1. Water container.
2. Juice container.
3. Bottle filling nozzle-valve (2 or 3 nozzles according to model).
4. Digital thermometer (shows the juice temperature at point of filling).
5. Thermometer for water bath temperature; the temperature control thermostat
for the water bath is initially set at 92 °C, this can be adjusted by
opening the electrical box between the two switches (6&9, undoing one
small screw) and altering the setting.
6. On/off switch and indicator for the water bath heating (press the green indicator).
7. Tube for ventilation of the filling valve.
8. Hose connection from juice container to the heating tube (inside the water
bath). Use the white-spiral polythene tube with NW25 stainless steel
connectors.
9. Unit switched 'ON' indicator; green light; as 6.
10. Heater 'ON' indicator; white light at the bottom.
Preparing the Pasteuriser for operation:-
Fill the water bath with clean water (pre-heated warm water enables the water bath to heat up
to the required temperature more quickly) up to the level 'MAX'.
Ensure the upper juice container is clean and fix it in place with the clips.
Connect the small ventilation tubes to the upper container.
Connect the hose between the juice container and the heating tube (which goes inside the
water bath).
Set the bottle height on the filler platform:
a. Put a bottle on the filling valve and adjust the height position of the
platform.
b. Put a suitable number of black rubber spacers on the nozzle so that the filling
valve opening is visible - as per the diagram.
Put 2 or 3 litres of cold water in the juice container.
Fill some bottles for a
trial.
Check the level against that specified for the bottle/container; a 75cl wine bottle
is typically stamped 63mm (below the top @ 20 °C), this being the level at which the volume of the contents will be 75cl.
Note: Hot juice reduces in volume as it cools to 20 °C, so the fill level must be
higher than that specified on the bottle. Some experience is required to set
this level for each particular size bottle, it may drop by about 10mm for a
75cl bottle, in which case the fill height should be adjusted (with the black
rubber spacers) to 45mm.
A small % tolerance is legally permitted when bottles are labelled with the 'e'
mark.
Important Notes:-
Warning: While in operation the parts of the machine become very hot and could cause
skin burns. Protective insulated gloves must be worn, so that hot bottles can
be handled (i.e. removed and the cap screwed on). The gloves should be thick
enough so that no liquid can penetrate them if a bottle with hot juice were to
break). Rubber outer gloves and Kevlar inner gloves are ideal.
Suitable shoes must also
be worn, not Wellingtons where it would be possible for hot juice to run down inside.
Protective
glasses and clothing should also be worn.
Tips:-
Filling into cold bottles increases the risk of glass breakage, so warming the
bottles to 40 degreesC or more is advantageous.
As long as the bottles (or plastic containers) are clean inside it is not
necessary to sterilise them with wine sulphur before use, since the
pasteurisation will achieve this.
Filling the bottles:-
Plug in the 5-pin 3-phase electrical plug (a 32 kWatt socket is needed) and switch on.
Press the green light at
the bottom until it lights up, the white light also comes on. The white light
stays on as long as the water bath is being heated.
Fill the upper juice container with liquid; the maximum level is 2 cm below the top
of the small ventilation tube. There is a ½" BSP ball-valve on the side
which can be used to fill the container; either by gravity from a tank higher
up, or by pumping.
Switch on the digital thermometer with the small switch on
the top. The temperature shown on the digital thermometer is the temperature
of juice when filling.
Use the blue-handled ball-valve to control the speed of filling so that the
temperature is maintained at the required level (82 °C for cider or apple
juice; 85 to 87 °C for grape juice or sweet wines); slowing the flow will
increase the temperature.
When
the white light goes out the filling can begin.
Place bottles on the filler heads and wait for them to fill to the preset height.
Empty the contents of the first few bottles back into the juice container, to ensure
that the filling nozzle is fully up to temperature.
When a bottle is filled satisfactorily and to the correct level, put a screw cap on
and lay it on its side so that the cap heats up and itself is pasteurised.
Finishing off:-
Switch off the electrical supply.
Let the water bath cool to 50
°C.
Clean out the juice container, filling valves and tubes, with water.
It is important to use 3 special 25mm orange rubber balls (in line together) to thoroughly clean the inside of the spiral
stainless-steel tube which is inside the
water bath; these are propelled through the tube by tap water from the mains or
from a pump.