Autoclave Sterilizer maker, water steam
spray batch autoclave sterilizer, batch autoclave design
Autoclave
professional
Design Manufacture of : Food
sterilization batch autoclave, Pharmacy sterilization autoclave
Full Automatic Water Steam Spray Batch
Retort, Batch Autoclave Sterilizer
Autoclave design principle
Sterilization process
Autoclave controller & setting
Autoclave Property compare
Important : for User and Maker (
about temperature )
Calibration of Mercury-In-Glass (MIG)
thermometer
The Us Code of Federal
Regulations
-
The sterilization autoclave must have a mercury-in-glass thermometer with
divisions easily readable to 1°F and a temperature range not to exceed
17 °F per inch of graduated scale.
-
Thus, to insure accurate autoclave sterilization temperature reading the
MIG thermometer must be checked for accuracy once a year against a known
accurate standard thermometer upon installation and at least once a year
thereafter.
-
The date of the test should be placed on the MIG thermometer so that the
operator can readily see when the next check for accuracy is to be made.
Checks for accuracy should be done at the approximate scheduled
autoclave sterilization temperature.
-
The date and name of the individual testing thermometers should be logged
and filed.
-
Resistance thermometer (RTD) devices are generally used as the reference
thermometer for programmable controlling systems. In no case will the
RTD replace the MIG as the reference thermometer for the sterilization
autoclave
-
The recording temperature device should have graduations no to exceed 2°F (1
℃) within range of 10°F (5.5 ℃) of processing temperature. The temperature
should agree as nearly as possible, with the known accurate mercury-in-glass
thermometer
Design basic : Physics theory,
Mechanical principle
Physics theory
- Thermodynamic equilibrium: Steam and saturate water phase equilibrium,
liquid phase and steam phase balance system
- The zeroth law of thermodynamics : Thermal equilibrium; multi-material
temperature balance system
Mechanical principle
- Steel thermal transfer conductivity : 54 Kcl/(hr)(m2)(℃)
- Steam to saturate water thermal transfer conductivity : 5,000 ~ 10,000
Kcl/(hr)(m2)(℃)
- Heat exchanger was heat conductivity transfer system, water steam spray
system was direct thermal transfer system
- Thermal transfer area : Small water drop would expand the thermal
transfer area to very large
- A few circulation water could be doing the thermal translation function
- Close equilibrium cycle system for cooling process, its very save for
food and pharmacy sterilizing process
Sterilization process: Water Steam
Spray Batch Retort, Batch Autoclave Sterilizer
Before sterilizing process
- Hot filling sterilizing process: should be pre-heating , the
temperature was same as products hot filling temperature, then the
product push into the autoclave chamber
- Glass bottles: hot filling glass bottles need preheating before
start sterilizing process, because the temperature differential between
glass bottles and room temperature too large , the glass container would
crack
- The working medium should be soft water (its same as steam generator
supply water)
Prepare sterilization process:
- Maker setting: at initial in the autoclave chamber is dry, when
process is done, all circulation water was automatically exhaust out of
chamber
- Stand by: maker setting automatically shut down all control system
and mechanical system except power
- Products package can't broken, should be good arrangement of bottles
or flexible pouches package, its necessary for good sterilizing process
Starting food sterilization process: (One
Touch start)
- Clean soft water inlet to the sterilization autoclave chamber, its
automatically control by level switch
- Automatically start circulation pump, automatically steam inject
into sterilizer chamber, compress air inlet to autoclave sterilization
for over pressure balance system
- Start heating process, temperature rise up speed could be adjust
between 3~15℃/min ( 5~27°F/min)
Sterilization autoclave heating process:
- Circulation water inject into the autoclave chamber from top and
site, the injection nozzle spray the circulation water to "water
droplets"
- Millions of droplets be heating immediately in the space of
autoclave chamber
- Uniform distribution of temperature, the nozzle's injection force
drive the droplets to everywhere in the chamber
Sterilization temperature keeping process :
- Temperature reaches the set point temperature, starting
sterilization process
- The average temperature precision keep in
±0.5°C (±1.0°F) during the process
- Sterilizing process approach to constant temperature and constant
pressure physical equilibrium circulation
- Saturate water sterilization process never over heating the
products, best remain protein and glucose, excellence mouth feeling
- Option equipment: sterilization F value recorder
Sterilization process finish :
- Time reaches the set time, (F value been sufficient), sterilizing
