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Retrofitting Tunnel Pasteurizers: A Step-by-Step Guide

PRO Engineering / Manufacturing Inc.

Introduction

  • Highlight the complexity and necessity of retrofitting tunnel pasteurizers.
  • Emphasize the importance of careful evaluation, planning, and execution.
  • Brief overview of the guide’s objectives.

Assessing Current Equipment

  • Evaluation of Efficiency and Compatibility
    • Inspection for wear and tear.
    • Assessment of age and performance of current equipment.
  • Compliance and Safety Standards
    • Verification against safety standards and regulatory requirements.
  • Identification of Upgrade Needs
    • Noting desired features or capabilities for the retrofit.

Planning for Retrofit

  • Project Planning
    • Creation of a detailed project plan with objectives and timelines.
  • Budget and Resources
    • Estimation of costs and identification of required materials and labor.
  • Regulatory Compliance
    • Review of permits and regulations relevant to the retrofit.
  • Stakeholder Communication
    • Ensuring informed involvement of all parties.

Upgrading Components and Systems

  • Component Evaluation and Selection
    • Analysis of key elements like conveyor systems, heat exchangers, and control devices.
  • Modernization
    • Integration of advanced technology for better control and automation.
  • Energy Efficiency
    • Upgrading to more energy-efficient components.
  • Data and Sensor Enhancements
    • Addition of new sensors for improved data collection.

Implementing Changes

  • Systematic Integration
    • Careful installation and testing of upgrades.
  • Documentation and Communication
    • Recording modifications and maintaining open lines of communication with the team.

Testing and Fine-Tuning

  • Performance Testing
    • Running test batches and adjusting settings for optimal performance.
  • Microbiological Testing
    • Ensuring the system effectively eliminates harmful microorganisms.
  • Adjustments Based on Feedback
    • Fine-tuning based on test results and continuous monitoring.

Frequently Asked Questions

  • Minimizing Production Disruption
    • Strategies for retrofitting without affecting the production schedule.
  • Common Challenges
    • Addressing equipment compatibility, downtime, sterilization levels, and staff training.
  • Regulations and Certifications
    • Compliance with industry standards and local guidelines.
  • Energy Efficiency and Cost Savings
    • Potential benefits of retrofitting for energy use and operational costs.
  • Timeline for Retrofitting
    • Expected duration of the retrofitting process and factors affecting it.

Conclusion

  • Recap of the steps taken and the importance of each in the retrofitting process.
  • The benefits achieved through retrofitting, including improved efficiency, compliance, and product safety.
  • Encouragement for continuous improvement and maintenance to ensure optimal performance.

Introduction

So, you think retrofitting tunnel pasteurizers is as simple as upgrading your phone’s operating system? Well, think again. The process requires careful evaluation, meticulous planning, and precise execution to ensure optimal performance.

But fear not, with our step-by-step guide, you’ll navigate through the intricacies of transforming your pasteurization system with ease. From assessing your current setup to fine-tuning the adjustments, each stage is crucial for achieving the desired results.

Stay tuned for a comprehensive walkthrough that will streamline your retrofitting journey.

Assessing Current Equipment

If you’re planning to retrofit your tunnel pasteurizer, begin by evaluating your current equipment for efficiency and compatibility with the new upgrades. Check for any signs of wear and tear, ensuring all components are functioning optimally.

Look at the age of the equipment and consider if newer models would offer improved performance or energy efficiency. Assess whether your current setup meets safety standards and regulatory requirements.

Take note of any specific features or capabilities you wish to add during the retrofitting process. Understanding the strengths and limitations of your existing equipment is crucial for planning a successful retrofit that enhances your tunnel pasteurizer’s overall performance and longevity.

Planning for Retrofit

When preparing for the retrofit of your tunnel pasteurizer, consider creating a detailed project plan to streamline the process efficiently. Start by assessing the current equipment to identify areas that need improvement. Collaborate with your team to establish clear objectives and timelines for the retrofit.

Evaluate the budget needed for the project, including costs for materials, labor, and any external services required. Determine if any permits or regulations need to be addressed before starting the retrofit. Communication is key to ensure that all stakeholders are informed and involved throughout the planning phase. By carefully planning for the retrofit of your tunnel pasteurizer, you can increase the chances of a successful and smooth upgrade process.

Upgrading Components and Systems

To enhance the efficiency of your tunnel pasteurizer, consider upgrading key components and systems in a strategic manner. Start by assessing the condition of crucial elements such as the conveyor system, heat exchangers, and temperature control devices. Upgrading these components can improve overall system performance and product quality.

Look into modernizing control systems with advanced technology for better monitoring and automation capabilities. Upgrading to energy-efficient components can also lead to cost savings in the long run. Additionally, consider retrofitting your pasteurizer with new sensors for enhanced data collection and analysis.

Implementing Changes

Consider systematically integrating the upgrades discussed earlier to enhance the performance of your tunnel pasteurizer.

Start by carefully implementing the recommended changes to the components and systems. Ensure that each upgrade is installed correctly and tested thoroughly before moving on to the next one. Pay close attention to any specific instructions provided by the manufacturer or technician.

Keep track of the progress and document any modifications made during the retrofitting process. Regularly communicate with your team to ensure everyone is on the same page and understands their roles in the implementation phase.

Testing and Fine-Tuning

To ensure the effectiveness of the implemented upgrades, thoroughly test and fine-tune the tunnel pasteurizer’s performance. Begin by running test batches through the pasteurizer, closely monitoring temperature, conveyor speed, and product flow. Adjust settings as needed to achieve the desired pasteurization levels and product quality.

Conduct microbiological testing on the output to confirm that the pasteurizer is effectively eliminating harmful microorganisms. Fine-tune the pasteurizer by making small adjustments to parameters based on the test results. Continuously monitor and record data during this process to track improvements accurately.

Engage with your maintenance team to address any mechanical issues that may arise during testing. By meticulously testing and fine-tuning, you can optimize your tunnel pasteurizer for peak performance.

Frequently Asked Questions

How Can I Ensure That the Retrofitting Process Will Not Disrupt My Production Schedule?

To ensure the retrofitting process won’t disrupt your production schedule, plan ahead by scheduling downtime, coordinating with your team, and communicating with suppliers.

Stay proactive in addressing any potential issues to minimize disruptions.

Contact PRO Engineering / Manufacturing to ensure a smooth transition, professionalism since 1977.

What Are Some Common Challenges That Companies Face When Retrofitting Tunnel Pasteurizers?

When retrofitting tunnel pasteurizers, common challenges companies face include:

  • Equipment compatibility issues
  • Downtime for installation
  • Ensuring proper sterilization levels
  • Training staff on new processes

Overcoming these hurdles requires careful planning and coordination.

Are There Any Regulations or Certifications That Need to Be Considered During the Retrofitting Process?

When retrofitting tunnel pasteurizers, you must consider regulations and certifications. Ensure compliance with industry standards like FDA or ISO. Check local health department guidelines.

Prioritize safety and quality to meet requirements and maintain the integrity of your pasteurization process.

Can Retrofitting a Tunnel Pasteurizer Lead to Increased Energy Efficiency or Cost Savings?

Retrofitting a tunnel pasteurizer can boost energy efficiency and save costs.

Upgrading components like heat exchangers and insulation can lead to improved performance.

Consider consulting PRO experts to optimize your system for maximum benefits.

How Long Does the Typical Retrofitting Process for a Tunnel Pasteurizer Take from Start to Finish?

The typical retrofitting process for a tunnel pasteurizer takes about 4-6 weeks from start to finish.

You’ll see improvements in efficiency and potentially cost savings.

Ensure proper planning and coordination for a successful upgrade.

Conclusion

After following the step-by-step guide for retrofitting tunnel pasteurizers, you have successfully upgraded your equipment to meet current industry standards.

By assessing your current equipment, planning for retrofit, upgrading components and systems, implementing changes, and testing and fine-tuning, you have ensured that your tunnel pasteurizers are operating efficiently and effectively.

Congratulations on completing this important process to improve the safety and quality of your products. Keep up the great work!

RESOURCES:

  • PRO Engineering/Manufacturing Inc. Overview:
    Provides insights into PRO Engineering/Manufacturing Inc.’s offerings in tunnel pasteurizers, including their PRO/LINE™ Series and Slim/Line™ tunnel pasteurizers. It highlights features like removable side panels, reduced energy use, and clog-resistant spray nozzles, showcasing the company’s expertise in customizing solutions for beverage product shelf stability and consumption safety​​.
  • PRO Engineering / Manufacturing Retrofit Division:
     This article delves into methods for retrofitting tunnel pasteurizers to improve energy efficiency and sustainability. It discusses heat recovery systems, insulation improvements, and the integration of alternative energy sources. The benefits of retrofitting include reduced energy consumption, lower operating costs, and minimized carbon footprint​​.

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:

Enhancing Energy Efficiency and Sustainability: Retrofitting Tunnel Pasteurizers

PRO Engineering / Manufacturing Inc.

Introduction

In the realm of food and beverage production, tunnel pasteurizers play a crucial role in ensuring product safety and shelf life. These large-scale machines are integral to the thermal processing of food and beverages, effectively sterilizing them by subjecting them to high temperatures for a specified period.

However, while tunnel pasteurizers are indispensable to the industry, they are also notorious for their high energy consumption and substantial environmental impact. In an era where sustainability is paramount, the need to retrofit tunnel pasteurizers for enhanced energy efficiency has never been more urgent.

Current Challenges in Tunnel Pasteurizer Efficiency

Tunnel pasteurizers, although indispensable, pose significant challenges in terms of energy consumption and environmental impact. The conventional operation of these machines involves the utilization of large amounts of electricity or fossil fuels to maintain the necessary temperatures for pasteurization.

Consequently, this results in a considerable carbon footprint, contributing to climate change and environmental degradation. Moreover, tunnel pasteurizers often require substantial volumes of water for cooling purposes, further exacerbating their environmental strain. Addressing these challenges is imperative for reducing the ecological impact of food and beverage production and moving towards a more sustainable future.

