UHT Pilot Plant for Beverage R&D and Dairy Pilot Lines
EasyReal engineers the UHT Pilot Plant as a scalable bridge between laboratory formulation and commercial production. Each module follows industrial thermal logic — pre-heating, sterilization, holding, cooling, and aseptic filling. Configurable as tubular, plate, or direct-steam-injection type, it covers up to 152 °C and viscosities to 6 000 cP.
Flowmeters, temperature/pressure transmitters, and automatic valve manifolds maintain process precision. Siemens PLC recipes let operators set heating ΔT, holding time, and flow rate. Batch data logging enables detailed pilot plant testing comparison. Skid-mounted stainless frames save floor space yet preserve full-scale logic — ideal for food processing pilot plants, universities, and beverage laboratories optimizing processes.
Automation extends beyond heating: optional inline homogenizer（Including Upstream inline homogenization and Aseptic Downstream inline homogenization), vacuum deaerator, and aseptic filling cabinet synchronize through the same control system. It is widely used for research on plant-based milk, juice blends, coffee drinks, sauces, or yogurt bases. This flexibility makes EasyReal’s Beverage Pilot Plant a universal R&D asset for academic and industrial innovators alike.
The EasyReal UHT Pilot Plant supports a wide range of beverage R&D and dairy pilot plant uses:
• Juice and Nectar Formulation – test different Brix, acidity, and flavor retention profiles.
• Milk and Plant-Based Drinks – compare UHT and HTST effects on texture and stability.
• Yogurt and Fermented Products – evaluate thermal profiles to optimize starter activity.
• Coffee, Tea, and Functional Drinks – develop ready-to-drink formulas requiring aroma protection.
• Sauce and Puree Development – handle viscous or particulate systems without scorching.
For universities and pilot laboratories, the line demonstrates industrial sterilization principles. For manufacturers, it acts as a pilot production line to validate formulations before scale-up. Using the same hygienic fittings and CIP logic as full-scale systems, results transfer directly — ensuring smooth technology transition and lower launch risk.
Thermal treatment is sensitive to viscosity, solids, and pH. When designing a food processing pilot plant, EasyReal tailors flow paths and heat exchangers for each product. Fruit juice requires short residence time for color retention, while dairy and protein beverages need uniform heating to prevent fouling. Selecting the correct tubular module is crucial for consistent results.
Safety and hygiene are equally critical. Sanitary piping, food-grade gaskets, and pressure-rated components meet international standards. Automated CIP routines prevent microbial growth and cross-contamination during multiple daily tests. Visual inspection windows and interlock alarms protect operators under pressure. These features make the EasyReal UHT Pilot Plant efficient, safe, and ideal for continuous R&D and pilot plant manufacturing.
Selecting the right configuration depends on formulation goals and throughput. EasyReal offers 2 standard models for your choice. The first model is 5–40 L/h or and the second one is 60–120 L/h continuous flow.
Key selection factors:
• Product Viscosity & Solids – tubular systems for thick sauces and low-viscosity liquids.
• Thermal Profile & Aroma Retention – choose direct steam injection for aroma-sensitive drinks or product has high content of fat or protein.
• Control Integration – Siemens PLC with data logging and recipe management.
• Filling Needs – pair with EasyReal Aseptic Filling Cabinet.
• Future Scale-Up – same logic as EasyReal industrial lines for 1:1 parameter transfer.
This structured approach helps both engineers and non-engineers balance precision, budget, and process similarity, turning every R&D pilot plant investment into real production insight.
1. Raw Material Preparation – blending, filtration, pre-heating.
2. Pre-Heating Stage – raise inlet temperature to 60–80 °C.
3. Inline Vacuum Deaeration (optional).
4. Upstream Inline Homogenization (optional).
5. Sterilization Section – UHT (135–152 °C) via tubular, or DSI module.
6. Holding Tube – maintain target temperature for microbial inactivation.
7. Cooling Stage – regenerative heat exchange for energy saving.
8. Aseptic Downstream Inline Homogenization (optional).
9. Aseptic Filling and Packaging.
10. Automated CIP cycle for next trial.
Depending on product type (dairy, plant-based, juice), the sequence can bypass or add steps such as fermentation or homogenization. The flow ensures uniform heat load and safe, energy-efficient processing.
The EasyReal UHT Pilot Plant integrates modular laboratory-scale components that mirror industrial performance with precise control and hygiene.
1. Chiller (Optional)
Provides chilled water for cooling sections and outlets. Closed-loop operation at 4–10 °C supports product cooling and storage.
Benefit: Shorter turnaround and better product preservation.
2. Lab Pilot Scale Homogenizer
High-pressure inline unit (up to 60 MPa) reduces particle size and stabilizes emulsions for dairy and plant-based drinks. We supply Upstream Homogenization and Downstream Homogenization for customers’ Choice.
Benefit: Improved texture, color uniformity, and stability.
3. Lab Pilot Scale Vacuum Deaerator (Optional)
Removes dissolved oxygen before UHT to prevent oxidation and color loss. Vacuum chamber and spray nozzles ensure efficient gas removal even for viscous liquids.
Benefit: Extended shelf life and flavor protection.
4. Lab Pilot Scale UHT Sterilizer
Core module performing precise heating (up to 152 °C) and holding for microbial inactivation involved Siemens PLC recipes and PID control.
Benefit: Industrial-grade sterilization in compact form.
