New AI DIPW Series Steam Injection UHT/HTST Processor Equipment Usage & Applications

AI Direct / Indirect (AI DIPW) Lab UHT/HTST Processing Line Benefit Highlights

MicroThermics’ highly automated AI Direct/Indirect (AI DIPW) Lab UHT/HTST Processing Lines are extremely; easy to use, flexible, and accurate to the production process. The thermal processors are fully integrated with our in-line homogenizers, Ultra-Clean Fill Hoods and AccuFill controls. Our sequential automation reduces operator errors and training needs. Additionally, our AI-DIPW sterilizes, reaches process conditions, and cleans up faster and more easily, resulting in more processing time.

During use, our Set-Up Guide walks the operator through preparing for the process. They simply select the process (steam injection or indirect), and answer a few basic questions. The processor then displays the flow diagram and jumper set-up. After setting up, the operator pushes the “Start” button, and is “hands-off” from there! The equipment automatically starts-up, conducts SIP (sterilization), transitions to process conditions, and alerts the researchers when it is time to process product.

Operators can then process their products and even change processing conditions throughout the day. When processing is complete, CIP and shut down automation also dramatically reduces operator involvement. MicroThermics’ AI processing lines make R&D easier. They help you get more processing done, in less time, with fewer errors. At MicroThermics, we are Always Innovating® to help you reduce your time to market with new products!

Steam Injection Processor
Atomo 3.0 Homogenizer
Ultra Clean Fill Hood

Insights of MicroThermics New AI Direct / Indirect (AI DIPW) Lab UHT/HTST Processing Line

The current market demands a diverse selection of Dairy and Plant-Based products, including milks, protein shakes, yogurts, ice cream, and desserts that can maintain their quality for extended periods. In-line homogenization plays a crucial role in preserving the nutritional value, flavor, and texture of well-formulated dairy products during various thermal processes. Pasteurized milk serves as the foundation for fermented products like yogurt and sour cream. Similarly, there is a growing need to create stable formulations for plant-based products.

Developing stable formulations for plant-based products can be challenging due to the diverse origins of plant-based ingredients. This poses a significant obstacle for ingredient and finished product manufacturers striving to achieve consistent product characteristics after undergoing thermal processing.

To address this challenge, MicroThermics AI DIPW Series UHT/HTST lab processors empower developers to accurately process new formulas and seamlessly transition them from the laboratory to full-scale production. This efficient solution enables swift and hassle-free scaling of innovative plant-based product formulations.

What Products Can You Make on MicroThermics New AI DIPW Series Lab UHT/HTST Processing Lines?

  • Milk & Flavored Milk
  • Plant-Based Milks
  • Nutritional Supplements
  • Fruit Concentrates
  • Enteral Feeds
  • Juices, Teas & Coffees
  • Broths
  • Apple Sauce, Yogurts
  • Gravies/Cheese Sauces
  • Puddings & More!

What Processes Can You Run on MicroThermics New AI Direct / Indirect (AI DIPW) Lab UHT/HTST Processing Line?

  • UHT Processing
 (Direct or Indirect):
  • Aseptic Processing
  • Extended Shelf Life (ESL)
  • High Acid Aseptic Processing
  • Ultra Pasteurization 
  • HTST Pasteurization
  • Starch Hydration
  • Continuous Cooking
  • Hot Filling 
(With or Without Hold)

Sample Flow Diagrams

(30 Processes & Flow Diagrams Are Standard)

FEATURES (Partial List)

  • Simple Process Set-Up Guide

  • Simple “Hands-Off Operations”

    • Start-up, SIP, & Process Transition

  • Sequential Automation

  • Automated Controls Include:

    • Inlet and Flow Rate

    • Product Pressures

    • Heating (Direct and Indirect)