Methods for Retrofitting Tunnel Pasteurizers

  1. Heat Recovery Systems: Heat recovery systems offer a promising solution for improving the energy efficiency of tunnel pasteurizers. These systems work by capturing waste heat generated during the pasteurization process and repurposing it for other heating applications within the production facility.

For example, in a food processing plant utilizing a tunnel pasteurizer, the heat recovered from the pasteurizer could be used to preheat water for cleaning purposes or to heat the facility during colder months. By utilizing this otherwise wasted heat, businesses can significantly reduce their reliance on external energy sources and lower their overall energy consumption.

Additionally, heat recovery systems contribute to cost savings by minimizing heating expenses and improving overall operational efficiency. Some advanced heat recovery systems even incorporate technologies such as heat exchangers and thermal storage to maximize efficiency and flexibility.

  1. Insulation Improvements: Another effective method for enhancing the energy efficiency of tunnel pasteurizers is through insulation improvements. Upgrading insulation materials and sealing gaps in the pasteurizer structure can minimize heat loss during operation, thereby reducing the amount of energy required to maintain optimal temperatures.

For instance, by installing high-performance insulation materials such as aerogels or vacuum insulation panels, businesses can achieve greater thermal efficiency and reduce energy consumption. Additionally, improved insulation can contribute to a more comfortable working environment for employees by reducing heat loss and fluctuations, leading to increased productivity and employee satisfaction.

  1. Integration of Alternative Energy Sources:
    Embracing renewable energy sources such as solar or wind power presents an opportunity to further enhance the sustainability of tunnel pasteurization processes. By harnessing clean energy from renewable sources, businesses can reduce their reliance on fossil fuels and minimize their environmental impact. For example, a food processing facility could install solar panels on the roof of the production facility to generate electricity to power tunnel pasteurizers.

Similarly, wind turbines could be installed on-site to provide an additional source of renewable energy. Integrating alternative energy sources into tunnel pasteurization operations not only reduces carbon emissions but also demonstrates a commitment to environmental stewardship. Furthermore, advancements in energy storage technologies, such as batteries or hydrogen fuel cells, enable greater integration of intermittent renewable energy sources, ensuring reliable and sustainable power supply for tunnel pasteurizers even during periods of low renewable energy generation.

Benefits of Retrofitting Tunnel Pasteurizers

The benefits of retrofitting tunnel pasteurizers for enhanced energy efficiency and sustainability are manifold. By adopting these retrofitting measures, businesses can:

  • Reduce energy consumption and lower operating costs.
  • Minimize their carbon footprint and mitigate climate change impacts.
  • Enhance operational efficiency and improve overall productivity.
  • Demonstrate corporate social responsibility and environmental leadership.
  • Enhance brand reputation and appeal to environmentally conscious consumers.

Conclusion

In conclusion, retrofitting tunnel pasteurizers for enhanced energy efficiency and sustainability is not just a prudent business decision—it’s a moral imperative. By embracing innovative technologies and sustainable practices, businesses can pave the way for a greener, more eco-friendly future.

Let us strive towards a world where efficiency and sustainability go hand in hand, one pasteurizer at a time. Together, we can make a meaningful difference in protecting the planet for future generations.

REFERENCES:

  1. Heat Recovery Systems:
  2. Insulation Improvements:
  3. Integration of Alternative Energy Sources:
  4. Case Studies and Success Stories:
  5. General Resources on Energy Efficiency and Sustainability:

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:

Revitalizing Beverage Production: The Environmental Upsides of Retrofitting Tunnel Pasteurizers

Introduction

  • Background: Introduce tunnel pasteurizers as essential equipment in beverage production, crucial for ensuring product safety and longevity.
  • Significance: Emphasize the increasing relevance of sustainable practices in the industrial sector, particularly in the face of global environmental challenges.
  • Thesis Statement: Argue that retrofitting existing tunnel pasteurizers, as opposed to replacing them, presents a significant opportunity for the beverage industry to reduce its environmental footprint.

Understanding Tunnel Pasteurizers

  • Definition and Function: Describe tunnel pasteurizers as large, industrial-scale equipment used for heating and subsequently cooling beverages to eliminate pathogens and extend shelf life.
  • Industry Usage: Discuss the prevalence of these systems in the production of beer, milk, juice, and soft drinks.
  • Energy and Resource Demand: Outline how traditional tunnel pasteurizers are energy-intensive and require substantial amounts of water, contributing to the industry’s environmental impact.

The Need for Environmental Efficiency

  • Industry Impact: Delve into the specific environmental impacts of the beverage industry, such as high-water usage, energy consumption, and CO2 emissions.
  • Global Context: Frame these impacts within the broader challenges of climate change, resource depletion, and environmental degradation.
  • Consumer and Industry Trends: Highlight increasing consumer demand for environmentally responsible products and the industry’s response through sustainability initiatives.

Benefits of Retrofitting

  • Definition of Retrofitting: Explain retrofitting as the process of updating and improving existing equipment with new technology to enhance efficiency.
  • Environmental Advantages:
    • Reduced Energy Consumption: Discuss how retrofitting can lead to more efficient heating and cooling processes, thereby saving energy.
    • Lower Greenhouse Gas Emissions: Link reduced energy consumption directly to decreased carbon footprint.
    • Decreased Water Usage: Explore innovations in water recycling and reduced water needs in retrofitted systems.
    • Improved Waste Management: Mention advances in reducing waste products from the pasteurization process.

Case Studies and Real-World Examples

  • Successful Implementations: Present examples of companies that have retrofitted their tunnel pasteurizers, detailing the process and technologies used.
  • Outcome Analysis: Assess the environmental and economic benefits observed post-retrofitting, providing quantitative data where available.
  • Comparative Analysis: Compare the performance of retrofitted systems against traditional models to highlight improvements.

Challenges and Considerations

  • Cost and Investment: Address the initial costs and investment required for retrofitting and how companies can manage these expenses.
  • Technological Barriers: Discuss any technical challenges or limitations in retrofitting older equipment and how these can be overcome.
  • Balancing Act: Explore the need for companies to balance economic and environmental objectives, and the role of regulatory frameworks and incentives.

Future Outlook

  • Technological Evolution: Speculate on future advancements in tunnel pasteurizer technology and their potential environmental benefits.
  • Industry Trends: Predict how industry standards might evolve to further embrace sustainability, influenced by policy changes and consumer demand.
  • Leadership and Responsibility: Encourage industry leaders to take proactive steps in adopting sustainable practices, setting a precedent for the entire sector.

Conclusion

  • Summary: Recap the environmental benefits of retrofitting tunnel pasteurizers and the importance of such measures in the beverage industry.
  • Broader Implications: Emphasize the role of these practices in contributing to global environmental sustainability.
  • Call to Action: Urge the industry to consider retrofitting as a viable and crucial step towards a more sustainable future.

Introduction

In the world of beverage production, tunnel pasteurizers play a pivotal role. These large, industrial-scale machines are not just integral to ensuring product safety and longevity; they are also at the heart of a significant environmental conversation. As global environmental challenges mount, the beverage industry is facing increasing pressure to adopt sustainable practices. This article posits that retrofitting existing tunnel pasteurizers offers a significant opportunity for the industry to reduce its environmental footprint, providing a pragmatic approach to eco-friendly production.

Understanding Tunnel Pasteurizers

Tunnel pasteurizers are essential in the beverage industry, used extensively for sterilizing products like beer, milk, juice, and soft drinks. By heating and subsequently cooling these beverages, they eliminate pathogens and extend shelf life. However, traditional tunnel pasteurizers are known for their substantial energy and water demands, contributing notably to the industry’s environmental impact.

The Need for Environmental Efficiency

The beverage industry, like many others, faces challenges in terms of high-water usage, energy consumption, and CO2 emissions. These challenges are set against the broader backdrop of climate change, resource depletion, and environmental degradation. Moreover, there’s a growing trend among consumers demanding environmentally responsible products, prompting the industry to respond with sustainability initiatives.

Benefits of Retrofitting

Retrofitting involves updating and improving existing equipment with advanced technology to enhance efficiency. The environmental advantages of retrofitting tunnel pasteurizers are considerable:

  • Reduced Energy Consumption: New technologies can significantly enhance the efficiency of heating and cooling processes in pasteurizers, leading to substantial energy savings.
  • Lower Greenhouse Gas Emissions: This reduced energy consumption directly translates to a decrease in carbon footprint.
  • Decreased Water Usage: Innovations in water recycling and management in retrofitted systems can drastically reduce the water needs of these machines.
  • Improved Waste Management: Advances in technology also mean better handling and reduction of waste products from the pasteurization process.

Case Studies and Real-World Examples

Several companies have successfully retrofitted their tunnel pasteurizers, employing new technologies and processes. These retrofitting projects have not only yielded significant environmental benefits but also, in many cases, economic ones. For instance, a particular beverage company reported a 30% reduction in energy consumption post-retrofitting. Comparative analyses further reveal that retrofitted systems often outperform traditional models in both efficiency and environmental impact.

Challenges and Considerations

Despite these benefits, there are challenges to consider. The initial cost and investment can be substantial, though they often pay off in the long run. Technological barriers can also pose a problem, especially when retrofitting older models. Companies must balance these economic considerations with environmental responsibilities, navigating the complexities of technological advancements and regulatory landscapes.

Future Outlook

The future of tunnel pasteurizer technology looks promising, with ongoing advancements poised to further enhance sustainability. Industry standards are likely to evolve, influenced by changing policies and increasing consumer demand for environmentally friendly practices. It’s crucial for industry leaders to take proactive steps in adopting these sustainable practices, setting a precedent for the sector.

Conclusion

Retrofitting tunnel pasteurizers presents a viable and crucial step towards more sustainable beverage production. By embracing these practices, the industry can significantly contribute to global environmental sustainability, meeting both consumer demands and ecological responsibilities. It’s a call to action for the industry, highlighting the need for continued innovation and commitment to environmental stewardship.

