.5, and 10), the PRO/Line™ series offers robust, reliable pasteurization for large production lines. The larger size also allows for greater versatility in beverage types, making it a go-to option for major beverage manufacturers.
  • Advanced Spray Technology: PRO’s pasteurizers feature state-of-the-art spray header systems that ensure even heat distribution across all bottles or cans. This eliminates temperature inconsistencies, which can result in under or over-pasteurization in certain areas of the batch.
  • Energy Efficiency: PRO Engineering places a strong emphasis on sustainability. Their tunnel pasteurizers are designed to minimize energy consumption by optimizing water and heat usage. The recirculation systems reuse water throughout the pasteurization process, significantly reducing waste and energy costs.
  • Hygiene and Maintenance: PRO pasteurizers are also built with easy maintenance and cleaning in mind. Their modular design allows for easier access to critical components, reducing downtime during cleaning cycles. This design also ensures that the system remains hygienic and free from contamination risks over time.

Benefits of PRO Engineering’s Tunnel Pasteurizers

PRO Engineering’s advanced tunnel pasteurization technology
  1. Consistent Quality: With precise control over temperature and time, PRO pasteurizers guarantee consistent beverage quality. This reduces the risk of batch-to-batch variability and ensures that every product meets the highest safety and quality standards.
  2. Extended Shelf Life: Effective pasteurization extends the shelf life of beverages by eliminating harmful microorganisms, making them more durable for storage and transport. This is especially important for products like juices, beers, and kombucha, where maintaining freshness over time is key.
  3. Custom Solutions: One of the major benefits of PRO Engineering’s systems is their ability to provide customized solutions for various beverage types and production scales. Whether it’s a compact system for small batches or a large-scale solution for mass production, PRO Engineering ensures that the equipment is tailored to meet the client’s specific needs.
  4. Increased Efficiency: PRO’s tunnel pasteurizers are designed for high efficiency, with features like energy-saving systems and rapid cooling technologies that minimize downtime and improve overall production speed. This ensures that manufacturers can maximize throughput while maintaining product quality.
  5. Cost-Effectiveness: By integrating energy-saving features and minimizing waste, PRO Engineering’s tunnel pasteurizers help beverage manufacturers reduce operational costs. The systems are also built to be durable and require less frequent maintenance, further contributing to cost savings.

Conclusion

The pasteurization process is a critical step in ensuring the safety and quality of beverages, from beers and juices to kombucha and infused drinks. PRO Engineering’s tunnel pasteurizers not only meet but exceed industry standards by offering precision, customization, and efficiency in their equipment.

With features like advanced spray technology, energy-saving systems, and customizable settings for different beverage types, PRO Engineering provides solutions that cater to the diverse needs of beverage manufacturers.

By investing in PRO Engineering’s tunnel pasteurizers, manufacturers can ensure that their products are safe, taste great, and maintain their quality over time. Whether you’re a small craft brewer or a large-scale beverage producer, PRO’s systems offer the flexibility, reliability, and performance needed to thrive in the competitive beverage industry.

Ready to enhance your beverage production with the industry’s best tunnel pasteurizers? Contact PRO Engineering / Manufacturing Inc. today for expert solutions tailored to your needs. Their advanced technology ensures beverage safety while preserving taste and quality.

Visit prowm.com or call (414) 362-1500 to speak with a specialist and explore how their customized equipment can optimize your production line. Don’t wait—boost your efficiency and product quality with PRO Engineering’s reliable pasteurization systems today!

References:

  1. PRO Tunnel Pasteurizers
  2. U.S. Food and Drug Administration (FDA) – Pasteurization

ABOUT PRO ENGINEERING / MANUFACTURING INC.

Trusted | Knowledge | Quality

We have been involved in pasteurizers since 1977.

PRO Engineering / Manufacturing Inc. has developed a range of small, medium, and large-sized tunnel & batch pasteurizers to fit the needs of BrewMasters and Beverage Makers. When our customers asked for more compact as well as full-size tunnel pasteurizers, PRO developed models to fit our customers’ needs. Then our customers needed a batch pasteurizer. We now provide batch pasteurizers; PRO is a business that continually innovates to meet customer needs.

For more than 40 years, we have been delivering solutions for beverage product shelf stability and consumption safety.

Edward A. Michalski CEO

Ed Michalski started his career in the beverage industry by designing stainless steel, higher flow, spray headers for Pabst Brewing. Along with the header design he also developed a process to produce the new headers.

