Issues such as food safety, hygiene standards, and extending the shelf life of products are among the fundamental building blocks of today's food industry. With increased consumer awareness, stricter regulations, and intensified competition in global markets, producers are faced with the necessity to offer both quality and safe products. In this context, elements such as the hygienic design of equipment used in production processes, process control, and energy efficiency are of great importance.
At this point, pasteurizer systems play a critical role. Especially used in the processing of liquid products such as milk, fruit juice, cream, and must that require thermal processing, these systems ensure product safety and extend shelf life by inactivating pathogenic microorganisms and spoilage-causing enzymes that may be present in food. However, pasteurizers not only provide microbiological safety but also contribute to preserving the physical, chemical, and nutritional properties of the product.
Another significant advantage of modern pasteurizer systems is their high energy savings. Based on the principle of regeneration, these systems use the heat generated during the process to preheat raw products, thus reducing energy costs and contributing to environmental sustainability. In this way, production processes are optimized with both an economic and environmentally friendly approach. With all these aspects, pasteurizer systems respond to the current needs of the food industry while also laying a strong foundation for the safe and sustainable production understanding of the future.
Pasteurizers are advanced food processing systems where liquid foods are subjected to controlled and short-term thermal processing at specific temperatures, thus inactivating harmful microorganisms (such as pathogenic bacteria, mold, yeast, and spoilage enzymes) within the products. The pasteurization method, named after the French scientist Louis Pasteur who scientifically developed this method in the 19th century, is widely used today to ensure food safety, extend shelf life, and maintain product quality, especially in food products consumed in liquid form.
Pasteurizer systems are designed to reduce the microbial load of the product, ensuring consumer health while also aiming to preserve the original taste, color, aroma, and nutritional values of the product as much as possible. In these systems, the product is usually heated at temperatures ranging from 60°C to 100°C for a specific period and then rapidly cooled to maintain microbiological balance. The combination of time and temperature is specially determined according to the type and sensitivity of the processed food.
Many foods, including milk, cream, yogurt mixtures, fruit juices, wine, beer, must, ketchup, mayonnaise, egg whites, various sauces, rose water, and herbal extracts, are made safe with industrial-scale pasteurizers. The dairy products sector is one of the areas where pasteurizers are most intensively used. Since milk is a product that can spoil easily due to its natural microorganisms, it must be pasteurized under hygienic and controlled conditions.
Modern pasteurizer systems can be produced at different flow rates according to the operating capacity. These systems, which generally have a processing capacity ranging from 5 tons to 50 tons per hour, are offered in different configurations for both small-scale businesses and large industrial production facilities. Thanks to automatic control systems, precise temperature regulation, hygienic design standards (CIP – Clean In Place compliance), energy recovery features, and modular structures, pasteurizers are among the indispensable components of food processing lines.
Moreover, the use of these systems is important not only for food safety but also for regulatory compliance and meeting international trade standards. Many countries have made pasteurization a legal requirement for imported or locally produced liquid foods. Therefore, pasteurizers are not just a process equipment but also a strategic tool for quality assurance and market access for food businesses.
What is Pasteurization?
Pasteurization is a controlled thermal processing method applied to inactivate pathogenic microorganisms, harmful enzymes, and spoilage-causing bacteria that may naturally be present in foodstuffs. A fundamental step in ensuring food safety and hygiene standards, pasteurization is widely used to extend the shelf life of products, reduce microbial load, and protect consumer health. Developed by Louis Pasteur in the 19th century, this method plays a critical role in ensuring reliability and quality continuity, especially in liquid and easily perishable products.
The pasteurization process is carried out at temperatures ranging from 60°C to 100°C, depending on the type, physical properties, and intended use of the product. During the heating process, the product is held at this temperature for a specific period and then rapidly cooled to maintain microbial balance. This process helps eliminate unwanted microorganisms in the product while also allowing for the preservation of nutritional values, aroma, color, and texture to a large extent.