References

This article draws on a variety of academic studies, industry reports, and expert opinions, all advocating for a more sustainable approach to industrial production. These resources provide a comprehensive view of the current landscape and future

Case Study: Retrofitting in a Major Brewery

Background:

  • A well-known brewery, facing rising energy costs and increased pressure for sustainable practices, decides to retrofit their tunnel pasteurizers.

Retrofitting Process:

  • The brewery installs advanced heat recovery systems and implements a closed-loop water system in their existing tunnel pasteurizers.
  • They also integrate smart sensors and control systems for more efficient operation and monitoring.

Results:

  • Post-retrofitting, the brewery reports a 40% reduction in energy consumption and a 50% decrease in water usage.
  • There is also a notable reduction in greenhouse gas emissions, aligning the brewery with regional carbon reduction goals.

Scenario: Improved Waste Management in Juice Production

Situation:

  • A juice manufacturing company recognizes the need to reduce its environmental impact, particularly in waste management.

Retrofitting Actions:

  • They retrofit their tunnel pasteurizers with new filtration systems that reduce the amount of waste produced during the pasteurization process.
  • They also implement a waste-water treatment plant that recycles water back into the production cycle.

Impact:

  • The retrofit leads to a 60% reduction in solid waste production.
  • The closed-loop water system cuts down the company’s overall water footprint by 35%.

Future Outlook: Innovation in Soft Drink Industry

Prediction:

  • As sustainability becomes a key factor in consumer choices, a leading soft drink company plans to retrofit its pasteurizers with the latest eco-friendly technology.

Anticipated Innovations:

  • The company plans to incorporate solar-powered heating elements in its tunnel pasteurizers.
  • Advanced AI systems for real-time energy management and efficiency optimization are also on the horizon.

Expected Results:

  • These changes are expected to reduce the company’s energy consumption by up to 70%.
  • The integration of renewable energy sources significantly lowers the carbon footprint of the production process.

Major Brewery’s Retrofitting Initiative

Background:

A leading brewery, aware of its high energy costs and environmental impact, decides to upgrade its existing tunnel pasteurizers.

Retrofitting Process:

  • Installation of Advanced Heat Recovery Systems: These systems capture and reuse heat that would otherwise be wasted, significantly reducing energy consumption.
  • Implementation of a Closed-Loop Water System: This system recycles water within the pasteurization process, drastically cutting down on water waste.
  • Integration of Smart Sensors and Controls: These technological enhancements allow for more precise operation, reducing unnecessary energy use and improving efficiency.

Results:

  • Energy Consumption Reduction: The brewery experiences a 40% decrease in energy use, leading to lower operational costs.
  • Water Usage Decrease: Water efficiency improves by 50%, aligning with sustainability goals and reducing environmental impact.
  • Greenhouse Gas Emissions: The retrofitting results in a notable decrease in emissions, helping the brewery meet regional and global environmental standards.

Juice Manufacturing Company’s Waste Management Improvement

Situation:

A juice producer aims to enhance its environmental performance, particularly in waste management during the pasteurization process.

Retrofitting Actions:

  • New Filtration Systems: These systems are installed to minimize the generation of waste during pasteurization.
  • Waste-water Treatment Plant: The plant enables the recycling of water, reducing the overall water footprint of the manufacturing process.

Impact:

  • Solid Waste Production Reduction: There is a 60% drop in the amount of waste produced, enhancing the company’s environmental sustainability.
  • Water Footprint Reduction: The introduction of the treatment plant cuts the company’s water usage by 35%, making their operations more sustainable.

Soft Drink Company’s Future Retrofitting Plans

Prediction:

Anticipating the growing consumer demand for sustainable products, a major soft drink manufacturer plans to retrofit its tunnel pasteurizers with cutting-edge eco-friendly technologies.

Anticipated Innovations:

  • Solar-Powered Heating Elements: These would harness renewable energy for heating, significantly reducing reliance on fossil fuels.
  • AI Systems for Energy Management: Artificial intelligence would optimize energy use in real-time, ensuring maximum efficiency and minimal waste.

Expected Results:

  • Energy Consumption Reduction: The company expects to reduce its energy use by up to 70%, significantly lowering operational costs and environmental impact.
  • Lower Carbon Footprint: By using renewable energy sources, the carbon footprint of the production process would be greatly reduced.

Conclusion

These examples serve to illustrate how retrofitting tunnel pasteurizers can lead to significant environmental benefits in the beverage industry. They highlight the reduction in energy and water consumption, improved waste management, and decreased greenhouse gas emissions. The examples also demonstrate that retrofitting is not only beneficial for the environment but can also be a smart economic decision, offering operational cost savings and aligning with consumer preferences for sustainable products.

RESOURCES:

Government websites offer a wealth of resources and information across a wide range of topics and services. Here are some notable examples:

  1. USA.gov: This is the U.S. Government’s official web portal, designed to help users locate and understand various government benefits, programs, and information. It offers guidance on how to access services like passport renewal, finding unclaimed money from the government, locating affordable rental housing, and obtaining government benefits and financial assistance. The website is a comprehensive resource for a variety of life events and services​​​​.
  2. Digital.gov: This site focuses on providing resources for building accessible, mobile-friendly government websites for the American public. It includes the U.S. Web Design System, a design system for the federal government, and offers an overview of how to design and deliver accessible digital products and services. This resource is particularly valuable for teams and individuals involved in creating or managing digital services within the government​​.
  3. Data.gov: As the United States government’s open data website, Data.gov provides access to a vast array of datasets published by agencies across the federal government. This platform is a valuable resource for researchers, policymakers, and the general public interested in government data and statistics. The datasets cover a wide range of topics and can be used for various research and analytical purposes​​.
  4. A-Z Index of U.S. Government Departments and Agencies: This resource on USA.gov offers an extensive index of U.S. federal government departments and agencies. It includes contact information such as websites, emails, phone numbers, and addresses, making it easier for individuals to find specific information or contact government entities directly​​.

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:

PRO has an Extensive Inventory of Refurbished Drive and Idle Shafts for Tunnel Pasteurizers for Most Manufactures

All shafts have been refurbished with savings of 10k to 60k less than the original manufacturer. Also, our delivery time is usually weeks instead of months resulting in shorter downtime with increased profits.

PRO is the Answer!

We can supply drive and idle shafts parts:

  • Faster
  • Less Cost
  • Shorter Downtime
  • Guaranteed Commercial Installation and Performance

List of manufacturers potentially covered by PRO’s rebuilds for Emergency Repair or Long-Term Replacement:

BW, H&K, KHS, Krones, Sander Hansen, Meyer, Evens, Sidel, Pama, NIKO, CFT, I&H, Semonazzi, Sasib, GEA, SMT, COMAC, Anticoro Babik, Hermis, Alibaba, Degong, Barry-Wehmiller.

Real Life Scenarios for Retrofitting Tunnel Pasteurizer or Refurbished Parts:

Scenario #1

“Due to the size of these units and often their location within the plant will make the replacement a challenge in cost and time.
An example is a client in Florida, has the packaging line locked in place behind several other packaging lines. So to remove and replace the plant would have to shut down totally for an extended time window.

Even if the line is not behind other lines, it still takes longer to demo out the old unit and move in the new one. When a total rebuild may only take 10 to 14 days. A rebuild may cost 3⁄4 of new unit but the option will double the cost of the new unit.”

Scenario #2

“ABC Brewing Company, for example, could have a major manufacturers pasteurizer. The pasteurizer could be 20 years old. For $250,000+ we can replace all the moving parts on the inside of the pasteurizer over 10 days and have the machine running like new.

The manufacturer may do the service work just as well as Pro Engineering, but because we do not have to use manufactures parts, we can provide more options. Moreover, manufacturer will push for ABC Brewery to buy one of their new pasteurizers for $800,000+”

FEATURES & BENEFITS:

Retrofitting drive shaft and idler shaft spare parts for tunnel pasteurizers can provide several benefits, especially in industrial settings where pasteurization processes are critical for beverage pasteurization.

Here’s some information and the potential benefits of retrofitting / rebuilding these essential parts:

1. Improved Reliability and Performance: Retrofitting with high-quality drive shafts and idler shafts can enhance the reliability and performance of your tunnel pasteurizer.

These components play a crucial role in the conveyor system, ensuring smooth and consistent movement of products through the pasteurization process.

2. Extended Equipment Lifespan: Replacing worn or damaged shafts with new spare parts can extend the lifespan of your tunnel pasteurizer. This can help avoid unexpected downtime and costly repairs, ultimately saving you money in the long run.

3. Enhanced Product Quality: Well-maintained drive and idler shafts contribute to consistent product movement and proper heat treatment during pasteurization. This can lead to improved product quality, ensuring that food and beverages meet safety standards and taste expectations.

4. Energy Efficiency: Retrofitting with high-quality refurbished parts can lead to more efficient operation. Smoothly functioning shafts require less power, contributing to energy savings and reduced operating costs.

5. Reduced Maintenance Costs: Investing in reliable retrofit spare parts can reduce the need for frequent maintenance and repairs. This can result in lower labor costs and reduced downtime, allowing your production line to run smoothly.

6. Compliance with Regulatory Standards: Maintaining and retrofitting tunnel pasteurizers with quality spare parts can help ensure compliance with food safety and quality regulations. This is essential for businesses in the food and beverage industry to avoid fines and maintain a good reputation.

7. Customization and Upgrades: When retrofitting, you have the opportunity to select spare parts that meet the specific requirements of your tunnel pasteurizer. This can include choosing materials that are more resistant to corrosion or wear, improving the overall durability and performance of the equipment.

8. Environmental Benefits: A well-maintained pasteurizer with efficient spare parts can help reduce the environmental impact of your production process by conserving energy and minimizing waste.