    • Vacuum Cooling

    • Vacuum Product Level

    • Homogenizer Flow

    • Cooling

    • Sample Filling & more

  • Touchscreen PLC

    • Process Recipes

    • Extensive Data Acquisition

  • Sanitary Design 

  • Vari-Speed Product Pump

  • Hold Tube Bank

  • Jumper Panel

  • Multi-piston, 2-stage Homogenizer

  • Lab Bench Enclosure w/sink

Top Benefits of AI Direct / Indirect (AI DIPW) Lab UHT/HTST Processing Line

  • Fast, Easy, & Convenient to Use: MicroThermics’ new, easy-to-use, “AI Series” UHT/HTST lab processing lines dramatically reduce training needs and eliminate hours of equipment operation per day. With the push of a button, they automatically conduct:
    • Start-Up & SIP
    • Transition to product processing conditions
    • Then notify the operators that it is ready to process product
    • Once product processing is complete, CIP is easy with high CIP velocities, and CIP timers. Then a fully automated shut-down is conducted with the simple push of a button.
  • Ease-Of-Ownership: These processors are not just easy-to-use; they are truly easy-to-own. They feature durable, sanitary designs, automated set-up guides, intuitive touchscreen controls, and highly automated operations. Their automation and ease-of-use dramatically reduces training requirements. Their sanitary designs combined with the automation also eliminate hours of daily operation, leaving more time for processing! Most products are processed at approximately 1 LPM, but they can go as fast as 3 LPM. Thus, multiple batches can be processed every day. Finally, their durability means they require little downtime for maintenance. This ease of ownership, accuracy, and ability to process products at a wide range of conditions dramatically reduces R&D time and costs, and makes them invaluable R&D tools.
  • Process Flexibility: The AI Series Processors are capable of processing at both the HTST and UHT temperature ranges in a single processing line. These processes can include a wide range of associated unit operations such as Homogenization, and Ultra-Clean Filling.
  • Numerous Applications: Their unique design enables a wide range of products to be created, all on the same equipment, so there is no need to purchase multiple processors. You can use them to develop Dairy and Plant-Based products ranging from milks, protein shakes, beverages, juices, tea, coffee, yogurts, ice creams, nutritional supplements, and even cheese sauces and puddings.
    Our clients use them for:
  • Formula Qualification & Development
  • Ingredient Qualification
  • Taste Panel Sample Creation
  • Trade Show Samples Creation
  • Shelf-Life Studies
  • Other Custom & Basic Research
  • Process Accuracy: The process you use in the lab must match commercial conditions, or your products will not scale up to production, and your R&D time is wasted. MicroThermics specializes in process-matching and scaling up/down thermal processes. Our designs and flexibility can enable you to go from research directly to production, saving you valuable time and money.
  • Durability: The AI series UHT/HTST processors are highly durable. MicroThermics knows that in R&D, unexpected reactions occur. These reactions can create burn-on/fouling, pressure increases due to high viscosities, and other other extreme conditions. Our equipment is built to stand up to these types of unexpected events, unlike other processing equipment. This durability ensures a very long life, simple maintenance, and very little down-time.
  • Extended Warranty & Technical Support: The MicroThermics team provides
    • Extended warranties
    • Extensive technical support
    • Processing advice
    • Custom maintenance and support services
  • Options (Partial List):  These processors are only 1 part of a complete laboratory processing line. For a full line, pair them with our options such as:
  • Custom Programming
  • Added Hold Tubes and Coolers
  • CE or NRTL marking
  • Feed/Mix Tanks
  • Steam Generators, Water Chillers
  • Spare Parts, Tool Kit, and More!
Get detailed insights into the products with easy displays with an intuitive interface. Our easy-to-use UHT/HTST lab processing line equipment saves time on multiple processes, allowing your whole R&D operations to run FASTER. You’ll get improved productivity in manufacturing and R&D, and a faster ROI on equipment.
Have Questions? Contact us today for more information about any of our equipment, services or trainings. MicroThermics serves the entire world with distributors in the United States, Europe, Thailand, and Japan. Special Discounts are available.

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