Ed, along with his brother David, formed PRO Engineering / Manufacturing Inc. Based on what they learned by re-designing and refurbishing other manufacturers’ pasteurizers, Ed and PRO started to offer the pasteurizer marketplace superior new pasteurizers. PRO Engineering / Manufacturing Inc. has been designing and manufacturing great pasteurizers for over four decades.

For more information on tunnel and batch pasteurization contact PRO Engineering / Manufacturing, Inc. at [email protected] or call (414) 362-1500 and ask for Ed Michalski, CEO.

Partner with a PRO!… PRO Engineering / Manufacturing Inc.

Internal Resources:

From Concept to Creation: The Journey of Custom Beverage Equipment Manufacturing and Sales at PRO Engineering

The Step-by-Step Process of Designing and Building Custom Beverage Equipment at PRO Engineering

Creating custom beverage equipment requires a meticulous approach, blending innovation, technical precision, and client-specific customization.

At PRO Engineering & Manufacturing Inc., a company with over four decades of experience, the process of designing and building custom beverage equipment—from initial concept to final installation—is a comprehensive journey that ensures quality, reliability, and efficiency.

Here’s a detailed look at how PRO Engineering transforms ideas into fully functional beverage systems.

Step 1: Initial Concept and Client Collaboration

The journey begins with a deep understanding of the client’s needs. Whether the request comes from a small brewery or a large beverage corporation, the team at PRO Engineering listens to the client’s requirements and envisions the solution.

This includes considering factors such as production volume, beverage type (e.g., beer, juice, energy drinks), pasteurization method, and the physical space available for the equipment.

Collaboration is key at this stage. The team ensures that every specification—whether it pertains to tunnel pasteurizers, batch pasteurizers, or cooling systems—is aligned with the client’s production goals. PRO’s extensive knowledge in beverage processing, especially in areas like post-fill pasteurization, is vital in customizing equipment that fits the client’s operational needs (PRO)​(PRO)..

Step 2: Design and Engineering

Once the requirements are clear, the engineering phase begins. PRO Engineering employs a team of skilled engineers who specialize in designing systems tailored to specific client needs. This phase involves selecting the appropriate pasteurization system—tunnel or batch—based on the beverage type and production scale.

Tunnel pasteurizers, for example, are often favored for their efficiency and ability to handle large-scale operations. They function by moving sealed cans or bottles through various heat treatment zones, ensuring the proper microbial control without compromising the quality of the beverage (PRO)​(PRO).

Batch pasteurizers, on the other hand, are ideal for smaller production volumes, using heat chambers to pasteurize batches of products at once (PRO). During the design phase, engineers also integrate automation systems for better control and real-time monitoring, which improves operational efficiency and product safety (PRO).

Step 3: Prototype Development and Testing

PRO Engineering / Manufacturing Inc. design team blueprints custom beverage equipment.

Before proceeding to full-scale production, a prototype is often created. This model allows engineers to test the equipment’s functionality under real-world conditions, simulating the client’s production process.

Testing is crucial for identifying any potential issues, such as temperature inconsistencies or mechanical inefficiencies.

For instance, in pasteurization, temperature control is critical. Too much heat can damage the beverage, while too little might leave harmful microorganisms intact. PRO’s advanced monitoring systems enable precise control of variables like temperature and flow rate, ensuring both safety and product quality ​(PRO).

Step 4: Fabrication and Assembly

Once the design is perfected, the equipment moves into the fabrication phase. PRO Engineering’s fabrication shop uses high-quality materials and advanced manufacturing techniques to build each component of the system. Whether constructing a full-scale tunnel pasteurizer or a compact batch system, the equipment is assembled with attention to durability and longevity, ensuring it can withstand the rigors of daily production ​(PRO).

During this phase, PRO Engineering often re-engineers or retrofits existing equipment for clients who need upgrades rather than brand-new systems. Their experience in rebuilding pasteurizers ensures that older systems are updated to meet modern standards, offering improved energy efficiency and productivity (PRO).

Step 5: Installation and Integration

After fabrication, the equipment is shipped to the client’s facility for installation. PRO Engineering’s team oversees the installation process, ensuring that the equipment is integrated smoothly into the client’s production line.

This involves aligning the system with existing infrastructure and ensuring compatibility with other machinery, such as bottling or canning lines.

During installation, engineers also calibrate the system to the client’s specifications, fine-tuning parameters like temperature zones in tunnel pasteurizers or batch processing times. Once installed, the equipment undergoes final testing to ensure everything is functioning correctly and meets the client’s performance standards (PRO).

Step 6: Training and Support

Even after installation, the journey doesn’t end. PRO Engineering provides comprehensive training to the client’s staff, ensuring they understand how to operate the new equipment and manage any troubleshooting. This is particularly important for automated systems, where real-time monitoring and adjustments are crucial for maintaining optimal production.