process is finish
- Automatically shut down the steam, and automatically starting the
cooling system
- Hot circulation water would be cooling by the heat exchanger, the
cold circulation water inject into the sterilization autoclave chamber
to cooled the product
- Cooling speed could be adjust between 5~15℃/min ( 9~27°F/min)
Autoclave sterilizer cooling process :
- Hot circulation water cooled by heat exchanger, the cold water
inject into the autoclave chamber, the cold liquid water with nozzle
spray its to " water droplets", cold droplets "pull out" the thermal
from products, the products should be cooling
- With close circulation system, the asepsis circulation is the best
for cooling process, the working medium ( water) had been fully
sterilizing, its clean and asepsis
- With close cooling system save a lot of cooling water, only need
about 3-7% cooling water of full water immersion autoclave
sterilization,
Working process finish :
- Final cooling temperature is higher then the temperature of
environment, average higher 15℃( 27°F), the products temperature
would between 30~45℃ ( 85 ~ 115°F), for special propose, you can set the
final cooling temperature more higher, but never over 60℃ ( 140 °F),
because after cooking were keeping cooking the product, final high
cooling temperature would damage your products, its cause over cooking
- Cooling speed too slowly or sterilization time too long or final
temperature too high, all will damage your products, its loss a lot of
nutrition
- Super cooling : Its option function; products cooling temperature
between 10℃ ~ 30℃ ( 50 ~ 85°F)
CY-3000 Automatic Water Steam Spray autoclave
sterilization layout
inner cages from 2 cages to 10
cages; sterilization autoclave length form 2M to 11M, static and rotary
sterilization autoclave
loading and unloading with manual and
automatic loading; the cages over 6 cages, automatic loading is better
Cross section layout of
autoclave sterilization ( sterilize condition)
Heat exchanger was option equipment;
the heat exchanger is for cooling cycle only, not for heating propose
The heat distribution and heat
penetration study testing and recorder system, its follow as US FDA CFR
regulations;
© 2006 All Rights Reserved
Remark :
- This machine was design for wet sterilizing purpose, the goods should be
water-repellent, usually with close container package material, but it's not
true.
This machine can do the working without vacuum sealing container, for
example : a pot with waterproof cap, its can cooking or boiling the food
without vacuum package material.
- Sterilize inflation package container : many container can't be vacuum,
for example ; soft can with liquid, or sauce or puree or paste, but all can
be sterilizing with our sterilization autoclave.
- Dry sterilizing method or pasteurization or pasteurizer or pasteurizing
column or flash pasteurizer can't be doing with this wet sterilizer, the
physical process and physical property was different, the germicidal action
was different, the storage was different too
- All the autoclave sterilizer function design was follow as the
regulation of:
- USA FDA ( UNITED STATES OF AMERICA, Food and Drug Administration )
- TAIWAN FIRDI
(The Food Industry Research and Development Institute) is a non-profit
legal entity established in 1965 with financial support from the
Canners' Association of Taiwan ,CIECD (Council for International
Economic Cooperation and Development) and JCRR (Joint Commission on
Rural Reconstruction).
- Mechanical design (pressure vessel design) follow as :
- ASTM---- American Society for Testing and Materials
- ASME---- American Society of Mechanical Engineers
- JIS------- Japan Industrial Standard
- CNS----- CNS regulation 9788 (Taiwan)
- Warning: utility of water and electrical power and steam
- Water supply
- The water should be soft water, or clean water, the source of soft
water could be from steam boiler water treatment machine, or independent
water treatment equipment.
- Boiled the city water (hard water), will separate out the calcium
carbonate, the calcium carbonate was a small particle; Its would adhere
to the package container surface, its was bad products
- The calcium carbonate will adhere to the shell and pipe inner face
too, its would damage the equipment, and looking was dirty
- Usually sterilize machine breakdown was caused by the calcium
carbonate
- Cleaning the calcium carbonate was hard working, not so easy
- Electrical power supply
- Electrical power supply should be stable, the differential of
voltage should be under 10%, otherwise the driver motor, PLC, relay,
micro computer, etc etc would be breakdown or be burnout.
- All the electric wire connector should be waterproof
- Steam supply
- The main pipe of steam should keep the pressure above 6 kg/cm2 (85
psi)
- Pressure air supply
- Must have a service tank to storage the pressure air, always keep
the air pressure above 5 kg/cm2 (70 psi)
- If insufficient air supply, the pouches package would broken, the
machine would unstable