9. Minimized Downtime: Retrofitting spare parts can be quicker and more cost- effective than replacing an entire pasteurization system. This can significantly reduce downtime, allowing you to maintain production schedules and meet customer demand.

10. Cost Savings in the Long Term: While retrofitting may involve an initial investment, the long-term benefits in terms of reduced maintenance, improved efficiency, and extended equipment life can lead to significant cost savings over time.

When considering retrofitting drive shaft and idler shaft spare parts for tunnel pasteurizers, it’s crucial to consult with experts in industrial equipment maintenance and select high-quality spare parts that are compatible with your specific equipment.

Proper installation and ongoing maintenance are essential to realizing these benefits and ensuring the continued reliability and performance of your tunnel pasteurizer.

PRO Engineering / Manufacturing Inc. is the industry leader in rebuilt / retrofit Drive and Idle Shafts:

  • Save Money
  • Save Time
  • Least interruption in plant shutdown
  • Industry leader in manufacturing customized pasteurizers and refurbished parts since 1997

Call Us Today for More Information: 414-362-1500

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:

A Brew with a View: World’s Most Scenic Brewery Locations

1. Introduction

  • Brief overview of the joy of combining scenic beauty with a cold brew.

2. The Rise of Scenic Breweries

  • The advantage and appeal of combining two sensory pleasures: taste and sight.

3. North America

  • U.S.: Sierra Nevada (California), Founders Brewing Co. (Michigan)
    • Overview of each, their signature brews, and what makes their locations scenic.
  • Canada: Tofino Brewing Company (British Columbia), Quidi Vidi Brewery (Newfoundland)
    • Distinguishing features of these Canadian gems.

4. Europe

  • Belgium: Abbey of Westvleteren
    • Rich history combined with a serene landscape.
  • Scotland: Isle of Skye Brewing Co.
    • Where Scottish tradition meets panoramic ocean views.
  • Norway: Ægir Brewery
    • Nestled amidst fjords and Viking lore.

5. Asia & Oceania

  • Japan: Hitachino Nest Beer, Kiuchi Brewery
    • Tranquil Japanese setting and unique brews.

6. Africa

  • South Africa: Clarens Brewery
    • Mountainscape meets artisanal brews.

7. South America

  • Argentina: Patagonia Brewery, Bariloche
    • Where Argentinian brews and Andean vistas unite.

8. The Experience: Beyond the Beer

  • How the ambiance and view influence the beer-tasting experience.

9. Ecological Considerations

  • Breweries that prioritize environment-friendly operations.

10. Conclusion

  • Encouraging readers to prioritize experience and ambiance on their next brewery tour.

11. Quick Tips & Recommendations

  • Best times to visit.
  • Specialty brews of each location.
  • Suggestions for making the most of your brewery tour experience.

1. Introduction

Nothing complements a cold brew better than a breathtaking view. Imagine sipping on a freshly brewed pint while gazing out over mountains, oceans, or historic cities. Breweries around the world are catching onto this concept, offering beer enthusiasts not just a drink, but an experience.

2. The Rise of Scenic Breweries

Historically, breweries were built based on practical considerations like water source and transportation1. Today, as the craft beer movement grows, many breweries are choosing locations that offer patrons a feast for their eyes as well as their taste buds.

3. Top Scenic Breweries of the World:

Sierra Nevada (California, U.S.)

Located in Chico and later expanding to Mills River in North Carolina, Sierra Nevada not only boasts of its rich history in American craft beer but also its pristine environment.

In Chico, the brewery lies near the foothills of the Sierra Nevada mountains, offering a verdant backdrop, while the North Carolina location is nestled within the lush forests of the Blue Ridge Mountains. Visitors can enjoy the scenic landscapes, with rivers cutting across and the grandeur of towering trees, adding to the charm of the brewery.

Founders Brewing Co. (Michigan, U.S.)

Founders Brewing Co., situated in Grand Rapids, Michigan, offers views of the Grand River. The river setting provides a tranquil atmosphere where visitors can appreciate the rhythmic flow of water while savoring their drinks. Moreover, the architectural charm of Grand Rapids complements the scenic allure, making it a dual treat of urban and natural beauty.

Tofino Brewing Company (British Columbia, Canada)

Tofino is a district on Vancouver Island’s west coast. The place is a meld of thick rainforests, vast beaches, and a stretching coastline. Tofino Brewing Company, amidst this beauty, encapsulates the spirit of the wild west coast, making every sip of beer feel like an embrace from nature.

Quidi Vidi Brewery (Newfoundland, Canada)

The brewery is situated in Quidi Vidi Village, a historic fishing community. Overlooking Quidi Vidi Harbor, the brewery offers mesmerizing views of rocky outcrops and the vast North Atlantic Ocean.

It’s not just a place for beer, but also for soaking in Newfoundland’s rich history and rugged coastal beauty.

Abbey of Westvleteren (Belgium)

Located in the West Flanders region of Belgium, this brewery is run by Trappist monks at the Saint Sixtus Abbey. The serenity of monastic life combines with Belgium’s rolling countryside, creating a peaceful, pastoral scene.

Here, beer becomes a bridge between spiritual contemplation and sensory delight.

Isle of Skye Brewing Co. (Scotland)

Portree, where this brewery is based, offers panoramic views of the surrounding Scottish highlands and the Atlantic Ocean. With rugged cliffs, verdant meadows, and a rich Gaelic history, this brewery’s setting captures the essence of Scotland’s wild heart.

Ægir Brewery (Norway)

Inspired by Norse mythology, Ægir Brewery in Flåm sits amidst the dramatic landscapes of Norwegian fjords. With steep mountain walls, cascading waterfalls, and the serene waters of the Aurlandsfjord, it’s a place where ancient Viking tales come to life.

Hitachino Nest Beer, Kiuchi Brewery (Japan)

Located in Ibaraki Prefecture, this brewery is surrounded by the serene Japanese countryside. With rice fields stretching out, and traditional Japanese architecture, it reflects an elegant blend of nature and tradition, making the beer tasting a meditative experience.

Clarens Brewery (South Africa)

Located in the Free State province, Clarens is often termed as the “Jewel of the Eastern Free State.” The brewery offers views of the Maluti Mountains, with its golden sandstone cliffs and vast landscapes making every brew feel like a toast to the wilderness.

Patagonia Brewery, Bariloche (Argentina)

Bariloche, in Argentina’s Patagonia region, is known for its Swiss alpine-style architecture and its location alongside the Andes. The brewery, with views of snow-capped peaks, azure lakes, and dense forests, offers a mesmerizing blend of wild landscapes and crafted beers.

8. The Experience: Beyond the Beer

The ambiance and setting of these breweries play a massive role in the tasting experience. Many breweries often use ingredients found in their surroundings, ensuring the drink reflects the locale’s essence.

9. Ecological Considerations

Being in such scenic locations, many breweries are adopting sustainable practices to ensure minimal impact on the environment. Breweries like Sierra Nevada lead in sustainable brewing operations, emphasizing the importance of giving back to nature.

10. Conclusion

In today’s world of craft beer, it’s not just about the taste. It’s about the experience. And what better way to enhance this experience than pairing it with nature’s finest views?

11. Quick Tips & Recommendations

  • Best Times: Many of these breweries offer seasonal brews, so checking in advance can enhance your visit.
  • Specialty Brews: Always ask for the locale’s specialty or limited-time offer.
  • Enhancing Your Visit: Consider local festivals or events when planning your brewery tour for an enriched experience.

Other Resources:

Beer Advocate – Beer Festivals

Food & Wine – Craft Brewery Guide

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:

What Are Some of The Best Fall Beers For 2022?

As the weather starts to cool down, beer drinkers consider which beers they will enjoy during the fall season. It’s no secret that a wide variety of beer is available during this time of year, but some breweries release special edition beers. Our list of top fall beers for 2022 explains why they’re perfect for the season and how to enjoy them.

What Exactly Are Dark Beers?

It is a common misconception that dark beer is heavy and filling. Dark beer is surprisingly refreshing and flavorful; many are low in calories. The first dark beer to be named after the fall season was doppelbock, which originated as a drink for monks during their fasts. Other names for this beer category include imperial stout, black stout, and chocolate stout.

While light lagers and dark beers have similar alcohol levels, darker beers often contain more malt and sugar. These beers have a richer flavor and a winning combination with spicy food and grilled meat.

What Should I Brew In Fall?

Fall is a great time if you’re considering a new beer recipe this year. Beer in this season is more balanced and complex than in the summer. Summer beers are citrusy and piney, while fall beers are richer and spicier.

Beer lovers everywhere are excited about the upcoming Oktoberfest beers. With fall just around the corner, you should start planning your brewing process for the coming year. You can enjoy many delicious beer styles, including pumpkin and amber ales. The calendar will surely have something you’ll like, whether you prefer lighter or heavier ales.

If pumpkin spice isn’t your thing, consider making a spiced beer. Try a pumpkin-infused ale from New Belgium. It is perfect for chilly autumn evenings. There is a beer for every taste, whether you prefer a pale ale or wheat beer.

What Are The Best Seasonal Beers To Drink During The Autumn Season?

You’ll be ready to start sipping a delicious new brew when fall comes around. Fall is a season for change, and beer is no exception. While summer beers are full of citrus notes and pine, fall beers are rich and complex. Their flavors can range from malty to sweet and spicy. This article will highlight a few options to help you celebrate the fall season in style. Read on to find the best beer for fall this year! Also, check out the many new fall beers hitting the market!

SHACKSBURY DRY CIDER

A crisp cider is the best way to welcome the season. Beyond being a boozy drink, however, this versatile drink pairs beautifully with delicious gourmet foods. This wine has a zesty, grape-like scent and a sweet, refreshing apple flavor on the finish.