Additionally, PRO Engineering offers ongoing maintenance and support services, helping clients to keep their systems in peak condition. This proactive approach helps minimize downtime and ensures the equipment continues to operate efficiently over time (PRO).

Frequently Asked Question

  • What Are the 5 Stages of the Engineering Design Process?

To design effectively, you start by defining the problem, then research, specify requirements, brainstorm solutions, and finally choose the best one. These stages guide engineers from problem-solving to creating innovative solutions through a structured process.

 Conclusion: A Commitment to Quality and Innovation

The process of designing and building custom beverage equipment at PRO Engineering is a step-by-step journey rooted in collaboration, precision, and innovation.

From the initial concept to final installation, the team at PRO ensures that each system is tailored to meet the specific needs of their clients, whether they’re producing beer, juice, energy drinks, or most other beverages.

With over 40 years of expertise, PRO Engineering has become a leader in the industry, constantly advancing their technology to provide solutions that extend shelf life, enhance safety, and preserve product quality ​(PRO)​(PRO). This dedication to excellence ensures that their custom beverage equipment not only meets but exceeds client expectations, from concept to creation.

For more information on how PRO Engineering / Manufacturing Inc. can improve your business and profits, call today at 414-362-1500 or visit their website at PRO Engineering / Manufacturing Inc.

ABOUT PRO ENGINEERING / MANUFACTURING INC.

Trusted | Knowledge | Quality

We have been involved in pasteurizers since 1977.

PRO Engineering / Manufacturing Inc. has developed a range of small, medium, and large-sized tunnel & batch pasteurizers to fit the needs of BrewMasters and Beverage Makers. When our customers asked for more compact as well as full-size tunnel pasteurizers, PRO developed models to fit our customers’ needs. Then our customers needed a batch pasteurizer. We now provide batch pasteurizers; PRO is a business that continually innovates to meet customer needs.

For more than 40 years, we have been delivering solutions for beverage product shelf stability and consumption safety.

Edward A. Michalski CEO

Ed Michalski started his career in the beverage industry by designing stainless steel, higher flow, spray headers for Pabst Brewing. Along with the header design he also developed a process to produce the new headers.

Ed, along with his brother David, formed PRO Engineering / Manufacturing Inc. Based on what they learned by re-designing and refurbishing other manufacturers’ pasteurizers, Ed and PRO started to offer the pasteurizer marketplace superior new pasteurizers. PRO Engineering / Manufacturing Inc. has been designing and manufacturing great pasteurizers for over four decades.

For more information on tunnel and batch pasteurization contact PRO Engineering / Manufacturing, Inc. at [email protected] or call (414) 362-1500 and ask for Ed Michalski, CEO.

Partner with a PRO!… PRO Engineering / Manufacturing Inc.

Internal Resources:

Simulation of Tunnel Pasteurization using a Triple Temperature Spray Batch Pasteurizer

By Edward A. Michalski 

CEO 

PRO Engineering/Manufacturing, Inc. 

Overall, pasteurization has been shown to be effective against a wide variety of pathogens and improves the shelf life of products. Two of the widely used types of pasteurization in the industry today are tunnel and batch pasteurization. However, the cost of this heat treatment and its complexity depends on the size of the production facility and other factors such as the pasteurizer’s water and energy expenditure. 

PRO Engineering / Manufacturing Inc. Triple Temperature Batch Pasteurization

Spray-based pasteurizers apply the theory of heat transfer using sprayed water at different temperatures onto the product container. Mixing of the liquid within the container occurs via thermal conduction and uses convection currents generated while the product is heated This circulatory motion across the surfaces reduces the internal surface resistance leading to uniformity in the product temperature.  

Tunnel pasteurizers encompass an enclosed chamber divided into several spray zones. The tunnel usually ranges between 15 to 30 meters, in which the packages move through by a conveyor.  
 
The zones include a heating zone where the temperature of the liquid being pasteurized is progressively raised to about 60°C (140°F); a pasteurization zone where the product is maintained at the desired temperature; and a cooling zone where the packages are cooled. The system includes a shell, tube heat exchangers, water heating, spray nozzles, conveyor mats and machine controls. 

Batch pasteurizers, on the other hand, are designed to provide heat treatment to beverages in “batches,” contrasting to the continuous heat treatment process of the tunnel (and flash) pasteurization. Batch pasteurizers use heated water to raise the temperature of the product already packaged (i.e., cans or bottles). A less desirable type of batch pasteurizer uses a dip tank approach, where the containers are submerged into a tank filled with heated water and held for the required amount of time. Then they are lifted out to cool down afterwards. The problem with the batch tank design is that there can be uneven heating of the packaged liquid being pasteurized.  

