Molenaar Retorts

RETORTS

Product Brochure

MOLENAAR Retorts

Over the past 40 years, Molenaar has established itself as a leader in in-container thermal processing technologies used in the Food and Beverage industries. The Molenaar range of Steam, Water Spray and Full Immersion retorts offer unparalleled processing due to their excellent heat distribution ensuring the highest standard in Food Safety. Modern process requirements require up-to-date solutions. With this in mind we can offer multi-mode functionality enabling a wide range of products to be processed. These systems can be further enhanced with the addition of innovative energy recovery systems, automated retort loading and materials handling technologies. Our well-equipped laboratory is available to customers for real-time processing trials and live environment product development. To ensure seamless execution, we have an experienced Projects Management Office that can clearly define battery limits for efficient project roll-out; from Factory Acceptance Testing through to commissioning and successful handover. Molenaar Thermal Processing – turning the heat up, because our customers demand reliable, high quality solutions that continuously deliver safe thermal processing.

Stefan Molenaar Stefan Molenaar Managing Director of HG Molenaar & Co. (Pty) Ltd.

IN-CONTAINER

Sterilizing & Pasteurizing

In all food manufacturing, the safety of the product is non- negotiable. Long shelf-life products in cans, pouches, jars, bottles, cups, trays, and cartons are thermally processed to ensure safety. The amount of heat required to achieve commercial sterility is dependent on many of the product features. To achieve the high temperatures required for sterilization these products are processed in retorts. Retorts (also referred to as autoclaves) are pressure vessels that use the temperature pressure thermodynamic relationship to process food at temperatures above 100°C. The way that bacteria and their spores die, is a logarithmic function of the amount of heat that they are exposed to; the higher the temperature, the faster they will die. It is therefore desirable to carry out the thermal process at the highest temperature the quality of the product can allow. Processing in modern well-designed retorts allows strict temperature and time control for exceptional product quality and confidence of safety.

There are two main temperature categories used in thermal processing: sterilization and pasteurization.

Products that are sterilised require critical heat treatment and are processed between 110°C and 135°C. These products have a pH of > 4.6 and are referred to as low acid. This low acid group has to undergo a more severe heat treatment as the process must be able to kill the spores of heat-resistant groups of pathogenic and spoilage bacteria such as Clostridium and Bacillus.

Products that are pasteurized need a milder heat treatment and are processed between 80°C and 105°C. They have a pH of 4.6 or below and are either naturally acid or acidified. This group can be pasteurized as the thermal process only needs to kill viable microorganisms, as the low pH restricts the germination of spores.

low acid heat

thermally processed commercial sterility quality

Quality Assurance Excellent heat distribution results independently audited.

HEATING Options

Guillotine Door

Immerse, Spray & Steam

Safety Valve

IMMERSE

Products and packaging which are susceptible to damage can be immersed in water, and are processed under a carefully controlled pressure profile. Water also provides an excellent heat transfer medium. The process is therefore suitable for glass jars and bottles, flexible pouches, semi-rigid punnets and soft packaging e.g. Polypropylene (PP) and High Density Polyethylene (HDPE) bottles. Water immersion with rotation is recommended for products where the colors and flavors are heat sensitive (e.g. milk-based drinks). Water immersion is highly energy efficient by recovering the superheated water for use in the next cycle.

Heat Exchanger

SPRAY

Water spray retorts use nozzles to spray a mixture of steam and water onto the packages to transfer the heat. By using specially designed trays and strategically placed nozzles Molenaar retorts achieve excellent temperature distribution and exceptional heat transfer throughout the retorts. Water spray retorts use less water, and they are very efficient in terms of steam consumption. Dynamic over-pressure control continuously adjusts the over pressure, making Water spray retorts suitable for glass containers, plastic bottles, plastic cups, pouches and punnets.

STEAM

Saturated steam is an excellent medium for sterilizing, since condensing steam results in rapid heat transfer. Venting of the retort is done to remove air, which results in an even heat distribution and quick come-up times. Steam, as a processing medium, is ideal for metal cans: both tinplate and aluminium.

High Volume Circulation Pump

Future-Proof your Retort Single Media or Multi-mode Systems available.

Immerse

Steam

Spray

PROCESS Modes

Rotation and Oscillation

Simulation of End-Over-End Rotation Full rotation of 360º.

Batch retorts can be operated using different processing media and in different modes. The mode used will depend on the kind of product being processed. Static retorts are used for solid products or products in viscous sauces which heat mainly by conduction. Any agitation for these products would result in very little heat transfer benefit. Delicate products that could get damaged by agitation should also be processed in the static mode. Products that heat by convection would greatly benefit from some agitation during processing. This would increase the rate of heat penetration into the product, and reduce the processing time; thereby reducing the total energy consumption of the process, and improving the product quality.

There are two types of agitation: end-over-end rotation and oscillation.

