Vertical autoclaves AV-2 AV-4

The long-term preservation of canned food without deterioration is achieved by suppressing the livelihoods of microorganisms in them, which can be carried out by various methods, of which the heat treatment method is the most common (in some cases it is both culinary heat treatment of raw materials).

The process of suppressing microflora in the product at temperatures up to 100 ° C is called pasteurization, at 100 ° C and above - sterilization. Equipment used for these processes is called pasteurizers and sterilizers, respectively.

Sterilizers are periodic and continuous They are vertical and horizontal. In some structures of autoclates, banks in the sterilization process are still, in others (for example, in horizontal rotary) are moved to increase the heat exchange rate.

The process of suppressing microflora in the product at temperatures up to 100 ° C is called pasteurization, at 100 ° C and above - sterilization. Equipment used for these processes is called pasteurizers and sterilizers, respectively. Sterilizers are periodic and continuous. Periodic sterilizers are usually called autoclaves. They are vertical and horizontal. In some structures of autoclates, banks in the sterilization process are still, in others (for example, in horizontal rotary) are moved to increase the heat exchange rate.

At the factories of the USSR, and after Russia, vertical autoclaves AB-2 and AV-4 were most common.

Continuing sterilizers are divided into hydrostatic, rotary and conveyor. From the hydrostatic sterilizers of continuous action at the canned plants of the country, the devices of the OHS-1 "Hunister" (Hungary) and A9-FSA were used more often than others. For the pasteurization of certain types of canned food, tape, or conveyor (A2-KPOs, A9-KSH), and lamellar pasteurizers were used.

Construction of vertical autoclave.

Vertical autoclaves AB-2 and AB-4 serve both for sterilization and pasteurization of canned food in hermetic container. Included with them is required to install in autoclave sterilization regulators that allow you to automate the process.

Vertical autoclave AB-2 (Fig. 1) consists of a housing 4, covers 1 with a counterweight 12, high-speed belt clamp 2. The body of the autoclave welded from sheet steel 6 mm thick
on the shell and 8 mm - on the bottom. On the support beams or rack, it relies with the paws 5. inside the case, at the bottom, the supports are welded to install an autoclave basket. Even below, the bottom cavity is a barbotter 6. The pairs enters it along the pipe 7. Drain of water from the autoclave is carried out through the pipe 8. Very often, the hole in the center of the bottom above the pipe 8 is closed on the plants with a metal grid to prevent entering the reinforcement on the drain highway. Small broken glass.

Fig. 1. Autoclave AB-2

A manometric box 10, connected by a circulation pipe 9 with a lower part of the autoclave, is welded to the housing shell. In a pressure gauge welded sleeve for installation
in it, the thermometer 11, closed by a protective casing. In addition, the box has a fitting for connecting the pressure gauge 16 and connecting to the sterilization software regulator.

In the upper part of the case there are nozzles through which the autoclave is filling with water and draining it during excess.

On a folding spherical lid 1, a safety valve 13 and a trial-shrinkable crane 15 are located. A ring bubbler is placed under the lid, which serves for uniform cooling of cans with a product after sterilization. Water in the ring bubbler comes from the highway through a flexible hose, fixed on the nozzle 14. Bounded with a lid with a load with a load serves to facilitate its opening and closing. The flanges of the lid and the housing are tightly pressed one to another fifteen sectoral grips, reinforced on the ring of spring strip steel. The ends of the belt clamp 2 are tightened manually using a lever system.

To eliminate the ability to open the autoclave cover at a pressure, it provides for a safety device 3, consisting of a housing, piston, glass, rod, stripping and trigger crane. The body of the safety device is connected to the autoclave nozzle on the flanges. The trigger crane will be screwed into the body from below, the glass is top.

Inside the glass is a piston associated with the rod. With an increase in pressure in the autoclave to 0.005 MPa, the piston with a rod rises and the rod locks the handle of the clamping device. Due to the unreliability of the safety device, mechanical locking devices (for example, such a spring-loaded rifle shutter) are manufactured and installed on autoclaves.

Inside the autoclave with the help of electric devices, metal baskets are loaded, which are perforated cylindrical shells with welded or removable bottoms.

To the top of the basket, the rocker from the rod steel is attached, for which the basket is captured by a hook. The protrusions located on the top edge of the shell provide a gap between the bottom of the top basket and banks in the lower basket.

Technical data of autoclaves AB-2 and AB-4 are shown in the table below:

Indicators	AV-2	AV-4.
Autoclave Capacity, M3	1,57	2,75
Internal diameter, m
Limit working pressure, MPa	0,35	0,35
Number of downloadable baskets
Gabarites, mm.
width	1350	1350
lid closed	2200	2200
lED with an open lid	1870	1870
lid height	2410	4000
lid height	3290	4790
Mass of autoclave, kg
without baskets		1317
with baskets	1150	1750

To prevent the cutting of the covers from glass cans and deformity of a heavy container of a large capacity or made of fine tin in autoclaves, the necessary pressure of the working medium is created, and therefore in the autoclave compartment, the pumps with an electric drive and an emergency steam pump should be installed (in case of power to turn off the electricity).