In the PRO batch family, PRO Engineering / Manufacturing Inc. has designed a Triple Temperature Spray Batch (Triple Temp for short) pasteurizer using hot and cold spray water from nozzles instead of immersion in tanks at different temperatures. This process simulates the temperature zones of a tunnel pasteurizer. 

As stated, The Triple Temperature Spray Batch mimics the temperature profile of a tunnel pasteurizer, being an economically practical device that reveals the impact of various temperature profiles. Both methods of pasteurization (tunnel and batch) use the measure of a Pasteurization Unit (PU) to monitor the process and the “lethal effect” A 1PU is “added” to a product when exposed to 60°C (140°F) for one minute, although PU accumulation starts at 49°C (120°F)  

PRO Engineering / Manufacturing Has Developed A Range Of Small, Medium And Large Sized Batch Pasteurizers To Fit Your Needs.

The Triple Temp Batch is a convenient tool for labs, testing agencies, and research centers. The profiles and PUs can be adjusted to find the lethal spectrum from a low-temperature time duration to a high-temperature time duration to kill microbes and yeast. 

The flexible parameters of a spray batch allow replicating a variety of full production scenarios. At the same time, they help to minimize energy and water usage. For example, heating of the spray water is done using an electric heater instead of a boiler and cooling is accomplished using chilled water.  

A Triple Temp Batch can be used to verify if the normative time/temperature profile is the most energy efficient profile. Additionally, the machine can be used to determine how various temperature profiles may impact color, flavor, aroma, and density. The Triple Temp Batch can also run at production levels of output. The machine can process over 2,400 bottles or 3,000 cans up to 12 PU in an 8-hour shift. 

PRO Engineering/Manufacturing, Inc. batch pasteurizers can be pallet-jacked for easy transportation and storage. Universities and research centers, along with the Quality Assurance departments of beverage bottlers can benefit from the compact unit that fits most anywhere. The machine cuts down on costs while having the advantages of a tunnel pasteurizer. The Triple Temp Batch from PRO is a most versatile pasteurizer. 

For more information on tunnel and batch pasteurization contact PRO Engineering/Manufacturing, Inc. at [email protected] or call (414) 362-1500 and ask for Ed Michalski, CEO.   

Edward A. Michalski Bio   

Ed Michalski started his career in the beverage industry by designing stainless steel, higher flow, spray headers for Pabst Brewing. Along with the header design he also developed a process to produce the new headers.    

Ed, along with his brother David, formed PRO Engineering/Manufacturing, Inc.  

Based on what they learned by re-designing and refurbishing other manufacturers’ pasteurizers, Ed and PRO started to offer the pasteurizer marketplace superior new pasteurizers.   

PRO Engineering/Manufacturing has been designing and manufacturing great pasteurizers for over four decades.  

ABOUT US:
PRO Engineering/Manufacturing was established in 1977 by Ed and Dave Michalski as a steel fabrication shop. For more than 40 years, PRO Engineering/Manufacturing, Inc. has been delivering solutions for beverage product shelf stability and consumption safety. As leading innovators in post-fill pasteurization, our skilled team offers the best in high-quality pasteurization equipment.

CONTACT US:
Phone: 414-362-1500 | Email: [email protected]



Previous Article: A BASIC GUIDE TO PURCHASING AND USING TUNNEL PASTEURIZERS

Everything You Should Know About Pasteurization and Kombucha Tea

If you saw the title of the article and thought, “isn’t it spelled kambucha?” you’re not suffering Mandal Effect, you’re just not region locked. The brewed, fermented tea beverage has been around for over a thousand years and has slipped through many countries. The name (and therefore spelling) mutated a few times as it circled the planet. 

What makes kombucha exciting is the range of chemical and microbial properties at work in its creation. Homebrewers and micro-brewers alike discover new flavors and textures with nearly every batch. If you’ve ever been fascinated by the alchemy of the ancient world, kombucha making puts you in that realm. 

Regardless of your specific goal or what you think is going on inside the bottle, health and safety are important. For a fermented beverage like kombucha, it’s challenging to know how much fermentation covers bacterial inhibition and how much pasteurization may be needed to ensure safety.  

If these questions are puzzling as you stew over your pot of flavors, this guide can help.  

Properties and Traits of Kombucha 

Kombucha owes it origins to China but is named after a Korean doctor who delivered it to Japan.  

It’s probiotic and microbial qualities have been known, but not well understood since the 60’s when Swiss researches looked into Kombucha and yogurt. 