For example, milk is usually pasteurized at 63°C for 30 minutes (LTLT – Low Temperature Long Time method) or at 72°C for 15 seconds (HTST – High Temperature Short Time method). At these temperatures, harmful bacteria are inactivated while milk proteins and vitamins are preserved without damage. Pickles are pasteurized at 82°C, tomato juice at 94°C, and fruit juices and beverages at different temperatures ranging from 70–95°C according to the product formulation. The optimum combination of temperature and time for each product is determined based on the microbial characteristics of the product and the targeted shelf life.
Pasteurization is not limited to the heating process alone; the rapid cooling phase that follows the process is as important as the thermal processing. During this phase, products are typically cooled quickly to below 40°C and preferably to 4–6°C levels. This rapid cooling prevents the proliferation of microorganisms that may have survived the thermal process and preserves the physical-chemical balance of the product. If rapid cooling is not performed, darkening in color, deterioration in aroma, reduction in nutritional value, and significant shortening of shelf life can be observed.
Pasteurized products should be stored under refrigeration conditions (approximately 5–7°C). Maintaining the cold chain is a critical factor for the continued effectiveness of pasteurization. With proper pasteurization and appropriate storage conditions, products can maintain their freshness, nutritional value, and flavor for an extended period.
Although pasteurization cannot provide long-term protection for high-protein foods such as meat and meat products, it is highly effective for liquid and semi-liquid products such as milk, eggs, fruit juice, wine, beer, and ketchup. In cases where a longer shelf life and complete sterilization are required, sterilization processes performed at temperatures above 100°C under pressure are preferred.
In conclusion, pasteurization is one of the cornerstones of the food industry, both to ensure microbiological safety and to preserve product quality at the highest possible level. This process provides legal compliance and market confidence to the producer and ensures that consumers are offered healthy, reliable, and extended-shelf-life products.
Working Principle of Pasteurizer: Step-by-Step Process Operation
Pasteurizer systems are designed based on an integrated heat exchange principle to ensure food safety and maximize energy efficiency. Especially for the safe and hygienic processing of sensitive liquid products like milk, these systems consist of a series of processes that follow each other step by step and work in a regenerative manner. This process is based on an advanced engineering arrangement that guarantees both product quality and economic operational efficiency:
1. Start with Balance Tank
The first step of the pasteurization process is the transfer of raw milk to the balance (equilibrium) tank. The most important function of this tank is to ensure that the flow in the production line occurs continuously and at a constant rate. If milk is fed directly and with variable flow rates to the production line, the system pressure and temperature balance may be disrupted. Therefore, the balance tank helps keep the process stable by ensuring that milk is fed into the system in a controlled manner via a pump. Additionally, the balance tank allows for the temporary storage of milk fed into the system, preventing momentary interruptions.
2. 1st Regeneration Zone
The raw milk pumped from the balance tank is first directed to the 1st regeneration zone. At this stage, the raw milk is indirectly compared with previously pasteurized and high-temperature milk. Through heat transfer plates, these two liquids exchange heat without coming into contact with each other. As a result, the temperature of the raw milk is raised to an average of 55°C. This preheating stage is critically important for both increasing the effectiveness of pasteurization and reducing energy consumption. Using preheated milk greatly reduces the need for additional external energy.
3. Separator (Fat Separation Stage)
At this point, the milk, which has reached approximately 55°C, is directed to the separator unit for fat separation, as it has reached the ideal viscosity for fat separation. This unit works on the principle of centrifugal force and physically separates the fat phase in the milk. Here, the milk is standardized by separating the cream according to the desired fat ratio and, if necessary, can be homogenized again. This process is an important step, especially for marketing dairy products with different fat ratios.
4. 2nd Regeneration Zone
The standardized milk passes to the second regeneration unit of the system. At this stage, the milk gains heat by coming into indirect contact with the milk coming out of the holding tube and at a high temperature. As a result of this heat exchange, the temperature of the product reaches approximately 60–70°C. Thus, the preparation before pasteurization is completed. Additionally, this stage increases the overall energy efficiency of the system by reducing the subsequent heating load.
