The fruit pulp is the most basic food product obtained from fresh fruit processing. It can be cold, stored for long periods, and can be used as key ingredients to fabricate a range of foods such as juices, ice creams, sweets, jellies, and yoghurt. Good quality and extended shelf life of the final product are key for market demand. Processing of fruit-based pulps and pastes has evolved from traditional methods to technologically advanced methods like pasteurization, sterilization, and aseptic processing. The main drivers for improvisation are to enhance the commercial viability of the end product in terms of colour, flavour, retaining nutritional properties, shelf life, and ease of packing and transportation.

The aseptic process uses the high-temperature–short-time (HTST) method in which foods are heated at a high temperature for a short period of time. The time and temperature conditions depend on several factors, such as size, shape, and type of food. HRS Monobloc Sterilizer is a state-of-the-art system for aseptic sterilization and filling of fruit pulp, offering a range of benefits in terms of product quality, safety, and efficiency. It is designed to process varying capacities up to 10,000 kg per hour of fruit pulp or puree concentrate of high viscosity. This high capacity makes it suitable for large-scale production of fruit pulp products, which can help to meet the demand for these products and increase their availability to consumers.

Aseptic processing is important for ensuring the safety and quality of food products by eliminating pathogens and microorganisms that can cause spoilage or illness. The fact that the HRS Monobloc Sterilizer is an integration of the Aseptic Sterilizer and Aseptic Filler on a single skid with fully automated PLC-based controls makes it a convenient and efficient system for food manufacturers. The automation & controls help to ensure precise and consistent sterilization and filling processes, while also reducing the need for manual labour.

The heart of this system is the Ecoflux Corrugated Tube Heat Exchangers in K/DT/AS series models, the main heat exchangers used in the aseptic sterilization process. These heat exchangers enable sterilization of the product at the desired temperature, which is important for achieving better product quality, safety, and shelf life. The HRS Monobloc Sterilizer can be customized with different variants of the HRS range of heat exchangers, depending on the application. The system can also be integrated with a Hygienic Piston Pump for particulate product flash sterilization or a homogenizer and de-aerator with an automatic vacuum control system supported by CIP pumps and peripherals. These features help to improve the efficiency and effectiveness of the sterilization and filling processes.

The system is integrated with the Aseptic Filler, which is a fully automated double (or single) filler head system with a bag clamping system, a conveyor to support the drums, and a sanitary steam line for sterilization of the filling chambers. This filling mechanism is suitable for bag-in-drum filling of fruit pulp products, which is a common method used in the food industry.

The HRS Monobloc Sterilizer is designed to process up to 10000 kg per hour of fruit pulp or puree concentrate of high viscosity, which is a significant capacity that can meet the demands of large-scale production. The system is suitable for processing a wide range of raw fruits and foods, including Mango, Guava, Papaya, Banana, Tomato, Amla, Chilli, Bottle Gourd, Pumpkin, Tamarind, and many more.

Overall, the HRS Monobloc Sterilizer is a comprehensive system that combines aseptic sterilization and filling in a single skid with fully automated controls. It offers a range of features and capabilities that can help to improve the quality, safety, and shelf life of fruit pulp products, while also improving the efficiency and productivity of the production process. These systems are running successfully for more than a decade at many of the food/ fruit processing companies in India and other continents.