The installation of blueberry juice production line is a systematic project that involves multiple links and requires careful planning and management. The following are detailed precautions, covering the entire process from early preparation to final debugging.
1、 Pre planning and preparation
This is the cornerstone of ensuring project success and must not be taken lightly.
Process design and equipment selection confirmation:
Clarify product plan: Determine whether to produce NFC (non concentrated reduced) juice, FC (concentrated reduced) juice, fruit pulp juice, or clarified juice. The requirements for equipment vary greatly among different products.
Verified production capacity and shift: Determine the hourly/daily output based on market demand, and select equipment models and production capacity matching based on this.
Review equipment list and layout: Confirm the final process flow diagram (PFD), piping and instrumentation diagram (P&ID), and equipment floor plan with the equipment supplier. Ensure that the layout conforms to the logistics direction (raw materials → finished products), reduces cross contamination, and reserves sufficient space for operation and maintenance.
Site preparation:
Space and height: Ensure that the space and clear height of the factory can meet the installation and future maintenance needs of the highest equipment (such as lifting and replacing components).
Ground and drainage: The ground should be flat, wear-resistant, slip resistant, and corrosion-resistant (usually using epoxy flooring or terrazzo), and designed with an appropriate slope to flow towards the floor drain to ensure no standing water.
infrastructure:
Electricity: Ensure that the total power meets the load of all devices operating simultaneously and provide a stable power source. It is recommended to equip critical equipment such as UHT and aseptic filling machines with backup power sources.
Water source and treatment: Provide sufficient water pressure and flow rate, and install water treatment systems that meet production requirements (such as reverse osmosis and softening water devices).
Steam: If thermal sterilization (such as UHT) is used, it is necessary to ensure that the boiler can provide stable and sufficient clean steam.
Compressed air: Provides clean, dry, oil-free compressed air for pneumatic valves, filling machines, etc., and requires oil, water, and dust filters.
Regulations and standards:
Ensure that the factory design, equipment materials, and installation process comply with national and local food safety production standards (such as GB 14881).
The equipment material (especially the parts in contact with the material) must be food grade stainless steel (such as 304 or 316L), and material certification must be provided.
2、 Core precautions during installation
This is a crucial stage in turning blueprints into reality.
Equipment positioning and positioning:
Follow the layout plan: Strictly position the equipment according to the pre confirmed floor plan.
Use professional tools: Use forklifts, cranes, and other specialized tools to lift and place equipment gently, to prevent collision and scratching of the equipment surface, especially the inner surface in contact with materials.
Adjusting levels: Using a level to accurately level key equipment such as filling machines, blending tanks, and pumps is the foundation for ensuring smooth operation and reducing wear and tear.
Installation of pipes and fittings:
Professional welding: All stainless steel pipes must be welded using argon arc welding and protected by argon filling on the inner wall to prevent oxidation of the welding inner wall and the formation of welding scars. These welding scars are a breeding ground for microorganisms and are prone to scaling.
Slope and emptying: The pipeline installation should have an appropriate slope to ensure complete emptying, avoid liquid accumulation, and achieve the best effect of CIP (in-situ cleaning).
Avoid dead corners: Pipeline design and installation should minimize dead corners (usually referring to areas that cannot be cleaned by flowing media, with lengths greater than 1.5 times the pipe diameter considered dead corners), and all valves should use sanitary diaphragm valves.
Clear identification: After installation, color or label the pipes for different media (juice, hot water, CIP liquid, steam).
Public works connection:
Electrical connection: Operated by professional electricians to ensure secure and safe wiring, and correct motor rotation. Take measures to prevent moisture and electrical leakage.
Pipeline connection: Water, steam, compressed air and other pipeline connections should be sealed reliably without any leakage or dripping. Before connecting the equipment, it is necessary to blow the pipeline and remove impurities such as welding slag.
Hygiene and Safety Design:
Wall and ceiling: Materials that are light colored, smooth, non hygroscopic, and easy to clean should be used.
Doors and windows: windows and self closing doors equipped with insect and dust prevention facilities.
Lighting: The production area is adequately illuminated and equipped with explosion-proof or appropriately protected lighting fixtures.
3、 Debugging and verification after installation
This is a decisive step in verifying installation results and ensuring product quality.
Single machine no-load trial operation:
Start the equipment one by one without loading materials, check whether the motors, pumps, transmission devices, etc. are running smoothly, whether there are any abnormal noises or vibrations, and whether the instrument displays are normal.
Water linkage test drive:
This is a crucial step. Use water instead of fruit juice to simulate the entire production process.
Purpose:
Check the sealing of the entire system and identify any leakage points.
Test the coordination of equipment such as pumps, valves, and heat exchangers.
Calibrate sensors such as flow meters, thermometers, and pressure gauges.
Preliminary testing of the effectiveness of the CIP cleaning system.
Train operators to familiarize themselves with the process.
CIP system validation:
Run the complete CIP program and use ATP fluorescence detector or microbial smear sampling methods to verify whether the hygiene condition of the cleaned equipment and pipelines meets the standards.
Hot commissioning and product trial production:
On the basis of successful water linkage, real blueberry raw materials were used for trial production.
Key control point verification:
Pasteurization or UHT: Verify the accuracy and stability of temperature time control to ensure sterilization effectiveness.
Filling: Check the filling accuracy, sealing quality (such as cap torque), and cleanliness of the filling environment (especially sterile filling).
Finished product inspection: Conduct comprehensive sensory, physicochemical, and microbiological index testing on the trial production juice to ensure product qualification.
Documents and Training:
File archiving: Collect all equipment certificates, manuals, PID diagrams, layout diagrams, welding records, etc., and establish a complete equipment file.
Personnel training: The equipment supplier provides comprehensive training for the operation, maintenance, and quality inspection personnel of the factory, including operating procedures, troubleshooting, daily maintenance, and CIP/SOP (Standard Operating Procedures).