End-Over-End Rotation

FULL ROTATION

End-over-end rotation uses the headspace bubble to aid mixing, as the packs are rotated 360°. The full rotation does not suit all packaging types.

OSCILLATING

STATIC

Static retorts are typically used where agitation is either not necessary, or may damage the product or packaging. Product heating occurs by conduction and/or by natural convection.

Gentle rocking induces mixing inside the packaging where end- over-end rotation may not be suitable. Products in flat-lying containers such as pouches and trays will especially benefit from the increased heat transfer rate induced by gentle agitation.

Rotary operation of a batch retort results in forced convection which speeds up the heat transfer to the cold spot of the package, even in products with high viscosity. Shorter processing times result in better quality and retain more of the nutritional value. Furthermore, the mixing of the product prevents clumping and product burn-on inside the packaging.

Oscillation

For flexible pouches - and semi-rigid cups and trays - the gentle rocking movement of oscillation is the preferred option.

CHOOSE YOUR Retort

MOLENAAR Baskets

Retort Mode and Method

Basket Sizes and Capacity

RETORT MODE SELECTION BY CONTAINER TYPE

BASKET SIZES

Rotary

Static

Internal Diameters

1275 mm 1550 mm

860(w) x 1085(l) x 760(h) 1000(w) x 1370(l) x 936(h)

695(w) x 825(l) x 695(h) 890(w) x 1370(l) x 890(h)

Plastic Tub, Cup or Tray

Glass Jar or Bottle

Plastic Bottle

Steel Food Can

Pouch

Handling Technology

ESTIMATED HOLDING CAPACITIES PER BASKET

Static Oscillation Full Rotation

√ √ √

√ √ x

√ √

√ √ √

Internal Diameters

Cans

Mode

Pouches

Plastic Cup

HDPE Bottle

Glass

* Not recommended

415 g (127 x 203 x 76 mm)

136 ml (Ø84 x 45 mm)

350 ml (Ø65 x 175 mm)

470 g (Ø75 x 135 mm)

430 ml (1M: Ø76 x 110 mm)

1275 mm 1275 mm 1550 mm 1550 mm

Static Rotary Static Rotary

1008 648 2080 1760

106 60 207 171

1820 819 3264 2560

988 432

880 550

COOKING TECHNOLOGY BY CONTAINER TYPE

2160 1560

1530 1320

Plastic Tub, Cup or Tray

Glass Jar or Bottle

Plastic Bottle

Steel Food Can

Pouch

Handling Technology

Steam Water Spray Immersion

√ √ √

x √

x √ √

The Molenaar range of baskets are available in galvanized carbon steel or stainless steel, with either a fixed or live bottom for automated loading.

For pouch processing, the baskets are placed with stainless steel racks and removable trays for easy loading. The position of the rails in the retort are optimized to accommodate both racks and baskets with no changeover required.

* Not recommended

MANUFACTURED Excellence

Retort Specifications

DOOR TYPES

Bayonet Lock doors with a rack-and-pinion opening mechanism. Front- opening, and can be manual or fully automated as needed. Guillotine Space-saving, vertical opening doors; used for fully automatic systems. The type of door selected depends on specific operational requirements, which may include layout optimization and future mechanization options, including: • Single or Dual Entry doors. • Automation requirements, possibly as a future upgrade. • Safety Standards

CERTIFIED CODES OF CONSTRUCTION

Pressure Vessel Manufacture Affiliations • ASME BPVC • Pressure Equipment Regulations (PER) and OHSA • Pressure Equipment Directive (PED)

Credentials • Certificate of Authorization ASME U-Stamp • Pressure Equipment Directive (PED) 2014/68/EU module A2

MATERIAL SELECTION

All Molenaar retorts are available in:

ASME SECTION VIII DIV.1 2019 ED. (American Standard)

PED 2014/68/EU (European Standard)

RSA/CI/OHSA 8.1-17-W (Local Standard)

• Carbon Steel • Austenitic Stainless Steel (304 or 316) • Duplex Stainless Steel

WATER & ENERGY RECOVERY SYSTEMS

MOLENAAR SHELL & TUBE HEAT EXCHANGER

RETORT CONTROL

Thermal Processing is a high energy demand process - and in an effort to reduce the carbon footprint and improve overall sustainability - Molenaar use innovative solutions for saving water and energy. Energy for heating, and water are two of the largest running expenses in retort operation. Water can be recovered and the heat required to sterilize products that can be exchanged in different ways to be used again in the next cycle. This can be done using either an integrally mounted reservoir, or remotely if multiple retorts are installed. In the case of immersion retorts, pressurised storage tanks are required.