5. Heating Unit
After regeneration, the milk is taken to the heating unit to reach the pasteurization temperature. In this section, the milk is indirectly heated through heat exchangers operating with hot water or steam. Thanks to this controlled heating process, the temperature of the milk reaches the target level—for example, the high-temperature short time method (HTST) is generally in the range of 72–90°C. This temperature value is a critical threshold for inactivating pathogenic microorganisms present in the product.
6. Holding Tube (Time-Controlled Thermal Processing)
After the milk reaches the pasteurization temperature, it is held at this temperature for a specific period in a special section called the holding tube. This structure, usually consisting of steel pipes arranged in a zigzag form, ensures that the milk stays in the system for about 15 seconds. This duration is considered sufficient for the elimination of pathogens and ensuring food safety. The automatic temperature sensor and control valve located at the end of the holding tube automatically redirect the product to the beginning of the system if it detects that the milk has not reached the desired temperature. Thanks to this mechanism, unpasteurized milk never reaches the filling stage under any circumstances.
7. Back Regeneration and Energy Recovery
The milk that successfully completes the pasteurization process is redirected to the 1st and 2nd regeneration zones. At this stage, the milk indirectly transfers its heat to the new raw milk, which is still raw. Thus, while the pasteurized milk cools in a controlled manner, the raw milk undergoes preheating. This bidirectional heat exchange enables energy recovery. In modern systems, this energy savings can reach up to 85%. This feature reduces operating costs in the long term and makes a significant contribution to environmentally friendly production goals.
8. Cooling Unit
As the final step after pasteurization, the milk is sent to the cooling unit. Here, the product is usually cooled to the ideal filling temperature of 4–6°C with the help of ice water or chilled water circulation. This rapid cooling process extends the shelf life of the product by preventing microorganism growth and makes it suitable for the cold chain. The cooled milk is now a hygienic, safe, and ready-to-fill product.
The Importance of Energy Recovery
One of the most important advantages offered by modern pasteurizer systems is their high level of energy efficiency. At the core of this efficiency are the regeneration units within the system. Thanks to these sections operating on the principle of regenerative heat exchange, the milk that has completed the pasteurization process and reached an average temperature of 85–90°C is reused before leaving the system to preheat the raw milk. During this indirect contact, the temperature of the raw milk is raised to approximately 60–65°C. Thus, the raw milk gains significant heat before being raised to the pasteurization temperature.
Thanks to this preheating process, the amount of additional energy to be supplied externally is significantly reduced. For example, when raw milk initially at 10°C is heated to 65°C during regeneration, there is no need for an external heater for only a 25–30°C temperature increase. This means that a large portion of the total heating requirement is met with energy recovered within the system. This heat, which was completely supplied by external sources in traditional systems, is greatly minimized thanks to the regenerative system.
Energy recovery not only provides a cost advantage but also carries great importance in terms of environmental sustainability, reducing carbon footprint, and green production goals. Less energy consumption means less fuel use and consequently lower greenhouse gas emissions. In this way, pasteurizer systems become more compliant with global environmental standards (such as ISO 14001) in terms of energy management and environmental responsibility.
Additionally, since both cooling and heating requirements are reduced thanks to regeneration, maintaining the thermal balance of the system becomes easier. The load on the heater and cooler units decreases, which extends the equipment's lifespan and reduces maintenance requirements. Since thermal stress that may occur in heat exchangers is also minimized, the long-term durability and performance of the system increase.
In large-capacity production facilities, such energy savings mean a significant amount of energy and cost advantage on an annual basis. For example, in a system processing 10 tons of milk per hour, energy recovery of 60–70% can be achieved just through regeneration. This offers a performance level that makes a difference both economically and environmentally.
In conclusion, thanks to regenerative energy recovery, pasteurizer systems offer the most suitable solution for the modern food industry's expectations not only in terms of hygiene and product safety but also in terms of energy efficiency and environmental responsibility. This feature is also a concrete application of the increasingly important green production concept today.
