Lab UHT/HTST Pilot Plants | Beverage Development Lines for R&D Trials
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What is UHT pilot Plant？
The EasyReal UHT/HTST Pilot Plant is a compact, mobile, and easy-to-install experimental platform designed for efficient Research and Experimental Development (R&D) on different liquid products. Its modular design integrates functional modules for raw material mixing, product fermentation, inline homogenization, heat treatment, and aseptic filling, enabling flexible combinations according to specific needs. The system achieves high adaptability through quick pipe disassembly and reconfiguration.
Equipped with integrated sensors and a touchscreen control panel, users can view, record, and export all experimental data in real-time. The system is easy to clean, supports processing liquids with various viscosities, and allows customizable sterilization times and temperatures. By providing a scalable small-scale production environment, it helps users quickly validate formulations, optimize processes, and reduce R&D costs.
Thermal Processing Strategies for Liquid Food Products
🧃 1. Fruit Juice Products (High-Acidity)
Typical Examples: Apple juice, orange juice, pineapple juice
pH: < 4.5
Sterilization: HTST or UHT (85–95°C or 121°C, short time)
🔄 Process Flowchart:
Juice Preparation → Deaeration → Preheating → HTST/UHT Sterilization → Cooling → Filling
✅ Juices are heat-stable and require lower sterilization temperatures. Deaeration is important to retain flavor and prevent oxidation.
🥛 2. Dairy Products (Neutral pH)
Typical Examples: Pasteurized milk, flavored milk, cream
pH: 6.5–6.8
Sterilization: UHT (135–145°C, 3–15 sec) or HTST (72°C, 15 sec)
🔄 Process Flowchart:Mixing → Homogenization → Preheating → UHT/HTST Sterilization → Holding → Cooling → Aseptic Filling
✅ Requires precise temperature control and rapid cooling. Homogenization ensures milk stability and mouthfeel.
🌱 3. Plant-Based Beverages
Typical Examples: Soy milk, oat milk, almond milk, coconut drinks
pH: Typically > 6.0
Sterilization: UHT + Homogenization + Strong deaeration
🔄 Process Flowchart:Slurry Grinding → Filtration → Deaeration → Homogenization → UHT → Cooling → Filling
✅ These products tend to separate. Double-stage homogenization and vacuum deaeration improve emulsion stability and texture.
🍵 4. Functional & Nutritional Beverages
Typical Examples: Apple juice, orange juice, pineapple juice
pH: < 4.5
Sterilization: HTST or UHT (85–95°C or 121°C, short time)
🔄 Process Flowchart:Juice Preparation → Deaeration → Preheating → HTST/UHT Sterilization → Cooling → Filling
✅ Juices are heat-stable and require lower sterilization temperatures. Deaeration is important to retain flavor and prevent oxidation.
🧊 5. Frozen Desserts & Fermentation Bases
Typical Examples: Ice cream mix, probiotic bases, starter cultures
pH: Variable
Sterilization: Pasteurization (65–75°C, 15–30 min)
🔄 Process Flowchart:Pre-mixing → Pasteurization → Holding → Cooling → Storage or Inoculation
✅ Not intended for commercial sterility but for microbial control before freezing or fermentation.
📘 Summary Table
| Product Type | pH Range | Temperature Range | Key Features |
|---|---|---|---|
| Fruit Juice | < 4.5 | 85–95°C / 121°C | Flavor protection, deaeration |
| Dairy | > 6.5 | 135–145°C | Homogenization, rapid cooling |
| Plant-Based Drinks | > 6.0 | 130–140°C | Deaeration, double homogenization |
| Functional Beverages | 3.5–6.5 | Varies | Customizable thermal treatment |
| Frozen/Starter Products | Variable | 65–75°C | Mild pasteurization for pre-process |
Installation and Connectivity
Easy Installation: Compatible with standard electricity and water supply; detailed installation manuals and on-site support provided.
Modular Design: Standardized interface connections allow for quick setup and easy maintenance.
Lab UHT/HTST Pilot Plant Key Features
● Modular Design: Integrates modules for sample mixing, Sample Preparation, product Fermentation, inline homogenization, heat treatment, evaporation, and filling, allowing flexible configuration based on requirements.
● Precise Control: High-precision temperature and flow rate controls ensure product consistency and quality.
● Multiple Operation Modes: Supports continuous and batch operations, catering to various production needs.
● Real-Time Data Monitoring: Collects and monitors process data in real-time, enabling rapid adjustment and optimization.
● Ease of Use: Simplified controls and settings through a touchscreen interface.
● Low-Cost Small-Scale Production: Ideal for R&D and trial production, reducing prototyping costs.
● High Reliability: Rigorously tested to ensure stable operation.
Flexible Expansion: Can be upgraded to a fully automated system with customizable Critical Control Points (CCP).
EasyReal Lab UHT Pilot Plant Unique Advantages
● High-Viscosity Handling: Processes liquids with viscosities up to 6,000 cps.
● Low Hold-Up Volume: Operates with a minimal batch size of 3 liters, saving raw materials.
● Fast Start-Up: Achieves steady-state operation within seconds of cold start.
● Independent Heating Control: Separate controls for each heating segment, supporting a wide range of temperature settings.
● Integrated Cleaning and Sterilization: Built-in CIP and SIP systems ensure compliance with hygiene standards.
● Two-Stage Cooling: Efficient temperature control ensures product stability.
● USB Data Logging: Facilitates easy recording and management of experimental data.
Installation and Connectivity
Easy Installation: Compatible with standard electricity and water supply; detailed installation manuals and on-site support provided.
Shipping Specifications
Transport Modes: Suitable for standard sea, air, and land transport, ensuring safe delivery.
Packaging: Each module is independently packed to prevent damage during transit.
Weight and Volume: System weight ranges from 10 kg to 500 kg depending on configuration; modular design ensures efficient transportation.
Installation Requirements
Power Supply: single-phase & 3-phase voltage, based on system configuration.
Water Supply: Standard water inlet connection.
Space Requirement: Installation space of 20–50 square meters, depending on module configuration.
Operating Environment: Room temperature; avoid extreme temperature and humidity conditions.