Autoclave Sterilizer maker, water steam spray batch autoclave sterilizer, batch autoclave design

title Autoclave
professional

Design Manufacture of : Food sterilization batch autoclave, Pharmacy sterilization autoclave

Full Automatic Water Steam Spray Batch Retort, Batch Autoclave Sterilizer

autoclave injection

Autoclave design principle
Sterilization process

control

Autoclave controller & setting

temperature property

Autoclave Property compare

energy

Batch retort
energy compare
PDF files

Important : for User and Maker ( about temperature )

Calibration of Mercury-In-Glass (MIG) thermometer

    The Us Code of Federal Regulations

  1. 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.
  2. 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.
  3. 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.
  4. The date and name of the individual testing thermometers should be logged and filed.
  5. 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
  6. 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

  1. Thermodynamic equilibrium: Steam and saturate water phase equilibrium, liquid phase and steam phase balance system
  2. The zeroth law of thermodynamics : Thermal equilibrium; multi-material temperature balance system

     Mechanical principle

  1. Steel thermal transfer conductivity : 54 Kcl/(hr)(m2)(℃)
  2. Steam to saturate water thermal transfer conductivity : 5,000 ~ 10,000 Kcl/(hr)(m2)(℃)
  3. Heat exchanger was heat conductivity transfer system, water steam spray system was direct thermal transfer system
  4. Thermal transfer area : Small water drop would expand the thermal transfer area to very large
  5. A few circulation water could be doing the thermal translation function
  6. 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

standby

Before sterilizing process

  1. 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
  2. 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
  3. The working medium should be soft water (its same as steam generator supply water)

starting

Prepare sterilization process:

  1. Maker setting: at initial in the autoclave chamber is dry, when process is done, all circulation water was automatically exhaust out of chamber
  2. Stand by: maker setting automatically shut down all control system and mechanical system except power
  3. Products package can't broken, should be good arrangement of bottles or flexible pouches package, its necessary for good sterilizing process

one touch

Starting food sterilization process: (One Touch start)

  1. Clean soft water inlet to the sterilization autoclave chamber, its automatically control by level switch
  2. Automatically start circulation pump, automatically steam inject into sterilizer chamber, compress air inlet to autoclave sterilization for over pressure balance system
  3. Start heating process, temperature rise up speed could be adjust between 3~15℃/min ( 5~27°F/min)

rise up

Sterilization autoclave heating process:

  1. Circulation water inject into the autoclave chamber from top and site, the injection nozzle spray the circulation water to "water droplets"
  2. Millions of droplets be heating immediately in the space of autoclave chamber
  3. Uniform distribution of temperature, the nozzle's injection force drive the droplets to everywhere in the chamber  

keep

Sterilization temperature keeping process :

  1. Temperature reaches the set point temperature, starting sterilization process
  2. The average temperature precision keep in ±0.5°C (±1.0°F) during the process
  3. Sterilizing process approach to constant temperature and constant pressure physical equilibrium circulation
  4. Saturate water sterilization process never over heating the products, best remain protein and glucose, excellence mouth feeling
  5. Option equipment: sterilization F value recorder

process finish

Sterilization process finish :

  1. Time reaches the set time, (F value been sufficient), sterilizing process is finish
  2. Automatically shut down the steam, and automatically starting the cooling system
  3. Hot circulation water would be cooling by the heat exchanger, the cold circulation water inject into the sterilization autoclave chamber to cooled the product
  4. Cooling speed could be adjust between 5~15℃/min ( 9~27°F/min)

cooling process

Autoclave sterilizer cooling process :

  1. 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
  2. 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
  3. With close cooling system save a lot of cooling water, only need about 3-7% cooling water of full water immersion autoclave sterilization,

process finish

Working process finish :

  1. 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
  2. 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
  3. 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 
10 cage

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;
inject view
Chang Yu machinery works
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Remark :

  1. 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.
  2. 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.
  3. 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
  4. All the autoclave sterilizer function design was follow as the regulation of:
    1. USA FDA ( UNITED STATES OF AMERICA, Food and Drug Administration )
    2. 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).
  5. Mechanical design (pressure vessel design) follow as :
    1. ASTM---- American Society for Testing and Materials
    2. ASME---- American Society of Mechanical Engineers
    3. JIS------- Japan Industrial Standard
    4. CNS----- CNS regulation 9788 (Taiwan)
  6. Warning: utility of water and electrical power and steam
    1. Water supply
      1. 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.
      2. 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
      3. The calcium carbonate will adhere to the shell and pipe inner face too, its would damage the equipment, and looking was dirty
      4. Usually sterilize machine breakdown was caused by the calcium carbonate
      5. Cleaning the calcium carbonate was hard working, not so easy
    2. Electrical power supply
      1. 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.
      2. All the electric wire connector should be waterproof
    3. Steam supply
      1. The main pipe of steam should keep the pressure above 6 kg/cm2 (85 psi)
    4. Pressure air supply
      1. Must have a service tank to storage the pressure air, always keep the air pressure above 5 kg/cm2 (70 psi)
      2. If insufficient air supply, the pouches package would broken, the machine would unstable