Kombucha itself is fermented from a SCOBY (symbiotic culture of bacteria and yeast). Many such SCOBYs exist and each brings with it a different heritage not unlike sourdough mother doughs. 

Fermentation 

Fermentation occurs when sugar and yeast get together and create an excess of carbon dioxide and ethanols. The acidic nature of carbon dioxide inhibits bacterial growth. As we all know, alcohol also has anti-microbial properties.  

Fermentation has been used for thousands of years to make liquids potable and safer for consumption. It’s why one of the earliest civilizations, the Egyptians, are well known for creating heqet (beer). 

Kombucha, specifically, undergoes aerobic fermentation. The fermentation process also creates acetic acid and acetaldehyde. In simple terms, the fermentation process may leave the final brew safe to consume. In reality, variations in the ingredients, temperature, fermentation time, and storage all influence the final product. 

If that final product arrives at a pH of <4.6 then it will kill off enough harmful bacteria. However, at the start, most SCOBY and flavor ingredients produce a mixture of pH 5 or greater. To meet food safety guidelines you need a pH of 4.2.  

Pasteurization  

The process of pasteurization aims to heat a consumable substance hot enough to kill off 99% of the harmful bacteria but not chemically transform the substance itself.  

Pasteurization can’t be a target process. It doesn’t have a list of ‘good’ bacteria that it keeps safe from ‘bad’ bacteria.  

That said, not all bacteria and microbes possess the same traits. Some are heartier than others and this key difference separates the range of pasteurization techniques. When you employ a pasteurizer like the Slim/Line model from PRO for processing beverages, you want the product to be safe, stable, and tasty. 

You certainly don’t want to destroy the beverage alchemy you’ve created in your kombucha. 

Low Pasteurization 

The first tier of pasteurization methods in the U.S. used even lower temps than today’s low-temperature methods.  

The products are held at the lower temperature for longer. The principle behind the technique relies on the stress of the heat to kill off the bacteria while leaving the heartier beverage ingredients chemically unaltered. 

Low-temp heating is done for thirty minutes.  

High Pasteurization 

High pasteurization techniques aim for higher temps but for a lower period of time. This kills the bacteria, which tend to be more fragile than surrounding ingredients, and then cools down the beverage quickly to avoid forcing other chemical changes. 

These include: 

  • Higher Heat Shorter Time (HHST) 161 F for 15 seconds, then cooled 
  • Ultra-Pasteurized (UP) 280 F for 2 seconds 
  • Ultra-High Temperature (UHT) 275-300 F for 2 seconds 

The first one (HHST) is associated with many refrigerated products mass-produced today. The latter two are used to pasteurize shelf-stable products that require little to no refrigeration before opening. 

Bacteria Benefits 

Clearly, pasteurization makes for a safer beverage that also enjoys a longer shelf life. Two things most people would love to get as long as it came at no trade-off.  

With kombucha tea, there is a trade-off in the amount of ‘good’ bacteria that gets to remain and the ‘bad’ bacteria that need to go.  

This is where things get both tricky to parse out and some ideologies start to clash. Kombucha, hailing as it does from a China of the past, gets wrapped up in the ideas of traditional Chinese medicine (TCM). This ‘everything natural is healthy’ approach starts to fall into confirmation bias. 

There are numerous studies that indicate that many of the compounds, bacteria, and acids in kombucha have beneficial effects. Some studies even point out that some compounds in Kombucha are themselves antimicrobial. The beverage actually inhibits the growth of harmful bacteria while sitting in the bottle. 

Kombucha contains many benefits, no argument there, the argument is what are the benefits and what are their levels. It’s a problem shared by many robust compounds. Lots of things going on means lots of variables to account for.  

Bacteria Risks 

What can be agreed on is that harmful bacteria such as salmonella, listeriosis, and brucellosis (to name a few) must be eliminated for the health of consumers.  

Additionally, without a secondary process to halt fermentation, carbon dioxide continues to build and makes canned and bottled fermented products into physical hazards.  

Tight controls need to be maintained for fermented beverages like kombucha to prevent toxic acidosis levels. Lowering excess alcohol, through decreased fermentation, to keep it under the <1% limit, is another reason to engage in kombucha pasteurization.  

Safety and Tasty  

In the end, when crafting and selling a beverage, you want it to be the best it can be. For kombucha, there is a tightrope to be walked between benefits.  

Summary 

Point 1 – Traditional kombucha is not pasteurized, which opens up risk for bacterial growth and other inconsistencies and quality concerns in the supply chain. 