Types of Pasteurizers
The need for pasteurization can vary depending on the physical properties, viscosity, content, packaging type, production volume, and process goals of the product to be processed. Therefore, different types of pasteurizer systems have been developed for industrial applications. Each is designed to provide the most efficient results in specific product groups. Below are the most commonly used types of pasteurizers and their areas of use:
Plate Pasteurizers
Plate pasteurizers are compact and highly efficient systems that operate with indirect heat transfer occurring between thin metal plates. Each plate, made of stainless steel and separated by a leak-proof gasket, has high thermal conductivity and performs both heating and cooling functions. In these systems, regeneration, heating, and cooling sections are usually present together.
Areas of Use:
• Milk (Drinking Milk and Milk-Based Beverages):
Used to ensure microbiological safety and extend shelf life in all types of milk such as drinking milk, cocoa milk, lactose-free milk, and flavored milk.
• Fruit Juices (Clear and Cloudy):
Ideal for preventing fermentation and ensuring shelf stability in freshly squeezed or concentrate-derived fruit juices such as orange, apple, grape, pomegranate, and cherry.
• Ayran and Kefir:
Fermented dairy products such as ayran and kefir are pasteurized before production or before filling to ensure yeast control and guarantee that the product stays fresh for a longer time.
• Whey:
This by-product, high in lactic acid and protein content, is pasteurized for use in the beverage industry.
• Liquid Egg Products (White, Yolk, or Mixture):
Liquid egg products used in industrial kitchens, bakery products, and the ready food sector are processed with plate pasteurizers to eliminate pathogens such as Salmonella.
• Rose Water, Lavender Water, and Herbal Extracts:
Aromatic liquids used in the cosmetics, food, and beverage industries are pasteurized to remove microorganisms without altering their natural structure.
• Herbal Teas and Functional Beverages:
In beverages prepared with herbal extracts such as black tea, green tea, hibiscus, and ginger, the preservation of color, aroma, and functional components without deterioration is ensured.
• Non-Carbonated Soft Drinks and Aroma-Based Waters:
Plate systems are suitable for both microbiological control and product balance in products such as lemonade, turnip juice, sherbet, and flavored drinks.
• Vinegar and Lightly Acidic Sauces:
Used to prevent unwanted fermentation and color changes in these low-density and acidic products.
Advantages:
• High energy efficiency (up to 90% regeneration possibility).
• Saves space with its compact design.
• Easy cleaning and maintenance (compatible with CIP systems).
• Quick start-up and process control.
Limitations:
Not suitable for products containing particles, high viscosity, or fibrous products. There is a risk of plate clogging.
Tube Pasteurizers
In these systems, heat transfer is carried out through tubes instead of plates. The heating and cooling medium (hot water or ice water) and the product progress through double-walled or nested tubes based on the counterflow principle. The diameter of the tubes can be adjusted according to the characteristics of the product.
Areas of Use:
• Tomato Derivatives (Paste, Puree, Tomato Sauce):
With its fibrous and thick consistency, tomato products can be processed without clogging thanks to tube systems, and the balance of color, consistency, and flavor is preserved during thermal processing.
• Fruit Purees and Fruit Concentrates:
Intense fruit purees such as apricot, peach, apple, and mango; due to their natural particle content and high viscosity, they are safely processed in tube systems. Similarly, high Brix value fruit concentrates are also suitable for these systems.
• Ketchup and Mayonnaise Derivatives:
These sauces with high oil and spice content and emulsified structure are pasteurized with sensitive control tube systems as they are prone to deterioration during temperature changes.
• Sauces (Barbecue, Hot Sauce, Mustard, etc.):
In products containing different particle sizes and densities, the tube system is an ideal solution for homogeneous pasteurization and product safety.
• Tahini and Peanut Butter Like Oily Products:
Due to high oil content, low fluidity, and particle content, these products cannot be processed in plate systems. A slow but effective thermal process is carried out in tube systems.
• Molasses, Grape Must, and Concentrated Sugary Products:
In products with high natural sugar content, controlled tube pasteurizers are preferred to prevent caramelization risk and to perform heating without causing adhesion.
• Vegetable Paste and Purees (Hummus, Eggplant Paste, Lentil Puree, etc.):
These types of products with a thick and particulate structure are pasteurized at a controlled temperature with tube systems to extend shelf life.