ELYSIAN BREWING CO. THE GREAT PUMPKIN

While most pumpkin-flavored beers fall short of expectations, Elysian’s “The Great Pumpkin” stands out. In this world’s first Imperial pumpkin ale, roasted seeds add flavor to the mash and some extra flesh during fermentation and kettling. Adding cinnamon, nutmeg, cloves, and allspice to the brew hides its boozy alcohol content, providing a rich, pumpkin pie-like taste.

NORTH COAST BREWING OLD RASPUTIN RUSSIAN IMPERIAL STOUT

Old Rasputin is a familiar name in the craft beer industry. And it’s for a good reason, too. An impressive imperial stout brewed with traditional English methods, it reaches a full 9% ABV with a creamy mouthfeel and plenty of malty characters. Intensely black and full-bodied, Old Rasputin beer is an excellent choice for a chilly autumn evening.

ANCHOR BREWING ANCHOR PORTER

This beer from Anchor Brewing has a little less bite than others, so it may be a good fit if you prefer darker beers with a bit less bite. Its blend of pale, caramel, chocolate and black malts remains a timeless classic 40 years after its original release. Despite its sweet candy and coffee flavors, it’s surprisingly light and refreshing.

DESCHUTES HOPZEIT AUTUMN IPA

PRO Engineering / Manufacturing Inc. has put together a list of autumn beers that are both unique and delicious.

It’s not so easy to find this beer nowadays, but if you do find it, it’s certainly well worth trying. Autumn IPA mixes classic Märzenbier flavors with modern German hop varietals, pouring bright orange with a spicy malt backbone. The aroma is lightly grassy and floral, followed by citrus fruit and a resiny-pine scent that defines classic IPAs. The wine pairs well with heavier foods like meat or pizza, but almost anything goes.

JACK’S ABBY COPPER LEGEND OKTOBERFEST

A leading expert in lagers, Jack’s Abby is ready to deliver a quality Oktoberfest brew. Case in point: Copper Legend. It pours a proper Märzen appearance and taste with a thick white head, mild carbonation, and deliciously bready-but-floral flavors. The 5.7% ABV might be surprising to IPA drinkers, though it makes for an enjoyable sip. Regardless of how you drink it, a stein is essential for the complete Oktoberfest experience.

NEW BELGIUM VOODOO RANGER ATOMIC PUMPKIN

New Belgium’s regular Voodoo Ranger offerings live up to their names with this pumpkin-infused offering. This pretty interesting beer is brewed with pumpkin, Saigon cinnamon, and habanero chilies and begins sweet, surprises with some heat, and finishes with a subtle brown sugar flavor. It might seem surprising that peppers would work in a beer, but they add a pleasant warming sensation that will keep you warm during even the coldest parts of the year.

BELL’S BREWERY EXPEDITION KALAMAZOO STOUT

Bell’s Kalamazoo stout is rich in flavor but still easy to drink. This beer is a classic Bell mash bill, combining coffee, dark chocolate, and malt from start to finish for an exceptional drinking experience. Even with the hops added, the creamy mouthfeel and licorice-like taste make it an acceptable choice for connoisseurs of dark beer.

HARPOON FLANNEL FRIDAY

It combines bready malt with lemon and kaffir lime varietals for an amber ale that is remarkably sweet, piney, and even caramelized. The beer starts strong, but its bitterness doesn’t compromise its drinkability. Flannel Friday is a great fall beer option for IPA fans looking for a bit of seasonality in their beer.

LINDEMAN’S FRAMBOISE

Lambics are more fruit-forward than stouts and are a good choice if you find the fall’s heavy meals and flavors overwhelming. The raspberry and sweet herbs notes in Lindeman’s Framboise complement everything from bready carbs to red meats well. No matter your drinking preferences, it’s an approachable option as it only clocks in at 2.5% alcohol.

ROGUE BREWING HAZELNUT BROWN NECTAR

In contrast to brown ales with muddier tastes, this hazelnut-heavy option from Rogue stands out. Aromas of bread and toast, punctuated by chocolate undertones, almost cereal-like, dominate the nose. Its nutty flavor will instantly captivate you on the first sip, lingering on long after it’s over.

FOUNDERS BREWING BACKWOODS BASTARD

Founders’ Backwoods Bastard fits the bill when light beers won’t do. This barrel-aged Scotch ale stands out for its toffee, caramel, tobacco smoke flavors, and classic bourbon characteristics. The alcohol content is 11%, but it’s a subtle burning sensation instead of an overpowering taste. A candy-like treat with a bite of whiskey.

ALLAGASH BREWING WINDFALL

Freshly picked peaches and Brettanomyces fermented with a blend of wild sour ale yeast make this one a true standout. Pouring a clear amber color with a low, wispy head, it’s tart and sweet yet funky. On the nose, you get lots of lemons, candy, white wine, and peach, though it is more subtle on the palate, reminiscent of apricots and marmalade. Due to its dry, crisp nature, it is a winning combination with savory foods like sausage and smoked vegetables.

SOUTHERN TIER PUMPKIN ALE

This Southern Tier ale lives up to its name, a creamy pumpkin ale that reigns supreme over all other pumpkin beers. Rich, creamy mouthfeel and a roasted fig finish accompany this pie-like brew. While other ales like it tend to go overboard with pumpkin, this ale keeps its balance with cinnamon spice and brown sugar sweetness.

SIERRA NEVADA OKTOBERFEST

Our list ends with Sierra Nevada’s Oktoberfest, a bonafide craft beer classic. This light, happier German-style lager is released annually during the brewery’s fall season. And here’s the thing: drinkers of all kinds are bound to appreciate this brew; between the Hersbrucker varietals, the Pilsner malts, and the lager yeast. It’s a complex offering that’s nevertheless approachable enough to be a true fan favorite. The fall beer scene is all about pumpkins. Pumpkin is the most autumn-inspired ingredient. Pumpkin beer is usually brewed with large amounts of spices, creating a heavier body and dessert-like taste. Pumpkin beers are becoming increasingly popular every year. Maple is another flavor that pairs well with autumn beer; maple ale is an example of this trend. Maple can be used to create a spicier, more complex beer than pumpkin and is a perfect match with this beer. If you’re looking for the best fall beers for 2022, check out the brewers we’ve highlighted above. These beers are perfect for the season, and with such wide varieties, there’s something for everyone. So get out there and start sampling!

Learn More About Pasteurizing!

If you’d like to learn more about pasteurization in general, pasteurizing unique sodas, or the equipment involved, we’d love to help!

Feel free to contact us with any questions or concerns you might have, and we’ll do our best to help you. We want you to feel confident in your understanding of this vital process and how you can make it work for you!

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 tunnel pasteurizers and batch pasteurizers for over four decades.  

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]

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Location: 11175 W Heather Ave, Milwaukee, WI 53224, USA

Stay in The Know: Eight of The Biggest Trends in The Beer Industry For 2022 Into 2023

For many beer brewers, 2022 into 2023 are years of cautious optimism. The beer market took a big hit in 2020 due to the pandemic, but there are several trends that suggest that things are slowly getting back on track and even starting to improve in some areas. The beer industry is constantly changing and evolving. Every year, there are new trends that come about that change the way we enjoy our favorite beverages.

What Beer Market Trends Did We Expect for 2022 Into 2023?

Drinking craft beer for many people is synonymous with social gatherings. So, it’s no surprise that one of the biggest trends in the beer industry for 2022 into 2023 is a return to normalcy.

We’ve all been cooped up for too long and are ready to get out and socialize again. While there still are some restrictions in place, people have been eager to get back to their old routines. That includes going out to bars and pubs and enjoying a cold one with friends.

Brewers should be on top of what is happening so that they can constantly improve on how they make their beer, even as new trends keep popping. Here are some of the other biggest trends in the beer industry for 2022 into 2023.

1. Domination of IPA (India Pale Ale)

IPA is a type of beer that contains a higher level of hops. The definition is simple, but the history behind it is interesting. In the early 19th century, India Pale Ale was first brewed in the UK. It was the first beer to be shipped overseas from Britain. The purpose of IPA was to preserve the beer during long sea voyages and therefore, it had a higher level of hops that would act as a natural preservative.

There is no denying that IPA is the most popular style of craft beer consumption in the United States. In fact, IPA has been the fastest-growing style of beer for the past few years, making up about 30% of all craft beer sales in the United States according to the US Brewers Association. There are a few reasons for this trend.

First, people are becoming more adventurous when it comes to their beer choices. They are willing to try new styles and flavors. IPA is a perfect example of this. It is a very flavorful and hoppy style of beer that has become very popular among craft beer drinkers.

Second, the craft beer movement has also played a role in the popularity of IPA. More and more people are interested in trying local and artisanal beers.

Finally, IPA is also popular because it is relatively easy to make. It does not require a lot of special ingredients or equipment. This makes it a great choice for small brewers who are just starting out.

So, what does this mean for breweries that don’t specialize in IPA? It means they will have to find a way to work around it.

2. Contactless Taprooms

The COVID-19 pandemic has changed the way we do a lot of things, including the way we drink beer. One of the biggest trends that have emerged as a result of the pandemic is contactless taprooms.

A contactless taproom is a beer bar or brewery where customers can order and pay for their beer without coming into contact with anyone else. This can be done through an app or an online ordering system.

One of the benefits of contactless taprooms is that they are much safer than traditional ones. This is because there is no need to exchange cash or cards, which can spread germs. Contactless taprooms are also more convenient since customers can order and pay for their beer without having to wait in line.

3. Ecommerce Growth in the Craft Brewing Industry

There is no doubt that e-commerce is one of the biggest trends in the beer industry. More and more beer companies are selling their products online, and many are even starting to deliver beer directly to customers’ homes. This is a convenient option for customers who want to buy beer without having to go to a store.

Ecommerce is also a great way for beer companies to reach a wider audience. By selling their products online, they can reach customers all over the world. This gives them a much larger potential customer base than if they were only selling in brick-and-mortar stores.

Ecommerce also gives breweries the ability to track customer behavior and preferences. This information can be used to improve the customer experience and marketing efforts.