For reliable and trouble-free operation, Molenaar use in-house designed and built Tubular Heat Exchangers, which have many advantages: Features & Benefits • Energy saving • Tube bundle is removable for cleaning • Small footprint • Modular and stackable • Low maintenance - no expansion joints • Resistant to thermal shock - a distinct advantage in a heat exchanger used for both heating and cooling

Our retort control ranges from manual to fully automated control systems with easy to use interface. The control hardware is state- of-the-art, Industry 4.0 ready, and is flexible enough to meet all clients’ needs. Retort Cycle Data is recorded to ensure batch process traceability. The data can be easily uploaded to the clients’ server or cloud system via a secure interface.

AUTOMATION Technology

Custom Excellence

FULLY AUTOMATED BASKET LOADING SYSTEM

Automatic basket loading is available in traditional sweep type machines, or it can be done by robotic systems. Speak to us to discuss the options and determine the method most suited to your requirements. Benefits: • Automated operation • Reliable • Small footprint

SEMI-AUTOMATIC BASKET LOADING SYSTEM

Molenaar are able to assist in customizing your operation. We offer solutions ranging from semi-automatic mechanized basket loading to fully automatic robotic handling systems. Semi-automatic systems are often chosen, while still using manual retort loading, which offers a means to mechanize a repetitive part of an operation. Benefits: • Simplified operations • Reduced container damage and product losses • Can be automated at a later date

ADDITIONAL MODULES PROCESS RECORDING • Paperless option which allows for exporting process data onto a USB flash drive or WiFi. • Circular Paper Chart recorder option. TRACKING SYSTEM Our basket tracking system keeps track of baskets throughout the retorting process. From loading into the retort, up to unloading with relevant Quality Control information.

SHUTTLE LOADING SYSTEM We offer fully automatic retort loading solutions; which includes door mechanization, automatic shuttles, retort loading and unloading.

Benefits: • Efficient • Safe • Reliable • Product security

Molenaar design and integrate turnkey automation modules.

Optionally, systems can be built to be automation-ready for future upgrades.

MOLENAAR Process Technology

Pilot Plant

TESTING FACILITY

PROJECT MANAGEMENT

The Pilot Plant Laboratory, at our Paarl-based factory, offers the opportunity for new or existing products and processes to be trialed. New packaging formats or different sizes can be packed, and development work on assessing the benefits of different processing media (steam, full immersion and water spray) can be done. The benefits of process optimization using end-over-end agitation, can be tested.

Thermal process validation expertise is available using calibrated, certified equipment. Process recommendations can be made with regards to product safety and process efficiency. Validation of seals and lidding materials can be made so as to minimize leakage and product waste. Recommendations regarding sealing times and temperatures are also on offer.

From inception to sign-off, projects undertaken are managed and monitored by our Project Management Team. Battery limits are clearly defined throughout, and the customer is kept abreast of developments and progress assuring certainty on where responsibilities begin and end. The Project Team relies on the expertise and direct support from our Engineering Department. Molenaar boasts a highly competent team consisting of Draughtsmen, Plant and System Engineers and Controller Programmers. Project management unites all Molenaar activities to create a single interface for our customers. THINK SERVICE EXCELLENCE

OUR SERVICES

Customer engagements include installing new equipment, maintenance, repairs, and operational support. You get direct, local expertise from professionals who can meet all of your technical requirements. These skilled expert technicians are applied to our customers’ facilities from the smallest to the largest to ensure consistent service standards across the board.

PROACTIVE SUPPORT

Our Customer Services Team has instituted a field monitoring and maintenance programme that can track machines. The unique equipment identification system monitor service and maintenance schedules of equipment. This proactive engagement ensures that you can benefit from improved maintenance outcomes that are scheduled with minimal unscheduled downtime. We track spare part items and service information to reflect an on-going record of the service and operational efficiency of equipment.

“RFG is a long-standing customer of HGM. We have their retorts installed at several of our fruit and vegetable canning operations. Their equipment is truly world-class. Not only is the engineering of the usual HGM high standard, but their process knowledge and support gives them the edge over anyone else in the market. Reliability is critical in our business, and HGM service is superb.”

Bruce Henderson | CEO RHODES FOOD GROUP (PTY) LTD, South Africa

“We have worked with the Molenaar team now for decades and it has always been a collaborative process between our organizations creating world class results. Molenaar has proven to be a leader in technology advancement/innovation and has a proven track record of making things happen on time and on budget. We value the continuous improvement spirit Molenaar brings to the table every day!”

Christopher Ward | Vice President, Operations PACIFIC COAST PRODUCERS, California, USA

Think Service Excellence

A HG Molenaar & Co. (Pty) Ltd. PO Box 5, Paarl, 7620 200 Jan van Riebeeck Drive, Paarl, 7646 SOUTH AFRICA

Tel +27 (0)21 868 2210 sales@hgmolenaar.com www.hgmolenaar.com

Page 1 Page 2-3 Page 4-5 Page 6-7 Page 8-9 Page 10-11 Page 12-13 Page 14-15 Page 16-17 Page 18-19 Page 20

hgmolenaar.com