• Ready Soup Bases and Dense Food Gels:
These starch-based or protein-based products undergo thermal processing more safely in tube systems due to their high consistency.
• Herbal Smoothies and Protein Mixtures:
Products containing fibrous fruit-vegetable mixtures are pasteurized with tube systems to ensure homogeneous distribution and prevent spoilage.
Advantages:
• Suitable for particulate products due to low clogging risk.
• Resistant to high temperatures.
• The hygienic design allows easy cleaning of surfaces in contact with the product.
Limitations:
Occupies more space compared to plate systems and has a relatively lower regeneration rate. Cleaning time is longer.
Autoclave Type Pasteurizers
Autoclave systems are systems where the product is pasteurized in its packaged form (glass jar, tin can, PET bottle, etc.), usually operating under pressure. Products are brought to the desired temperature with steam, hot water, or dry heat and held there for a specific period. The pasteurized product is then taken to the cooling stage.
Areas of Use:
• Canned Foods:
Vegetables such as peas, beans, corn, chickpeas, kidney beans, mushrooms, potatoes, and dishes with meat or olive oil (e.g., baked beans, pilaki, stew) are pasteurized in autoclaves in glass jars, tin cans, or glass bottles to achieve a long shelf life.
• Ready Meals and Single Portion Menu Products:
Ready meals (pasta sauces, meatball menus, stews, etc.) filled in vacuum packaging or canned containers used in industrial food production provide both high safety and a long shelf life of 6 months to 1 year with autoclave systems.
• Vegetable and Fruit Jar Products:
Products such as jams, marmalades, compotes, boiled vegetables, roasted peppers/eggplants, olives, and cucumber pickles are pasteurized after filling with autoclave pasteurization to increase shelf life and prevent color and flavor deterioration.
• Meat and Meat Derivative Products:
Protein-dense and high-risk foods such as sausage, salami, roast, meat sauces, and jellied meat products are processed at high temperatures in an autoclave to ensure food safety. Since meat products are usually pasteurized under pressure, it is guaranteed that the heat reaches every region equally.
• Fish and Seafood Canned Products:
In seafood products canned such as tuna, sardines, salmon, anchovies, and squid, autoclave pasteurization is one of the basic methods due to the critical importance of microbiological safety.
• Sauce and Paste Types (Tulum Cheese Paste, Acuka, Pepper Paste, Olive Sauce, etc.):
These products, marketed in glass jars or vacuum packaging, are stabilized with autoclave pasteurization due to their acidic and oily content.
• Desserts and Dairy Food Products:
Packaged kazandibi, rice pudding, and custard can be subjected to short-term high temperatures in an autoclave after filling in special containers. This process can extend the shelf life from a few weeks to a few months.
• Baby Foods and Special Medical Foods:
Sensitive content foods such as baby foods filled in heat-resistant plastic packaging or glass jars and special enteral nutrition products are pasteurized in an autoclave under controlled conditions and stored in a sterile environment.
• Confectionery, Pudding, and Gel-Based Products:
Jellified desserts, puddings, or filling products in packaging can be processed in an autoclave to maintain both microbiological safety and consistency balance.
Advantages:
• Since pasteurization is done with the packaged product, the risk of contamination afterward is eliminated.
• Provides a long shelf life.
• Offers flexible use according to different packaging sizes.
Limitations:
The thermal processing time is longer, which can increase energy consumption. Additionally, sensory losses (color, aroma, nutritional value) may occur in the product content.
Tunnel Type Pasteurizers
Tunnel pasteurizers are systems where bottled or canned products are pasteurized by progressing on a conveyor belt and being sprayed with hot water or steam. The process is usually multi-stage, consisting of heating, holding, and cooling sections. Water is poured over the product through spray nozzles, ensuring homogeneous pasteurization.
Areas of Use:
• Non-Carbonated Beverages (Lemonade, Iced Teas, Functional Beverages):
Lemonade, flavored diluted drinks, and green tea/hibiscus-based beverages filled in PET or glass bottles are made safe with tunnel type pasteurizers.
• Fruit Juices and Nectars:
Products such as fruit juices in clear or cloudy form (orange, cherry, apple, pomegranate, apricot) are usually processed in a tunnel pasteurizer after filling in glass or PET bottles to extend shelf life.