4. Diversity and Inclusion in the US Beer Industry: A Positive Report

There is an increasing trend towards diversity and inclusion in the beer industry. This means that a wider range of people is being represented in the industry, including people of all genders, races, and sexual orientations. This is a positive trend as it makes the industry more inclusive and welcoming to everyone.

One of the reasons for this trend is that the craft beer movement has made people more aware of the different styles of beer that are available. This has led to a greater appreciation for beers from all over the world.

Another reason for the trend is that people are becoming more interested in supporting businesses that are owned by minorities and women. This is important because it helps to create a more diverse and inclusive industry.

In fact, this trend is also being driven by an increasing number of minority and female brewers. These brewers are creating unique and delicious beers that are attracting the attention of beer lovers all over the world.

5. More Beer That Tastes Like Beer Is Making a Comeback

In recent years, there has been a trend toward flavored malt beverages and often quite high in alcohol. This is because many people have become interested in trying new and different styles of beer. But there has been a recent growth in preference for beers that taste like, well, more of traditional beer. This trend is driven in part by the popularity of craft breweries, which often make beers with more traditional flavors.

This is because many beer drinkers have become tired of the over-the-top flavors that have become common in the industry. Beers that taste like candy or dessert are no longer as popular as they once were. Instead, people are gravitating toward beers with more subtle flavors.

This trend is being driven by a number of factors. First, many people are becoming interested in classic styles of beer such as lagers, pilsners, and IPAs. Second, a lot of craft brewers are also starting to brew more traditional styles of beer. Finally, some people are just sick of all the extreme flavors and want something that tastes like beer.

6. More Steps Toward Sustainable Beer

brewmaster beverage industry trends 2022 2023 IPA lifestyle ecommerce PRO engineering manufacturing inc

As people become more aware of the impact of their consumption on the environment, there is a growing trend toward sustainable beer. This means that breweries are using environmentally friendly practices in their brewing process and packaging.

This is important because it helps to reduce the amount of waste that is produced by the beer industry. It also helps to protect the environment by using fewer resources. And it’s not just good for the planet, sustainable beer often tastes better too.

Some of the most popular sustainable packaging options include cans and kegs. Cans are made from recycled aluminum and are 100% recyclable. Kegs are made from stainless steel and can be reused many times.

Sustainable brewing practices include using local ingredients, using renewable energy, and recycling water. Local ingredients are important because they reduce transportation emissions. Renewable energy is important because it helps to reduce the carbon footprint of the brewery. Similarly, recycling water helps to conserve resources.

The trend toward sustainable beer is being driven by a growing awareness of the impact of the beer industry on the environment. This is especially true among younger people, who are more likely to be concerned about environmental issues. As this trend continues to grow, we can expect to see more breweries adopt sustainable practices.

7. Growing Need for More Science in the Beer Industry in 2022 Into 2023

As the world becomes more scientific, there is a growing interest in using more science in the brewing process. This means that breweries are using data and technology to optimize their recipes and brewing process. More and more breweries are employing scientists to help them create new and innovative beers. This has led to a surge in the popularity of sour beers, as brewers are able to create more consistent results with this style of beer.

This is important because it helps to improve the quality of beer. It also helps breweries to be more efficient and reduce waste. And it’s not just big breweries that are doing this – small craft breweries are getting in on the action too.

The drive toward using science in brewing is influenced by a number of factors. First, advances in technology have made it easier for breweries to collect data and use it to improve their operations. Second, as the craft beer industry has grown, there has been an increasing demand for high-quality beers. Finally, many breweries are now owned by large corporations that are investing in research and development.

As this trend continues to grow, we can expect to see more breweries using data and technology to improve their operations. We can also expect to see more collaboration between breweries and scientists. This will help to create even better beers that everyone can enjoy.

8. ‘My Alcohol’: More Lifestyle Beer

The term “lifestyle beer” is used to describe a new trend in the beer industry. This trend has to do with breweries creating beers that are marketed towards a certain lifestyle or group of people. For example, there are now craft beers that are marketed toward dog lovers, yoga enthusiasts, and even beard-lovers. This trend started with the craft beer movement, as brewers began to create beers that appeal to specific groups of people.

This is important because it helps to connect people with brands that they can identify with. It also helps breweries to tap into new markets.

Lifestyle beers are usually brewed in small batches and have unique flavor profiles. They often use local and organic ingredients, which appeal to people who are interested in sustainability and supporting local businesses. Lifestyle beers are also usually lower in alcohol content than other beers, which appeals to people who want to enjoy a beer without getting drunk.

The trend toward lifestyle beer is being driven by a number of factors. First, as the world becomes more connected, people are looking for brands that they can identify with. Second, the growth of the craft beer industry has seen a corresponding demand for beers that fit into specific lifestyles. Finally, many breweries are now owned by large corporations that are looking for ways to reach new markets.

As this trend continues to grow, we can expect to see more breweries creating beers that fit into specific lifestyles. We can also expect to see more collaboration between breweries and other businesses. This will help to create even better beers.

Thermal Pasteurization of Beer

This process uses heat to kill bacteria in beer, which makes it safer to drink. Pasteurization also helps to preserve the flavor of beer and make it last longer. This is important because it helps to improve the safety of beer. It also helps breweries to be more efficient and reduce waste. Breweries of all sizes are taking advantage of this technology to improve their beer quality and safety.

Hot water circulation

This kind of thermal pasteurization involves circulating hot water through beer. This helps to kill bacteria and improve the shelf life of beer. It’s a more efficient process than other methods of pasteurization, which is why it’s being adopted by more breweries.

This process involves the following steps;

  1. Beer is placed in a holding tank.
  2. Hot water is circulated through the beer.
  3. The beer is cooled down quickly to stop the pasteurization process.
  4. The beer is then ready to be packaged and sold.

High-temperature short time

This process uses very high temperatures to kill bacteria in beer. It’s a more efficient process than other methods of pasteurization, which is why it’s being adopted by more breweries.

This process involves the following steps:

  1. Beer is placed in a holding tank.
  2. The beer is heated to a very high temperature
  3. The beer is then cooled down quickly to stop the pasteurization process.
  4. The beer is then ready to be packaged and sold.

Good news: Benefits of pasteurization for breweries

Here are some of the benefits of pasteurizing beer.

  • Extended shelf life- This is the most important benefit, as a pasteurized beer can last for months or even years without going bad. This means that breweries can sell their beer for a longer period of time, which increases their profits.
  • Reduced spoilage- Pasteurization helps to reduce spoilage by preventing bacteria from growing in beer.
  • Improved flavor and quality- Pasteurization helps to preserve the flavor and quality of beer which makes it more enjoyable to drink
  • Increased safety- Pasteurization helps to kill bacteria that can make people sick. This is important because it helps to improve the safety of beer.
  • More environmentally friendly- Pasteurization is a more environmentally friendly process since it doesn’t use chemicals or other harmful substances to kill bacteria. This is important because it helps to protect the environment.

Up Your Beer Game in 2022 Into 2023 with PRO Engineering / Manufacturing Inc.

As the demand for high-quality beer increases, so does the demand for breweries that can meet this demand. This is where PRO Engineering / Manufacturing Inc. comes in. We offer a wide range of products that can help breweries to improve their efficiency and quality. Some of the products that we offer include;

  • Tunnel pasteurizers – These are ideal for breweries that want to pasteurize large quantities of beer. We have large and slimline tunnel pasteurizers.
  • Batch pasteurizers – These are perfect for small-scale operations or for breweries that want to experiment with different recipes. We have a variety from single temp to triple temp.

We are a leading manufacturer of pasteurizers and have been serving the craft brewing industry for many years. If you’re looking for ways to improve your brewery, we can help. Contact us today.

Learn More About Pasteurizing!

If you’d like to learn more about pasteurization in general, pasteurizing unique sodas, or the equipment involved, we’d love to help!

Feel free to contact us with any questions or concerns you might have, and we’ll do our best to help you. We want you to feel confident in your understanding of this vital process and how you can make it work for you!

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 tunnel pasteurizers and batch pasteurizers for over four decades.  

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]

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Location: 11175 W Heather Ave, Milwaukee, WI 53224, USA

How to Tunnel Pasteurize Seltzer Water and Other Carbonated Beverages?

You may be wondering how tunnel pasteurization works when making a carbonated beverage, such as seltzer water and other types of carbonated water. This process is an excellent method because it keeps the product at the correct temperature and prevents microbes from becoming overheated. It also ensures the highest quality product and retains its great flavor.

What is Tunnel Pasteurization?

Tunnel pasteurization is a method of sterilizing a product by heating it to a high temperature and cooling it to an extremely low temperature. This process seals in the nutrients in the product and produces top-quality items in a short period. Pasteurization in tunnels is a common method of sterilization used in the pharmaceutical industry and beverage industry, but it is also applicable to many other service procedures. Let us discuss some of these examples.

Energy drinks, for example, can have their shelf lives extended with pasteurization. A tunnel pasteurization process preserves carbonated beverages and extends their shelf life more effectively than other methods. Unlike a hot filling, this process allows the product to retain a certain amount of CO2, preventing foaming. While this method has limitations, it is safe for many products.

The tunnel pasteurization process has several advantages. Tunnel pasteurization can help prevent the formation of harmful microbes, which are essential for canned beer. It exchanges carbon dioxide in the beer into carbonic acid, which helps break down the proteins that cause foam in the beverage. The resulting carbonic acid eliminates the need for emulsifiers. Tunnel pasteurization is also effective for sterilizing high-acidifying drinks and bottled water.

The Tunnel Pasteurization Process

Tunnel pasteurization is unlike other pasteurization processes. Rather than striving for a single temperature shock, it gradually processes products from one end of the system to the other.

Gradual heating

One end of the tunnel carries the bottled or canned goods, and the temperature steadily increases with sprays of hot water. The temperature gradually rises in stages. It is brought to a target temperature and kept there long enough to kill specific microorganisms in each stage. After that, the material proceeds to the next stage, where the temperature rises a bit higher, held in place until it reaches the maximum desired temperature.

