COMPLETE PROJECT FOR ICED COFFEE CAN PRODUCTION

For a client, we executed an entire project focused on iced coffee can production, achieving a line speed of up to 50,000 cans per hour using rotary retorts. The initiative started at the request of a leading energy drink manufacturer looking to broaden their product offerings to include coffee beverages. The client was in search of a partner capable of overseeing every facet of the sterilization line, encompassing loading, unloading, sterilization, the entire cooling system, and project piping. Thermal Process Systems proved to be the competent company for this task, collaborating with the right partners. Beyond supplying the equipment, we managed the project, provided 3D drawings, and facilitated the initial setup of the recipe and technology input.

The real work began following a preliminary design phase. Repurposing an old industrial building for this new venture presented its own set of challenges. It necessitated the planning of new drains and the integration of rails for the loading shuttle into the floor. To address this, we worked alongside partners capable of measuring the floor and accurately placing the drains and rails as per the specifications from Thermal Process Systems. After these preparations, we completed the floors and walls, setting the stage for the equipment installation.

Aiming for a product of superior quality that includes a variety of coffee and milk beverages like iced coffee, iced cappuccino, iced latte mixed with energy drinks, and other novel products, we chose to use Lagarde rotary autoclaves. This choice ensured effective mixing of the product components during processing and efficient heating thanks to the steam flow in the rotary cage. To accelerate the process and guarantee high productivity, special interlayers were introduced. The decision to employ a steam/air process was made to reduce energy consumption and effectively manage water in the absence of a substantial steam flow, fulfilling both aims successfully.

In terms of the loading system, we collaborated with a seasoned company that had previously partnered with us on similar projects for loading the same type of rotary retorts. This established arrangement helps avoid unexpected issues during the commissioning phase of the project.

The discussion on the cooling system led to the adoption of a hybrid approach, capable of leveraging free energy during winter and switching to a chiller or combined system in summer. This strategy reduces energy consumption while maintaining a stable cooling water temperature. The cooling setup was installed atop the factory roof, with pipe connections linking the control tank and retorts for an efficient system. Each retort is provided with a dedicated cooling water supply and a central return tube, which is directed either solely to a dry cooler, to a dry cooler then to the chiller, or exclusively to the chiller. These control mechanisms were installed and executed by Thermal Process Systems.

All piping for the project was completed by our local subcontractor, based on our engineering drawings and under the guidance of our engineering team. Following the installation of the tubing and connections to all utilities, basic testing began, initially with empty runs of the line, I/O testing, and circulation of accessories, and subsequently, with product testing.

Cans from the client’s filling line are delivered to our supply buffer table, organized into a pattern, and loaded into the retort baskets in a fully automated process. Full baskets are then moved to the loading shuttle, which automatically selects the appropriate retort for processing.

The project incorporates a retort supervision system that offers a comprehensive view of the line and ensures seamless communication with both the loading and cooling systems. Consequently, this cutting-edge project for iced coffee facilitates the high-speed movement of cans along the line, providing the client with a professional solution and ultimately producing delightful cans of iced coffee.