• Energy Drinks and Vitamin-Enriched Products:
Functional drinks offered in aluminum cans or tin cans, multivitamin liquids, or beverages containing herbal supplements are processed in a tunnel system for homogeneous pasteurization.
• Beer and Alcoholic Beverages (Wine, Cider):
In beer production, especially in low-alcohol types and some craft beers, tunnel pasteurization is applied. This process stops fermentation and increases shelf life. It is also preferred in sensitive alcoholic beverages such as wine and cider.
• Dairy Beverages (Flavored Milks, Milk Coffees, Protein Drinks):
Bottled chocolate milk, vanilla milk, UHT milk-based latte/coffee drinks, sports drinks, and similar products are processed with tunnel type pasteurizers to increase content stability and shelf life.
• Pre-Label Pasteurization in Carbonated Drinks (Limited Cases):
In some cases, light pasteurization may be required for low-acid, carbonated products (e.g., kombucha). The tunnel system can be adapted to these applications.
• Vinegars and Pickle Juices:
Especially apple cider vinegar with added aroma, honey vinegar, and probiotic pickle juices, special formulation products are processed in glass bottles with the tunnel system.
• Bottled Natural Flavored Waters and Herbal Extract Drinks:
Used to extend the shelf life of flavored waters containing natural ingredients such as ginger, lemon, mint, and basil in glass or PET packaging.
• Hybrid Products Between Cosmetics and Beverages:
Preferred for pasteurization in packaged form for products marketed as both beverages and cosmetics, such as rose water and lavender water.
• Pre-Stabilization for Cold Chain Products:
In some special products, tunnel type light pasteurization can be applied to maintain stability throughout logistics (e.g., products containing probiotics).
Advantages:
• Suitable for mass production; can operate at high capacity.
• Since the process is done with the packaged product, the risk of contamination afterward is eliminated.
• Provides water and energy savings with an automatic water circulation system.
Limitations:
High installation cost. Requires a large area. Special carrier systems are needed to minimize the risk of breakage, especially in glass bottles.
Conclusion: The Center of Safe Food Production and Energy Efficiency – Pasteurizer Systems
Today, the food industry is shaped not only by product quality and hygiene standards but also by multi-dimensional criteria such as energy efficiency, environmental sustainability, legal compliance, and competitive advantage. In this context, pasteurizer systems are now considered not just a technical equipment but a strategic investment at the heart of the production process. The role they play in the processing of liquid products is of vital importance both in ensuring the safety of the final product and in making the production process more efficient, economical, and environmentally friendly.
Pasteurizers significantly reduce energy costs in production processes thanks to advanced heat recovery technologies, while their safety-focused equipment, such as holding tubes, guarantees the microbiological safety of each product batch. These systems provide operational sustainability with elements such as automation systems that manage the temperature-time balance with high precision, CIP (clean-in-place) compatibility, surface designs shaped according to hygienic design principles, and return valves that enhance process safety.
Moreover, thanks to modern pasteurizer systems, producers not only meet legal requirements but also enhance product quality, strengthen brand trust, gain advantages in export markets, and comply with global quality standards (HACCP, ISO 22000, FDA, etc.). Considering the increasing competitive conditions in the food sector, investments in such equipment increase short-term operational performance and contribute to brand value and customer loyalty in the long term.
As Ekin Industrial, our MIT brand pasteurizer solutions, developed to meet the multi-faceted needs of food businesses, combine experience in process engineering and high technology to bring both quality and safety to your production line. Our systems, designed in different capacities and configurations, such as plate or tube, for products such as milk, fruit juice, must, cream, beverages, herbal extracts, and similar products, offer high performance even in the most challenging production conditions with their energy-saving regenerative structures, fully automated temperature control modules, and hygienic stainless steel bodies.
If you want to increase food safety in your business, reduce your production costs, and build an environmentally friendly production process, meet MIT pasteurizer systems. We are here to offer you the most accurate solution tailored to you by combining our expertise in food technologies with our engineering quality.