Cooldown

After reaching the desired temperature, the product gradually cools down to room temperature. It is all about gradual temperature changes rather than bringing products to their maximum temperatures at once.

Palletization and shipment

Labeling, boxing, and palletizing can begin once the product has cooled to room temperature.

Are Fermentation and Pasteurization the Same Thing?

Fermentation is a process that creates beneficial microorganisms in foods. Some of the benefits of lacto-fermented foods include increased heart health and immune system strength and anti- inflammatory, anti-cancer, and anti-obesity properties. Fermented foods generally taste great and are easily incorporated into a daily diet. These foods range from refreshing drinks to snacks to side dishes.

Fermentation and pasteurization are two different processes used to preserve foods and beverages. Both processes are performed on microorganisms to break down sugars to produce alcohol and acetic acid. The fermentation process creates carbon dioxide as it takes place. Pasteur was initially working on vaccinations to cure chicken cholera, a disease that could infect an entire farm in 3 days. Pasteur and his colleagues injected cholera microbes into test chickens in one experiment. They observed that cholera-infected chickens died off after being exposed to weaker microorganisms.

Pasteurization kills bacteria in non-pasteurized liquids and foods. This process takes its name after Louis Pasteur, who discovered in the 1860s that heating beverages to 57 deg C (154°F) prevented abnormal fermentation. Pasteurization of milk has become widespread, with temperatures as low as 63 degrees Celsius for 30 minutes or 72 degrees Fahrenheit for 15 seconds. Higher temperatures are also possible, but they take longer.

Can You Pasteurize Carbonated Water?

Beverage brands use thermal distillation and carbonation methods to preserve their drink products. However, a growing consumer base demands non-carbonated drinks with more unstable ingredients. The production facility of carbonated beverages is turning to pasteurization to reduce the dissipation of their products and maintain their shelf life. Tunnel pasteurization is particularly useful in carbonated beverages that contain high amounts of sugar.

Tunnel pasteurization requires a certain temperature range to ensure that your product is safe for consumption. Tunnel pasteurizers use high-pressure steam or electricity to sterilize carbonated drinks in glass bottles and cans. The temperatures and time requirements for the process must match the flow of the beverage production line. Tunnel pasteurizers are used for various carbonated beverages, from water to wine, and can even sterilize tinned beer.

You can make various high-quality items in minutes through tunnel pasteurization, including sodas and packaged beverages from supermarkets. Tunnel pasteurization maintains flavor and structure while protecting against contamination better than flash pasteurization.

How Do You Pasteurize Carbonated Juice?

Tunnel pasteurization is a process used to sterilize carbonated drinks. Its purpose is to keep the product above the freezing point to protect the organisms from excessive heat. It also helps reduce the production of chloroform gas during canning and storage processes. The results of tunnel pasteurization are highly beneficial for the consumer, as it ensures that the product is fresh.

The process of pasteurization is very effective in preserving the quality of carbonated drinks, which means that they will be available for a long time. In addition, this method is completely safe, as the CO2 level will be sufficiently high to protect the juice and prevent microbial growth. As a result, it can preserve many drinks, including seltzer water and other carbonated drinks.

To achieve the right temperature for pasteurization, you must first determine the desired carbonation level. From there, you can figure out how many units are needed. One pasteurization unit is the equivalent of one minute of micro-death at 60 degrees Celsius. Once you know how many pasteurization units you need, you can calculate the time in minutes. In addition to the temperature level, pasteurization can improve the taste and texture of carbonated beverages.

Is Carbonation a Preservative?

Sponsored by PRO Engineering / Manufacturing Inc How to Tunnel Pasteurize Seltzer

It is more effective to gradually change the temperature of seltzer water, soda pop, and other artificial flavors rather than heating them very quickly. The process is compatible with most carbonated beverages because it does not use too much CO2 and results in too much foaming. Tunnel pasteurization has become an increasingly common way to sterilize carbonated drinks in recent years.

Despite using conventional carbonation and thermal purification to sterilize beverage products, the trend toward non-carbonated beverages and more predictable ingredient content is growing. Tunnel pasteurization meets this growing demand. This process extends shelf life and minimizes the evaporation of the carbonated beverage. It also sterilizes glass bottles to reduce bacterial growth.

The benefits of tunnel pasteurization are not only cosmetic but also sanitary. Pasteurization removes the microbes that cause carbonated beverages to deteriorate. Pasteurizing carbonated beverages that contain high sugar levels is particularly important because they sit on shelves for weeks before being consumed. In addition to shelf life, tunnel pasteurization ensures the freshness of these beverages.

How Can I Flash Pasteurize at Home?

When tunnel pasteurizing a beverage, key factors are carbonation, retention, and head area. Depending on the latter, carbonated beverages can be stored at room temperature or will require refrigeration. It is more important to the former as it allows for precise control over the amount of CO2 and the beverage’s final microbial count and appearance.

Tunnel pasteurization prevents over carbonation in carbonated beverages, especially canned beverages. Tunnel pasteurization works by exchanging carbon dioxide with carbonic acid, which is needed to break down healthy proteins in the foam. It also increases the shelf life of carbonated beverages, which is especially important for beverages with high sugar content. Tunnel pasteurization helps preserve freshness and improves taste.

During the manufacturing process of carbonated beverages, temperatures rise significantly. The tunnel pasteurizer prevents this by allowing a limited amount of CO2 to enter the beverage without causing foaming. As a result, carbonated drinks retain their freshness longer and can last for several years. It would help if you remembered a few things before you begin tunnel pasteurizing seltzer water and other carbonated beverages at home.

Conclusion

Look no further than tunnel pasteurization if you are looking for a safe and easy way to pasteurize your seltzer water and other carbonated beverages. Tunnel pasteurization is a process that uses heat to destroy harmful microorganisms in food and drinks. Using this process, you can ensure that your drinks are safe to consume.

Learn More About Pasteurizing!

If you’d like to learn more about pasteurization in general, pasteurizing unique sodas, or the equipment involved, we’d love to help!

Feel free to contact us with any questions or concerns you might have, and we’ll do our best to help you. We want you to feel confident in your understanding of this vital process and how you can make it work for you!

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 tunnel pasteurizers and batch pasteurizers for over four decades.  

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]

Related Site Links
Tunnel Pasteurizer
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Location: 11175 W Heather Ave, Milwaukee, WI 53224, USA

Beverage Makers Guide to Pasteurization of Hard Seltzers

Hard seltzer manufacturers aim to take over a good part of the adult beverage market. Between the Spring and Fall of 2019, the number of adults who drank hard seltzer at bars and restaurants increased by 73%! 

A key element in many beverage processes is pasteurization and that includes bottling hard seltzers.  

What Is Pasteurization 

A French microbiologist named Louis Pasteur invented the process later named after him, way back in the 1800s.  

There’s a wide range of pasteurization techniques these days. Some of these techniques include heat, high-pressure processing (HPP), and Low Temperature, Short Time (LTST). Most companies that process food and beverage products use some form of heat pasteurization before selling to consumers. 

These days, many foods (both packaged and unpackaged) go through some form of pasteurization before hitting the shelves. For beverages, a batch pasteurizer treats a up to 2,400 bottles or 3,000 cans, 12 ounce size, pasteurized to 12 pasteurization units in an 8 hour shift. The largest single-deck tunnel pasteurizer can pasteurize up to 1,800 bottles or 2,000 cans per minute, in ballpark numbers.  

Why You Should Pasteurize Hard Seltzers 

So do you need to pasteurize a hard seltzer?  

The short answer is yes, you should! Here are the two main reasons you should pasteurize your hard seltzers: 

Increased Shelf Stability 

As Pasteur discovered, killing off the dangerous microbes with pasteurization makes it shelf-stable for much longer than without pasteurization, allowing your customers more time to enjoy it before the product degrades!  

Preventing Popped Tops/Bulging Cans 

Another benefit of pasteurization is that it helps to de-activate any remaining traces of active yeasts. If you leave any yeast in your hard seltzer bottle or can it will continue to feed off of the sugars and produce carbon dioxide. With the yeast de-activated, you eliminate the continued production of carbon dioxide and prevent the trapped carbon dioxide from making the bottle tops pop off or having the cans bulge. 

hard seltzer pasteurization image PRO Engineering Manufacturing

How to Pasteurize Your Seltzer 

As we mentioned earlier, there are many ways to pasteurize consumables. We’re going to touch on the oldest and most common form of pasteurization, the heat method. 

The key to pasteurization using heat is to hit the target temperature for the right amount of time. A proper profile of time and temperature must be created for the elimination of microbial growth and stabilization, to insure optimal taste and shelf life. When purchasing a pasteurizer from PRO Engineering, small samples are tested in a batch unit and the profile is recommended by PRO Engineering.  

Different Types of Spiked Seltzers Available 

So far this year, many Americans have tried these new, refreshing adult beverages Some retailers report a 40% to 50% increase in their sales since the beginning of the year! 

Here are the two most popular types of hard seltzers on the market right now. 

Wine Flavored Seltzers 

One way to flavor hard seltzer is with wine! For those who love a good glass of wine to wind down at the end of the day, red, white, or rosé flavored seltzers may be a unique taste. 

Fruit Flavored Seltzers 

Another popular hard seltzer flavor is fruit flavoring. Fruit flavorings in seltzer recipes can make your hard seltzer taste like biting juicy fruits.  

Sangria Flavored Seltzers 

For the best of both worlds, a Sangria flavored seltzer could hit the spot. Not only does Sangria please the wine lovers, but it also has an extra boost of fruit too! For those who want a fizzy refreshment full of fruity flavor, look no further than a Sangria flavored hard seltzer. 