Point 2 – You can achieve a stable kombucha product through pasteurization, which eliminates most of the above risks.   

Point 3 – However, pasteurization will also kill the ‘good’ bacteria in kombucha, also known as probiotics.  This means a kombucha producer who is operating a pasteurizer will also need to introduce shelf-stable probiotics as an additional ingredient in the kombucha. 

Point 4 – While this will lead to a non-traditional kombucha, the benefits of a shelf-stable product are plentiful and retailers and customers alike are seeking this form of kombucha. 

If you have more questions or comments about pasteurization techniques and technology, contact us.  

ABOUT US:
PRO Engineering and Manufacturing was established in 1977 by Ed and Dave Michalski as a steel fabrication shop. For more than 40 years, PRO Engineering and Manufacturing, Inc. has been delivering solutions for beverage product shelf stability and consumption safety. As leading innovators in post-fill pasteurization, our skilled team offers the best in high-quality pasteurization equipment.

CONTACT US:
Phone: 414-362-1500 | Email: [email protected]

Tips on Pasteurizing Infused Beverages: How it Works

If you are interested in providing new drinks, this guide can help. Here is a quick guide on how pasteurizing infused beverages works. 

The introduction of unique beverages continues in America. If you are a beverage bottler you’ve had to adapt to industry changes. One of those changes includes providing infused beverages to your consumers.  

But how do you pivot to meet the consumers’ need for pasteurizing infused beverages? If you’re a beverage maker looking to expand your knowledge and skills, read on. Discover how to pasteurize infused beverages and deliver what the customer wants! 

What Is Pasteurization? 

If you’re looking to infuse your beverage with fruit or other unique ingredients, pasteurization can help you stabilize your product. 

The pasteurization process helps protect the general population from harmful foodborne illnesses that can be a problem for bottlers. Because heat destroys bacteria, it’s easy to use it to deactivate bacteria in a liquid. 

In beverage making, pasteurization stops the growth of yeast that remains in beer post-packaging. Breweries usually only have to worry about sterilizing canned and bottled beer. But with brewing infused drinks, that changes. 

The pasteurization of bottles and cans happens after the package is sealed. This process involves running the bottler or can through hot water spray for the correct duration of time as dictated by the beverage and the bottle/can.  

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What Are the Benefits of Pasteurizing Infused Beverages? 

The benefits of pasteurization far outweigh the costs.  

Reduces Over-Carbonation  

Infusing beverages with CBD, fruit and other ingredients in beverages can affect carbonation levels. Some microorganisms produce excess CO2. Pasteurization prevents the over-carbonation by reducing the organisms before they can cause too much havoc.  

Increases Beverage Shelf-Life  

By removing microbes, pasteurization extends the beverage’s shelf-life and allows you to experiment with different infusions for longer. If you’re not sure whether your new CBD-infused beverages will sell, pasteurization can extend your consumer research longer.  

Pasteurization is especially helpful in times like these because COVID caused unpredictability in consumer behavior. Craft brewers are especially uncertain that they can stay open, let alone sell all of their non-pasteurized product. 

Pasteurization allows breweries and other beverage makers to pivot and concoct different beers to keep their customers loyal and engage new customers. It’s better to do so with a pasteurized product because it has a longer shelf life.  

Non-pasteurized beers have a shelf life of 45 to 60 days, and pasteurized beers can last up to double that. Often, pasteurized beers can last for six to nine months, which is a crucial advantage given the state of the food and beverage industry.  

A popular type of pasteurizer is the tunnel pasteurizer because it can offer high throughput and aseptic conditions do not need to be maintained downstream, as the beverage that has been pasteurize is sealed inside the bottle or can. 

Does Pasteurization Impact the Flavor? 

Many connoisseurs debate whether pasteurizing affects the taste of, say, beer. The answer depends on who you ask. For most, it’s a matter of preference. 

When you take into account that you’re infusing beer with different flavors, it’s tough to determine whether pasteurization has a significant effect on taste.  

Since many infused beers have never been taste-tested, how can you tell if there’s a difference once you pasteurize them? In any case, drinking infused beverages changes will change the flavor profile more than the pasteurization process. 

Consider Pasteurizing Infused Beverages Today  

Pasteurizing infused beverages is an excellent decision for any brewery or beverage bottler that is concerned about how infused beverages affect their product. It is also a standard procedure to use in uncertain times such as these.  

Check out PRO’s pasteurizers and keep your brewery secure and innovative!  

ABOUT US:
PRO Engineering and Manufacturing was established in 1977 by Ed and Dave Michalski as a steel fabrication shop. For more than 40 years, PRO Engineering and Manufacturing, Inc. has been delivering solutions for beverage product shelf stability and consumption safety. As leading innovators in post-fill pasteurization, our skilled team offers the best in high-quality pasteurization equipment.