5. Direct Steam Injection (DSI) Sterilizer (Optional)
Injects culinary steam directly into the product for instant heating and vacuum flash cooling.
Benefit: Maximum aroma retention and color stability.
6. Aseptic Filling Cabinet
Class-100 HEPA-filtered clean-air enclosure for sterile bottle or bag filling, with temperature and pressure interlocks.
Benefit: Reliable aseptic validation for pilot-scale packaging.
The EasyReal UHT Pilot Plant accommodates diverse materials:
• Dairy & Plant-Based Milks – cow, soy, oat, almond, coconut blends.
• Juices & Nectars – clear or pulp types like mango, apple, orange, carrot.
• Fermented Products – yogurt bases and probiotic drinks.
• Sauces & Condiments – tomato puree, chili sauce, cream soups.
• Specialty Drinks – coffee, tea, nutraceutical formulas.
Modules handle fresh, frozen, concentrated, or aseptic inputs. Quick-release clamps allow rapid recipe changeovers, and output options include hot-fill, cold-fill, or aseptic packing. This adaptability makes the Beverage Pilot Plant a universal innovation platform.
Automation drives repeatability. A Siemens PLC links all modules through a touchscreen HMI. Operators can select recipes, adjust parameters, and track real-time temperature, flow, and pressure trends.
Core functions: recipe management, alarm system, data logging, remote diagnostics (optional), and user access levels. Data exports in CSV/PDF formats for QA or HACCP records. This digital framework ensures each pilot plant test is consistent and ready for industrial replication.
Beyond manufacturing equipment, Shanghai EasyReal Machinery Co., Ltd. operates a fully functional Beverage R&D and Pilot Testing Center that welcomes both domestic and international clients.
This center allows product developers, startups, and universities to perform real trials using EasyReal’s UHT Pilot Plant, Lab HTST system, and other beverage lab equipment before investing in full production.
Clients can:
• Book on-site pilot trials at EasyReal’s facility in Shanghai.
• Ship raw materials or premixes to conduct remote testing under NDA protection.
• Join real-time online sessions via live video to observe process parameters and sample collection.
• Evaluate finished samples for texture, color, flavor, and shelf stability before scale-up.
The center supports projects such as plant-based milk, dairy alternatives, fruit juices, sauces, teas, coffees, and probiotic beverages. Each trial generates a technical report detailing temperature curves, flow rates, pressure profiles, and product outcomes — helping clients validate formulations efficiently.
This open-lab policy demonstrates EasyReal’s commitment to being more than a machinery manufacturer. We act as a true partner in beverage innovation, offering the tools, expertise, and environment for R&D teams to bring new formulations to life.
Clients can schedule a visit, discuss project scope, or request a virtual demo anytime through our official contact page.
Book a trial or consultation: sales@easyreal.cn
Visit our R&D Center: https://www.easireal.com/contact-us/
Whether you’re setting up a beverage R&D lab, expanding a dairy pilot plant, or building a food pilot facility, EasyReal delivers end-to-end solutions:
1. Scope definition → product range & capacity.
2. Layout & P&ID design.
3. Manufacturing & FAT in Shanghai.
4. Installation & operator training.
5. First season support for trials and tuning.
6. Long-term spares & technical service.
With 25 years of experience and clients in 30 countries, Shanghai EasyReal Machinery Co., Ltd. is trusted by global brands and universities. Each UHT Pilot Plant bridges idea and production — a reliable platform for innovation and scale-up.
Contact: sales@easyreal.cn
Website: https://www.easireal.com/contact-us/
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1 |
Name |
Modular Lab UHT HTST Pasteurizer Plant |
|
2 |
Model |
ER-S20, ER-S100 |
|
3 |
Type |
Lab UHT HTST & Pasteurizer Plant for R&D Center and Laboratory |
|
4 |
Rated Flow Rate |
20 l/h & 100l/h |
|
5 |
Variable Flow Rate |
3~40 l/h & 60~120 l/h |
|
6 |
Max. pressure |
10 bar |
|
7 |
Minimum batch feed |
3~5 liters & 5~8 liters |
|
8 |
SIP function |
Inbuilt |
|
9 |
CIP function |
Inbuilt |
|
10 |
Inline Upstream Homogenization |
Optional |
|
11 |
Inline Downstream Aseptic Homogenization |
Optional |
|
12 |
DSI Module |
Optional |
|
13 |
Inline Aseptic filling |
Available |
|
14 |
Sterilization Temperature |
85~150 ℃ |
|
15 |
Outlet Temperature |
Adjustable. the lowest could reach ≤10℃ by adopting water chiller |
|
16 |
Holding time |
5 & 15 & 30 Seconds |
|
17 |
300S Holding tube |
Optional |
|
18 |
60S Holding tube |
Optional |
|
19 |
Steam generator |
Inbuilt |
EasyReal Tech. is the State-certified High-tech Enterprise located in Shanghai City, China which has obtained ISO9001 Quality Certification, CE Certification, SGS Certification, etc. We provide the European-level solutions in the fruit &beverage industry and have received widespread praise from customers from both domestically and overseas. Our machines have already been exported all over the world including Asian countries, African countries American countries, and even European countries. Till now, more than 40+ independent intellectual property rights have been occupied.
The Department of Lab&Pilot Equipment and the Department of Industrial Equipment were operated independently, and the Taizhou Factory is also under construction. All these lay a solid foundation for providing better services to customers in the future.
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