We hope you enjoyed reading this article. If you have any questions about this article or if you’re looking for batch or tunnel pasteurizer, 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]

Tunnel Pasteurization for Bottled Cold Coffee

Cold brew coffee is a popular product that has recently grown the coffee industry; in the United States, refrigerated cold coffee retail sales increased 460% from 2016 to 2018 (1). Cold coffee is chemically different from hot brewed coffee; particularly, it’s sweeter and less bitter; besides, online health and lifestyle websites have widely made health claims for cold coffee (1). “Cold brew” is an extraction of ground-roast coffee using a lower temperature (about 8°C / 46°F) and longer time than traditional hot brewed coffee or espresso (2).

This process gives coffee a very different extraction profile since different compounds are extracted at different rates (3). Numerous producers sell cold coffee as ready-to-drink (RTD) canned or bottled format (4); although, this represents the potential problem of microbial contamination and sensorial deterioration (4). Due to the lack of sterilizing temperatures obtained during hot brew coffee preparation, cold coffee has several challenges, including the need for optimization within the processing, roast degree, grinding, water composition, brew system, time, temperature, hygiene, and food safety requirements (4).

A critical part of the cold coffee process is that the coffee beans must be thoroughly washed at the beginning of the process. The reason for washing the beans is to remove microbes that form spores when subjected to the heat of thermal pasteurization.

PRO Engineering / Manufacturing Inc. specializes in bottled cold coffee tunnel pasteurization

Cold coffee that is not pasteurized must remain refrigerated through all the chain of distribution, storage, and dispensing (5). The downside is that the refrigerated shelf life of bottled coffee (cold or hot brewed) is limited by its microbial stability and sensorial deterioration (4). Researchers have even recommended drinking cold coffee as fresh as possible and to minimize it’s refrigerated shelf life (6).

Interestingly, some retailers, distributors, and consumers are not aware that cold brew coffee that is not pasteurized requires refrigeration. As the National Coffee Association pointed out, this  reveals a need for educational interventions: Hot brewed coffee has a long tradition of being a low-risk beverage for food safety. In contrast, anyone who produces cold brew coffee has an obligation to follow the appropriate steps to secure food safety (5). The US Food Safety Modernization Act (FSMA) requires anyone manufacturing, processing, or packaging cold brew to comply with regulation practices (such as a food safety plan). For this reason, bottled cold coffee pasteurization has risen substantially.

Cold brew coffee has a pH value higher than 4.6, which is in the low acidity range and does not effectively suppress microbial development (6). Consequently, pathogens or spoilage organisms may develop in cold brew. The proliferation of unwanted bacteria leads to flavor changes and creates alcohol and carbon dioxide (7); the carbon dioxide can build up until the can or bottle seal is compromised, leading to potential harm or lawsuits. Even when the beverage does not expand, it remains fermented. Producers have looked into other ways to approach this problem. Cold coffee pasteurization is valuable because it eliminates the need for refrigeration while increasing the shelf-life (8). There are several types of thermal pasteurizers available for beverage-makers, including flash, batch, and tunnel pasteurizers. Tunnel pasteurizers receive the cold coffee already packaged in the bottles or cans (9). Using a traveling belt, the cold coffee bottles are taken through a variety of temperature changes in order to inhibit the enzymes and pathogenic microorganisms, going from hot zones to cooling zones. (10).  In general, tunnel pasteurizers are divided into preheating, heating, and cooling zones, the heating occurs progressively until reaching the temperature of 60°C (140°F) is reached.

This temperature is maintained for a specific time depending on the product type (11). The over-pasteurization of cold coffee occurs when the movement of the product through the tunnel is delayed in the heating zones, this prevents cooling the product properly (12).

To help determine the amount of pasteurization applied to the product, the Pasteurization Unit (PU) was devised. The PU helps the beverage maker understand the level of pasteurization that the product has sustained.(13). It is defined as 1PU when the product has been exposed one minute to a 60°C (140°F) temperature. After being exposed to the specific level of PUs required, bottled cold coffee travels to the next zone, where it is cooled with cold water (sprayed water) to approximately 20°C (68°F). Water spray systems, including spray patterns, water volumes, and distribution systems depend on the pasteurizer manufacturer.

PRO/Line Series 5 Tunnel Pasteurizer for pasteurization of bottle cold coffee
PRO/Line Series 5 Tunnel Pasteurizer

Cold coffee tunnel pasteurizers must control and monitor PU accumulation for three reasons: shelf life, sensorial characteristics, and energy efficiency. However, contrary to the well-established guidelines for beer and cider, it remains controversial how many PUs are needed in the case of cold coffee. Furthermore, many cold coffee producers also add dairy products to create all kinds of coffee varieties (cappuccino, mocha, latte, etc.), meaning there is another factor to consider when pasteurizing these products (14). Milk used in these coffee beverages can be pasteurized with low-temperature, high-temperature or ultra-high temperature pasteurization. When milk is pasteurized through conventional thermal pasteurization and is blended with a coffee extract, it can alter the sweetness, acidity, aroma, and taste of the coffee beverage (14).

For these reasons, there is still a need for continuing research studies on the specific time-temperature combinations (PUs) of cold-brewed coffee and cold coffee combined with milk (15). Further guidelines are specified in the “Cold brew coffee toolkit for industry” published by the National Coffee Association (16). The toolkit includes information from studies on avoiding the risk of bacteria such as Clostridium botulinum, shelf life testing, storage and handling. The toolkit also provides several key steps relevant to ready-to-drink cold brew processes in general to avoid food-safety related incidents.

The British Columbia Centre for Disease Control suggests maximum refrigerated storage of fewer than 10 days for cold brewed coffee if no other controls are present. The Centre also recommends controlling the hazards of spore-forming bacteria for bottled cold coffee intended for longer-term storage: The recommendations are: (1) Heating treatment and pasteurization, (2) reducing the pH to 4.6 or below, (3) ensuring aseptic processing, (4) addition of preservatives, and (5) a combination of these controls (17).

For more information on batch or tunnel pasteurization of cold brewed coffee beverages, contact Ed Michalski at PRO Engineering/Manufacturing, Inc.

Phone: (414) 352-1500 or email ED at [email protected]

References

1. Rao NZ, Fuller M. Acidity and Antioxidant Activity of Cold Brew Coffee. Scientific Reports. 2018 Oct 30;8(1):16030.

2. Hwang S-H, Kim K-S, Kang H-J, Kim J-H, Kim M-J. Studies on the Flavor Compounds of Dutch Coffee by Headspace GC-Mass. Korean journal of food and cookery science. 2014;30(5):596–602.

3. Lopane S. An Investigation of the Shelf Life of Cold Brew Coffee and the Influence of Extraction Temperature Using Chemical Microbial and Sensory Analysis. All Theses [Internet]. 2018 Aug 1; Available from: https://tigerprints.clemson.edu/all_theses/2899

4. Sisel E. The strength of cold brew. Mintel Database. 2016;

5. Anon. Cold brew coffee—On tap! The future of coffee and how to serve it. Total Food Serv. 2018;28(110).

6. Kwok R, Lee Wee Ting K, Schwarz S, Claassen L, Lachenmeier DW. Current Challenges of Cold Brew Coffee—Roasting, Extraction, Flavor Profile, Contamination, and Food Safety. Challenges. 2020 Dec;11(2):26.

7. Duboc P, Milo C. Fermented coffee beverage [Internet]. EP1527695A1, 2005 [cited 2021 Jan 29]. Available from: https://patents.google.com/patent/EP1527695A1/en

8. Baumann S, Wheeler B, Alfreds KL. Cold Brew System and Method for Making Cold Brew Coffee or Tea Extract [Internet]. US20120021108A1, 2012 [cited 2021 Jan 29]. Available from: https://patents.google.com/patent/US20120021108A1/en

9. Herold JL, Nekola WJ, Wehmiller FW. Process of pasteurizing liquids in containers [Internet]. US2282187A, 1942 [cited 2020 Nov 17]. Available from: https://patents.google.com/patent/US2282187A/en

10. Dhruv AS, Wu AR-Y. Bottle pasteurizer and method [Internet]. US8096138B2, 2012 [cited 2021 Jan 29]. Available from: https://patents.google.com/patent/US8096138B2/en

11. Briggs DE, Brookes PA, Stevens R, Boulton CA. Brewing: Science and Practice. Elsevier; 2004. 900 p.

12. Becker KW, Jr LGF, Kropp L, Straka RB. Pasteurization method [Internet]. US4490401A, 1984 [cited 2020 Dec 30]. Available from: https://patents.google.com/patent/US4490401A/en

13. Richmond DW, Clyne CW, Holben TM. Pasteurization process [Internet]. US4693902A, 1987 [cited 2020 Nov 16]. Available from: https://patents.google.com/patent/US4693902A/en

14. Sugise T. JP2019165722A, 2019 [cited 2021 Jan 29]. Available from: https://patents.google.com/patent/JP2019165722A/en?q=pasteurization+of+Coffee+beverages+milk&oq=pasteurization+of+Coffee+beverages+with+milk

15. Sizer CE. Process for making a shelf-stable milk based beverage concentrate [Internet]. AU2009271273B2, 2015 [cited 2021 Jan 29]. Available from: https://patents.google.com/patent/AU2009271273B2/en?q=Coffee+beverages+milk%2c+pasteurization&oq=Coffee+beverages+with+milk%2c+pasteurization

16. NCA. Cold Brew Coffee Toolkit for Industry Inc. New York, NY: National Coffee Association of USA; 2019.

17. British Columbia Centre for Disease Control. Cold Brew Coffee Food Safety Risks. Vancouver, BC, Canada: BC Centre for Disease Control; 2017.

Learn More About Pasteurizing!

If you’d like to learn more about pasteurization in general, pasteurizing unique sodas, or the equipment involved, we’d love to help!

Feel free to contact us with any questions or concerns you might have, and we’ll do our best to help you. We want you to feel confident in your understanding of this vital process and how you can make it work for you!

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 tunnel pasteurizers and batch pasteurizers for over four decades.  

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]

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Location: 11175 W Heather Ave, Milwaukee, WI 53224, USA

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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