In accordance with the OST 18-344- 79 Autoclave baskets are equipped with springs for fixing a rocker at an angle of 60 °. The springs are selected so that a suspended basket of the rocker was in a vertical plane, and wheninstalling a basket on a basket (in the autoclave) lightened under the weight of the topbaskets.

Mercury glass thermometer on the autoclave must have a scale up to 200 ° C,pressure gauge - up to 0.6 MPa (6 kg / cm2).Autoclaves set strictly vertically in the ads of a depth of 2.2 mfor AV-2 and 3 m for AV-4. The distance between the centers of autoclaves in one row should be at least 2 m, between the rows - at least 3.5 m.

With double row the location of autoclaves is recommended to mount their frontal part topassage (in the passage should not be transmitted). The hull shelter protrudes over the floor by 0.8 m. The veil is equipped with a supply and exhaust ventilation.Water merges from the autoclave with the obligatory rupture of the jet.

Work 1 vertical autoclave "AV-2"

Technological task: Thermal processing (sterilization) canned food.

Purpose of work: Assess the technical level (state) of the vertical autoclave "AV-2" and give proposals for the development of its design to improve the efficiency of the sterilization process.

Tasks of work:

1. To explore the device and the principle of operation of the vertical autoclave "AV-2".

2. Consider the features of the sterilization process.

3. Determine theoretical and experimental performance, as well as the power of the heaters of the vertical autoclave "AV-2" with various modes of operation and process test results.

4. Give proposals for the maintenance of the vertical autoclave "AV-2".

5. Assimate the rules of safe operation and adjustment of the vertical autoclave "AV-2".

Equipment, Tools and Inventory: Autoclave vertical AB-2, hours, technical scales with multiple times.

Products:canned food in tin cans with a total volume of 6.0 liters.

Studying the device and principle of work

Vertical autoclave AB-2 (Fig. 5.9.1) is intended for the sterilization of canned food in mini-productions.

The autoclave consists of sterilization 11 and waterfour 4 chambers, which are a single design, cooked from two isolated containers. The sterilization chamber on top is closed with a lid 12, equipped in the center outside by clamping 14 and having a slot on the periphery to pass the clamps 14 (woven with flywheels). The waterproof column 7 with the upper 8 and the lower 3 cranes is attached to the waterfall chamber in its upper and lower part of the fittings.

Fig.5.23. Autoclave vertical AV-2:

1 - casing; 2 - hose; 3, 8 - lower and upper cranes; 4, 11 - waterfall and sterilization chambers; 5 - bottom; 6 - cassette for canned goods; 7 - waterproof column; 9 - funnel; 10 - shelf; 12 - cover; 13 - Manovakuumetre; 14 - clamp; 15 - electrocontact pressure gauge; 16, 22 - Ejection and filter valves; 17, 20, 23 - water, steam, condensate valves; 18 - Ejector; 19 - Safety valve; 21 - filter; 24 - bolt fastening of electric heating elements; 25 - box; 26 - Electric heating element; 27 - electrical panel; 28 - switch; 29 - Signal Lamp

Over the upper crane is installed funnel 9, the nipple of the rubber hose is screwed onto the lower below. 2. Above the bottom 5 of the sterilization chamber is located the lower crane of the cassette 6 with sterilized objects.

To the upper part of the chamber, with the help of fittings, Manovakuumetre 13 and the electrocontact pressure gauge 15 are attached, as well as the ejector 18 with valves 16 and 17. It is equipped with a block with a condensate valve 23, filter 21 and filter valve 22. Safety valve 19 is connected to the top of the steampling chamber. which through the pipe with steam valve 20 is connected to the sterilization chamber 11. The autoclave is equipped with a protective casing 1, based on three supports. The casing below is a box 25, which closes the terminals of the electric heaters 26 and their mounting bolts 24. Electric heaters are located at the bottom of the waterfall chamber, under the bottom of the sterilization chamber. Electrical switch 2 with switch 28 and a signal lamp 29 mounted to the wall next to the autoclave from the opposite to the safety valve.

The operation of the autoclave is carried out as follows.

Load to the sterilization chamber of the cassette 6 with canned foods (first loading is recommended to be carried out in a preheated autoclave). Close the cover of the sterilization chamber 12, lift and tighten the screw fittings tightly with handwheels 14.