CONTACT US:
Phone: 414-362-1500 | Email: [email protected]

What Beverage Makers Should Know About Tea Pasteurization

Why is it important to pasteurize tea?

As bottlers become increasingly creative with flavors of bottled tea products, every tea maker should ensure that they know how to pasteurize tea properly. For any responsible manufacturer in the beverage industry, the safety and wellbeing of valued customers should be of paramount importance.

Selling a faulty product that is potentially hazardous to someone’s health can do irreparable damage to a brand. This can be hard to bounce back from, both from the perspective of the retailer and the customer. The good news is that for bottled tea beverages, ensuring microbiological stability is simple and can be achieved with pasteurization.

The science behind pasteurization of tea is straight forward . The yeasts and bacteria responsible for spoilage can be introduced in various ways during production. For instance, it may result from improper sterilization of equipment and machinery. Microbes may also be present in the tea itself. This is particularly true of exotic teas and teas prepared with flowers. While risks are lower for traditional black or green teas, anything added later in the process such as fruit juice, extracts, or natural sugars can also result in contamination.

Furthermore, there are certain teas that are conducive to spoilage once microorganisms are present. For instance, teas with a higher sugar content create an opportunity for yeasts to thrive and convert sugars into carbon dioxide. Naturally, this completely alters the taste profile of the product, but more importantly, there is no guarantee of how safe for consumption the product will be at this point. Additionally, the pressure build-up from trapped carbon dioxide can lead to popping bottle tops.

How does pasteurization of tea work?

The key to the process has one central feature: heat. With thermal processing, microorganisms such as yeasts can be deactivated, redusing the risk of fermentation and as such, hazards to the customer. The procedure can be carried out using pasteurizers that transfer heat through water sprays. This can be conducted fast enough that it has a minimal effect on the tea’s flavor (if any at all).

What kind of tea pasteurization equipment is best for you?

When purchasing pasteurization equipment, one should consider the scale of operation. With batch pasteurizers, a lower quantity of bottles are processed at a time. Batch pasteurizers are ideal for beverage makers who want to try new recipes before going into large scale production, bottlers with reduced floor space or even universities educating students in the Food and Beverage field.

Larger producers with a high throughput may want to consider if a higher capacity model such as a tunnel pasteurizer is more in line with their needs. These sophisticated machines typically feature a conveyer belt that passes bottles through a thermal processing unit. If rapid cooling is required to preserve flavors, the system can be combined with a tunnel cooler.

Make sure your bottled beverages are stable, safe for consumption, and tasting their very best. Head to our page to find out more about our pasteurization equipment.

ABOUT US:
PRO Engineering and Manufacturing was established in 1977 by Ed and Dave Michalski as a steel fabrication shop. For more than 40 years, PRO Engineering and Manufacturing, Inc. has been delivering solutions for beverage product shelf stability and consumption safety. As leading innovators in post-fill pasteurization, our skilled team offers the best in high-quality pasteurization equipment.

CONTACT US:
Phone: 414-362-1500 | Email: [email protected]

Single & Triple Temperature Batch Pasteurizers

Hello and Welcome to PRO Engineering and Manufacturing.
This presentation will explore the subject of batch pasteurizers. Batch pasteurizers, as the name implies, are designed to pasteurize beverages in small batches as opposed to continuous pasteurization seen in tunnel and flash pasteurizers.

Batch Pasteurizers use heated water to increase the temperature of the beverage in the can or bottle.

Some batch designs use a dip tank approach where a batch of bottles/cans are lowered into a tank filled with heated water.
The containers are left in the tank for a specified time and then are lifted out.

Batch pasteurizers that use a dip tank design rather than a water spray design can present the user with problems because…the water that the beverage containers are submersed in may not circulate very well, leading to over or under pasteurization.

Other designs use a spray of hot water to heat the beverage in its container.
The beverage containers are placed in trays which are then placed inside the pasteurizer enclosure.

The machine starts the spray process that results in water covering the bottles/cans for a calculated amount of time.
When that time is up, the door is opened and the trays containing the bottles/cans are removed from the pasteurizer.

Batch pasteurizers are typically used by beverage bottlers who have lower throughput needs, smaller financial resources or less production floor room…

Additionally, large bottlers may use a batch pasteurizer on new products before they are introduced to the marketplace.

Universities may also use batch pasteurizers to educate students.
PRO Engineering has two batch pasteurizer models, the Single Temperature, and the Triple Temperature.  Both use heated water sprays. Both models can be pallet-jacked for ease of moving around the production floor.

