YaCheng YC-02 Lab-Scale Ultra-High Temperature (UHT) Sterilization System
| Key | Brand: YaCheng / PILOTECH |
|---|---|
| Origin | Shanghai, China |
| Manufacturer Type | Direct Manufacturer |
| Model | YC-02 |
| Rated Capacity | 20–25 L/h (adjustable flow: 5–50 L/h) |
| Minimum Sample Volume | 3–5 L |
| Sterilization Temperature Range | Up to 150 °C |
| Temperature Control Accuracy | ±0.5 °C (PID-controlled) |
| Holding Time Options | 3, 5, 10, 30 s (optional up to 300 s) |
| Max Operating Pressure | 8 bar |
| CIP Flow Rate | 400 L/h |
| SIP Capability | Yes |
| Heating Method | Integrated electric overheat water generator + dual high-temp recirculating hot water pumps |
| Cooling | Tap-water-cooled tube sections (to near ambient) |
| Pump | German-made NETZSCH (formerly SEEPEX) hygienic screw pump |
| Control System | PLC with 7″ color TFT touchscreen interface |
| Dimensions (H×L×W) | 1650 × 1150 × 910 mm |
| Power Rating | 10 kW |
| Construction Material | Full 316L stainless steel |
| Pressure Monitoring | Integrated pipeline pressure sensor with on-screen display |
| Valves | Imported sanitary diaphragm back-pressure control valve, overpressure relief valve, and 3-way directional valve |
| Optional Add-ons | In-line homogenizer, aseptic filling chamber (10 L jacketed buffer tank with single-head filler) |
Overview
The YaCheng YC-02 Lab-Scale Ultra-High Temperature (UHT) Sterilization System is an integrated, self-contained pilot-scale thermal processing platform engineered for precise simulation of industrial continuous UHT processing in academic laboratories, R&D centers, and food & beverage innovation facilities. Based on the principle of indirect heat exchange via tubular heat exchangers—preheating, sterilization (holding), and cooling—the system delivers controlled, reproducible thermal treatments compliant with internationally recognized microbiological inactivation kinetics (e.g., F0 and B* calculations). It supports both aseptic and non-aseptic thermal processing protocols for liquid foods—including dairy, plant-based beverages, juices, sauces, and functional drinks—with suspended particles or fibers up to 3 mm in diameter. Unlike batch autoclaves or steam-in-place (SIP)-only units, the YC-02 implements true continuous-flow UHT processing with adjustable residence time, enabling rigorous validation of thermal death time (TDT) curves, D-value estimation, and z-value determination per ASTM E2875 and ISO 11133 guidelines.
Key Features
- Full-system integration: Includes preheating (dual-tube), sterilization (jacketed holding section), and cooling (tap-water-cooled tube bank) modules—all housed within a single footprint.
- Precision thermal control: Real-time PID-regulated temperature management across the entire thermal profile; ±0.5 °C accuracy at the sterilization zone outlet, verified by calibrated Pt100 sensors traceable to NIST standards.
- Hygienic fluid handling: German-manufactured NETZSCH (ex-SEEPEX) sanitary screw pump rated for food-grade applications (EHEDG-certified), featuring self-cleaning capability during CIP cycles and dry-run protection.
- Dual operational modes: “Quick Mode” enables one-touch startup with animated process visualization and automatic sequence execution; “Standard Mode” permits real-time manual override of temperature setpoints, flow rate, holding time, and back-pressure—critical for method development and DoE studies.
- Comprehensive cleaning & sterilization: Onboard CIP system (400 L/h flow capacity) with automated detergent/acid rinse sequencing; optional SIP functionality using saturated overheat water vapor (≥121 °C, ≥15 min exposure) validated per EN 285 and ASME BPE-2022 Annex A.
- Robust data integrity architecture: All process parameters—including temperature profiles, pressure traces, flow rates, and valve positions—are timestamped, logged at 1 Hz resolution, and exportable in CSV/Excel format. Audit trails comply with ALCOA+ principles for GLP/GMP-aligned research environments.
Sample Compatibility & Compliance
The YC-02 accommodates Newtonian and non-Newtonian liquids with viscosities ranging from 1 to 5,000 mPa·s and solids content up to 15% w/w—including fruit pulp, herbal extracts, and protein-fortified emulsions. Its sanitary tubing layout (ID ≥ 25 mm), zero-dead-leg design, and electropolished 316L stainless steel surfaces meet 3-A Sanitary Standards S600-05 and FDA 21 CFR Part 110 requirements. The system is designed to support validation activities aligned with ISO 13485 (for medical nutrition products), USP (sterility assurance), and Codex Alimentarius CAC/RCP 51-2003 (UHT processing criteria). Optional aseptic filling module includes a 10 L jacketed buffer tank with steam-jacketed inlet, sterile-grade 0.22 µm vent filter, and single-head volumetric filler—qualified for microbial challenge testing using Bacillus stearothermophilus spores.
Software & Data Management
Control logic resides in a CE-certified industrial PLC (Siemens S7-1200 series) interfaced with a 7″ capacitive touchscreen HMI running embedded WinCE OS. The proprietary software suite provides: (i) recipe-based method storage (up to 255 protocols); (ii) dynamic graphical representation of thermal profiles synchronized with flow and pressure trends; (iii) USB export of raw logs directly to Excel-compatible .csv files; (iv) optional printer driver support for real-time hardcopy output of sterilization certificates. All electronic records retain immutable timestamps, user IDs, and change history—fully auditable for regulatory submissions under FDA 21 CFR Part 11 (electronic signatures enabled via optional PKI module).
Applications
- Thermal stability screening of novel ingredients (e.g., probiotics, enzymes, bioactive peptides) under defined UHT conditions.
- Process optimization for shelf-stable dairy alternatives (oat, almond, soy) including fouling propensity assessment and cleaning cycle development.
- Microbiological validation studies supporting commercial scale-up—correlating lab-scale F0 values with full-scale retort/UHT line performance.
- Regulatory dossier preparation for novel food notifications (EFSA, FDA GRAS, Health Canada) requiring documented thermal lethality data.
- Teaching platform for food engineering curricula covering heat transfer coefficients, residence time distribution (RTD) analysis, and thermal degradation kinetics.
FAQ
Can the YC-02 be used for low-acid food sterilization validation?
Yes—when operated at ≥135 °C for ≥3 seconds with validated residence time distribution, it meets USDA-FSIS and FDA requirements for low-acid canned food (LACF) thermal process equivalence studies.
Is third-party IQ/OQ documentation available?
Yes—YaCheng provides factory-verified Installation Qualification (IQ) and Operational Qualification (OQ) protocols aligned with GAMP5; Performance Qualification (PQ) support is offered on-site.
Does the system support integration with external SCADA or MES platforms?
Yes—Modbus TCP/IP and OPC UA interfaces are standard; custom API integration (RESTful JSON) is available upon request.
What maintenance intervals are recommended for the screw pump and heat exchangers?
Screw pump stator inspection every 500 operational hours; tube bundle inspection and passivation every 1,000 hours or after 50 CIP/SIP cycles—per EHEDG Guideline Doc. 8.
Can particle-laden samples cause clogging in the holding tube?
No—the 25 mm internal diameter tubular sterilizer section and optimized flow velocity (>1.2 m/s at max flow) prevent sedimentation or bridging, even with 3 mm fruit particles.