Turn on the electrical heaters by turning the switch 28 knob to the position is on (the warning lamp 29 should turn around). After reaching the required pressure in the waterfoot chamber, open the steam valve 20, to withdraw over the previously open condensate valve 23 air along with a part of the steam. After 2 ... 3 min. Close the valve 23. Then wait for the upper value of the sterilization pressure on the electrocontact pressure gauge 15, secure the start time of sterilization. During sterilization, it is necessary 2-3 times at 10 ... 15 with a conclusion of the valve 23 to remove condensate from the sterilization chamber, as well as for a better washed by a ferry of sterilized objects. After the specified sterilization time is expired, close the valve 20, open the three-way crane of the Manovakuumometer and blow the siphon tube, release steam and condensate from the sterilization chamber, opening the valve 23, and drain sterilized canned food. To do this, open the water intake valve 17 into Ejector 18 and the steam suction valve 16 of the sterilization chamber. We produce ejection for 10 minutes, with a vacuum measured by manovacuumometer 13, should reach at least 44 kPa. At the end of the ejection, close the valve 16, then the valve 17 and open the valve 22 to connect the sterilization chamber with the atmosphere, open the cover 12, close the valve 22 and unload canned food.

Vertical autoclaves are manufactured by two and four-seat, differing only in the height of the case.
A two-stage vertical autoclave of the AB-2 brand of the Batumi Machine-Building Plant (Figure 1) has a welded cylindrical body made of carbon steel st. 3. The tightness of the cover of the cover with the case is provided by a laying of oiled asbestos. Inside the autoclave above the bottom is a barbotter. On the support ring, steel grids are installed with holes on the entire side surface. On the autoclave lid installed a crane for purge. Under the lid autoclave is strengthened by a ring shower. Pipe for draining water is attached to the bottom of the autoclave in the center. The box on which the thermometer is installed (up to 150 ° C), a pressure gauge (up to 0.6 MPa) and a safety valve are welded to the cylindrical part of the autoclave. To circulate water in the box, it is connected by a tube with the bottom of the autoclave; This ensures the correct sensation of the thermometer.
The Batumi Machine-Building Plant produces autoclaves, in which the cover is pressed against the body with a special clip (instead of several baratic nuts), which facilitates the work of autoclars and reduces the time for closing and opening the lid of the autoclave.
On the housing of the autoclave and on the cover, the rings (flanges) of the trapezoidal section are strengthened, between which is located

A-2 AB-2: 1 - Autoclave Case; 2-lid autoclave; 3 and 4 - rings (flanges); 5 - sealing gasket; 6 - belt clamp; 7 - segments; 8- outer autoclave belt; 9 - counterweight; 10 - grids; 11-barboter for steam supply; 12 - bottom, I-Marks AB-4; 1- support; 2 -Bandage; 3 - circulating tube; 4 - dash box; 5 - air crane.
Figure 1 - Spreading Autoclaves

Sealing gasket. The high-speed belt clamp has 15 sector captures (segments), reinforced on the ring of spring strip steel, and a lever system for tightening and breeding the clip. When turning the lever lever, the clamp tightens segments. Segments, taking care, enter your inner cuts into the protrusions of the rings and pressed the cover to the autoclave case. The outer belt limits the movement of the segments and holds them in a certain position when the lid is open.
The communication scheme of one autoclave is shown in Figure 2. As can be seen from the scheme, autoclaves for sterilization with a backpressure, except for conventional pipelines, have a pipeline, under leading compressed air (usually via a barbwater for steam), or a pipeline for water supplied under pressure from centrifugal or steam pump. In addition, a tube associated with the sewage is located on the top of the autoclave case.

1.2 and 4 - pipelines; 3 - centrifugal pump; 5 - compressor; 6 - Receiver with compressed air.
Figure 2 - Communication of the autoclave

