Our expertise
In the agrifood or pharmaceutical industry, selecting your thermal treatment lines is crucial for ensuring profitability. While batch processing using traditional autoclaves is suitable for medium volumes, larger productions have increasingly shifted towards continuous sterilization or pasteurization solutions as the standard. To meet this demand, Steritech has been designing custom automated continuous systems for over 25 years, capable of radically transforming your workflows. Let us explore how…
Continuous systems vs batch: which equipment is best for large-scale industrial productivity ?
Unlike batch processes that divide production into successive loading and unloading cycles, Steritech’s continuous solutions incorporate the sterilization/pasteurization of products directly into the core of your factory flow. These products circulate continuously, without any interruption in pace.
Moving towards a continuous solution allows :
- To reduce cycle times by up to 45% : eliminating latency associated with the loading and unloading of baskets facilitates an increase in overall throughput. Furthermore, the time required for heating or cooling machines, particularly in the case of batch autoclaves, is also avoided.
- Achieving up to 80% savings in floor space : through predominantly vertical and compact architectures, Steritech’s continuous systems free up floor space compared to a traditional configuration of batch autoclaves, thereby allowing for the repurposing of these square meters for other production needs.
- To optimize production flows using the FIFO (First In, First Out) principle : the production flow aligns seamlessly with the upstream (packaging) and downstream (secondary packaging), eliminating intermediate storage areas and potential bottlenecks.
- To achieve energy savings : especially since continuous equipment can be integrated with the WatterloW energy recovery system.
As they move one by one on a dedicated conveyor, all products experience precisely the same thermal profile (cooking and cooling). The outcome : perfect uniformity and identical organoleptic quality for 100% of your production.
Discover how these automated flows integrate into your factory :
A customized range tailored to meet the requirements of the agri-food and pharmaceutical industries.
Instead of modifying your products to fit a machine, Steritech develops continuous sterilization/pasteurization systems that align with your actual constraints (throughput, complex products, types of packaging, ceiling height).
Depending on the nature of your flows and products, our continuous range is available in four customizable technologies :
- Flexible packaging : the modular counter-pressure technology of the Serial Tower maintains the integrity of your packaging (a solution supported by the European Eco-Innovation program).
- Adaptable mass treatment suitable for all types of production : the continuous hydrostatic systems CHS and CHP provide precise thermal and barometric control at very high speeds for cans, jars, bottles, doypacks…
- Without back pressure : the modular solution on CMP plates provides maximum agility during rapid format changes.
- Height constraints : the horizontal CMR solution enables continuous operation without significant alterations to your production infrastructure.
Steritech’s continuous solutions and energy sobriety
Decarbonization and the management of energy costs are essential components of modern industry, and continuous system sterilization/pasteurization is a significant asset for adapting your production area to these new constraints.
Standard batch autoclaves typically consume more resources, particularly during the repetitive heating and cooling phases, whereas continuous flow equipment optimizes energy usage.
Through our innovations focused on heat recovery between heating and cooling zones, Steritech’s continuous solutions enable significant energy savings :
- Up to 23% steam savings compared to a line of batch autoclaves.
- Up to 15% savings on water and overall energy.
These eco-efficient performances directly integrate the modernization of your production tool within an environmentally responsible framework of the industry.
Security process : the intelligent management of flows with Trilogy 4.0
How can we ensure the safety of products undergoing sterilization or pasteurization in the event of an unforeseen incident on the line? The Trilogy 4.0 control system from Steritech automates regulation and safeguards your production in real-time :
- Upstream hazard (for instance on your seaming machine) : the entry of products into the continuous solution is automatically halted. The products that are already engaged continue their normal heating and cooling cycle without any risk of overcooking.
- Downstream hazard (for instance on your packaging system) : an automatic switch instantly redirects flows to a secondary or manual packaging area to maintain the pace.
- Hazard on the internal conveyor system : through individualized monitoring (gondola by gondola) and real-time analysis of regulation zones (pressure, temperature, downtime…), Trilogy 4.0 records the precise history of each product. Consequently, at the exit, units that do not meet criteria are immediately isolated for targeted quality control.
Result : your traceability is complete, your health safety is assured, and your production tool along with your goods remain safeguarded and functional against any unforeseen circumstances.
Validate your return on investment in our testing laboratory
Replacing a batch line or designing a new continuous production line is a significant strategic project. To safeguard your investment, Steritech offers to test your products under real conditions.
In our testing laboratory, our engineers accurately replicate the behavior of our industrial equipment on a smaller scale. These tests enable the validation of your packaging compatibility, the determination of the optimal thermal scale, and the selection of the most suitable and cost-effective continuous system for your project.
Do you wish to modernize your production tool and transition to continuous flow? Contact our teams to analyze your specifications and conduct a tailored feasibility study.