Each model has PRO Engineering custom-designed spray nozzles that resist clogging. The Single and Triple Temp models have numerous additional features that make them stand out from the competition.

ABOUT US:
PRO Engineering and Manufacturing was established in 1977 by Ed and Dave Michalski as a steel fabrication shop. For more than 40 years, PRO Engineering and Manufacturing, Inc. has been delivering solutions for beverage product shelf stability and consumption safety. As leading innovators in post-fill pasteurization, our skilled team offers the best in high-quality pasteurization equipment.

CONTACT US:
Phone: 414-362-1500 | Email: [email protected]

PRO Engineering/Manufacturing, Inc. Tunnel Pasteurizers

PRO is the leader in tunnel pasteurizers… why? PRO Engineering has been building, repairing, refurbishing and re-designing tunnel pasteurizers for over 42 years! We have learned what works and what doesn’t in a tunnel pasteurizer over the past four decades. We use this knowledge to design and build tunnel pasteurizers that are low maintenance, high production and easy to use. From the compact yet full-featured SlimLine pasteurizer. To the PRO/Line Series 4, that is often purchased by smaller craft brewers. Along with the very popular PROLine Series 5, that has a process area that is 5 feet wide and up to 60 feet long. To the high capacity PROLine Series 14, that has a process area of 14 feet wide and up to 72 feet long.

PRO SLIM/LINE™ PASTEURIZERS | AN EXTENDABLE SLIM DESIGN

If you need to pasteurize your beverage but your facility will not accommodate a large pasteurizer, consider the Slim/Line™ family of tunnel pasteurizers from PRO. The PRO Slim/Line series of pasteurizers has most of the same features as the PRO full-size pasteurizer line but with a smaller footprint and an economical price.

The PRO Slim/Line™ has a unique design. It can accommodate additional 15 foot modules as your production demand grows. You can start with the basic Slim/Line™, which is 15 feet long. As your production demand grows you can add additional 15 foot modules. You can also start out with a longer machine and add to it. You can start with a 30 foot long Slim/Line and add 15 foot modules all the way up to a 60 foot long pasteurizer.

PRO/Line™ Series 4 PASTEURIZERS | SMALL FOOTPRINT

A compact pasteurizer, with through-conveyor that is 4 feet wide and 24 feet long.

  • Wide access, removable side panels.
  • Extra-large-orifice nozzles.
  • 304 stainless steel constructions.
  • HMI touch screen interfaces with PLC.

PRO/LINE™ SERIES 5, 8, AND 14 PASTEURIZERS | THE COST CUTTER

The Large Series of pasteurizers from PRO are, quite possibly, the most economical large pasteurizers to operate today.

You will find:

  • Low water consumption
  • Low maintenance costs
  • Reduced energy costs
  • Reduced downtime
  • Process width areas 5’, 8’, 14’ and beyond

Check out the PRO website, click on products, and you will find the tunnel pasteurizer that fits your production capacity needs, your plant floor space and your budget. E-mail PRO at [email protected] or Call PRO at (414) 362-1500

ABOUT US:
PRO Engineering/Manufacturing, Inc. was established in 1977 by Ed and Dave Michalski as a steel fabrication shop. For more than 40 years, PRO Engineering/Manufacturing, Inc. has been delivering solutions for beverage product shelf stability and consumption safety. As leading innovators in post-fill pasteurization, our skilled team offers the best in high-quality pasteurization equipment.

CONTACT US:
Phone: 414-362-1500 | Email: [email protected]

Resources:
Blog Channel: https://prowm.com/blog
Blogger Channel: https://pasteurizationsolutions.blogspot.com/
YouTube Channel: https://www.youtube.com/channel/UC8QjDQkDMEosn72MQdrojvQ

Related Articles:
Role of Tunnel Pasteurization: https://prowm.com/brewing/the-role-of-the-tunnel-pasteurizer-how-safe-is-safe/
Special Beers | Pasteurization: https://prowm.com/brewing/special-beers-the-case-for-pasteurization/
Tunnel Pasteurization | Beer: https://prowm.com/brewing/tunnel-pasteurizers-and-beer/
First Beer Syndrome: https://prowm.com/brewing/first-brew-symptom/
Location: https://www.google.com/maps?cid=13831141424893706238

ABOUT US

PRO Engineering/Manufacturing, Inc. was established in 1977 by Ed and Dave Michalski as a steel fabrication shop. From this modest beginning, complete machine fabrication capabilities were quickly added followed by the installation of our own in-house engineering and design group.

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