On pipelines serving the steam and water autoclave, there are check valves; They prevent the movement of water from the autoclave to the network if the pressure is reduced there. Two lock valves are installed on the steam pipeline.
Before work, the status of the autoclave, the serviceability of all the valves, instrumentation and gaskets check.
Sterilization of canned food in a tire in a steam medium is as follows. With the help of electricity, baskets with cans in the autoclave are loaded, cover the lid and the belt clip pressed the cover to the autoclave with the rotation of the lever. Then open the purple tap and the steam valve; The air is supplanted with a ferry from the autoclave. With the appearance of a jet of steam from the blowing crane, it is closed and continued to heighten up to the set temperature in the autoclave. The duration of heating is set by the sterilization mode. The rate of increasing temperature is adjusted by feeding steam into the autoclave. Upon reaching the sterilization temperature, it is supported throughout the sterilization time, controlling the thermometer and adjusting the supply of fresh steam.
Upon expiration of the sterilization time, the steam valve is closed and gradually reduced pressure and temperature, releasing steam through the damping tap during the sterilization mode. Then the banks are cooled. To do this, the autoclave is served under pressure cold water or unload meshes from autoclave and can be cooled under water shower or in air. Banks are cooled to a temperature on their surface 40-45 ° C. If they are not cooling, then the rigging of the product is continued in the bank. When cooling to lower temperatures, the banks do not dry and can be covered with rust.
Sterilization of canned food in glass jars in water with water tuxties is as follows. In the autoclave "filled with water, the temperature of which is different by 10-15 ° C on the temperature of the cans, load filled baskets. The lid is sealed and filled with autoclave with water, leaving a small air layer under the cover. The layer is a buffer that prevents sharp pressure fluctuations when the part of the water is released. Then steam is applied to the autoclave, gradually increasing the temperature and pressure in it to the set values.
The pressure in the autoclave is increased by the resulting condensate from steam. If the pressure in the autoclave becomes more permissible, and the temperature does not reach the desired value, the pressure reduces, carefully releasing part of the water through the drain pipe.
The set temperature is continuously supported throughout the entire sterilization time, while maintaining constant pressure in the autoclave. At the end of the sterilization, the banks are cooled. For this purpose, cold water is implied on top into the autoclave and the same amount of water is released through the triggered pipe.
Studies have shown that when cooled heat resistance, beets are significantly lower than when heated. It is explained by the fact that when heated, the outer layers of the wall of the glass can have compressive efforts, and when cooling, stretching efforts arise, as a result of which cracks are obtained and banks are destroyed. As the experience shows most dangerous is the cooling stage of cans from sterilization temperature to 70 ° C. In this temperature range, there are particularly high voltages in the material of the cans, sometimes leading to their destruction. In order to prevent combat battle battle, the temperature in the autoclave should decrease gradually and evenly. For this, cooling water is served with small jets through a bubbler or a shower, fortified under the lid of the autoclave. This method in the factory conditions showed good results.
When the temperature in the autoclave approaches the ultimate, the pressure is gradually reduced by continuing cooling. At the end of the cooling, it is closed with all the valves, open the damping fauce or the valve on the drain pipe and the pressure in the autoclave is adjusted to atmospheric. Then produce part of the water and unload baskets with banks.
Devices for loading autoclave grids with banks and unloading them from the grids greatly facilitate the work of working, increase productivity and reduce the battle battle. The easiest way to load tin cans in the grid is loading with water cushion. In this method, the empty grid is immersed in a water vessel, the level of which is slightly above the mesh edge. With conveyor, banks are fed into water that protects them from strain or battle. When the grid is replenished with banks, it is unloaded from the vessel with water and loaded into the autoclave.
For unloading grids after sterilization, the same vessel, but filled with a solution, whose share is more specific weighing cans.
To download cans in the grid and unloading them from the grids, installations with a hydraulic lift are also used, as well as with an electromagnetic head.
The quality of canned and the possibility of their long-term storage is largely dependent on the accuracy of the sterilization mode. The most reliable are automatic control and automatic temperature control in the autoclave and the duration of the sterilization itself. In periodic autoclaves for regulating and controlling the increase in pressure and temperature, duration and temperature of sterilization, automatic purge of the autoclave from air, backpressure, duration of pressure and cooling, various automatic circuits are used with water.
For automatic control and regulation, pneumatic and electrical software thermostat are used using a time relay, sound and light alarm, with an automatic recording in time of temperature and pressure in the autoclave.
In the sterilization of canned food in tin and glass container in a periodically active autoclave, working with the counterpart, apply the temperature regulators of temperature and pressure of the PRP-2 and PRP-2U system. These regulators provide a steady sterilization process according to the specified mode with a temperature deviation from a given ± 1.5 ° C.
Horizontal autoclave. The body of the autoclave (Figure 3) is set in a horizontal position on the paws.

1 - body; 2 - cover; 3- clamping steering wheel; 4-hurgroke.
Figure 3 - horizontal autoclave

The end sides of the housing with one or both sides are closed with hermetically covers on the loops. Inside the autoclave, a barbarboater for feeding steam and rails, along which trolleys with banks are moved. Horizontal autoclaves are based on one, four and six trucks; They differ among themselves only the length of the housing. These autoclaves are equipped with the same control and measurement devices and communication as vertical autoclaves.
For horizontal autoclaves (in contrast to the vertical; no channels (mines) are required when they are installed, as well as monorans with electrical or cranes for loading cans. The presence of covers allows you to load an autoclave on one side and unload it on the other side; this ensures some speed of movement Cans, especially if the loading of the autoclave is to produce in the sterilization workshop, and unloading - at the warehouse of finished products. However, horizontal autoclaves occupy a large area and it is difficult to sterilize canned food in water, in addition, the degree of use of their volume is less. Studies have shown that At less sterilization time, canned quality is higher.