Product Application Guide Retort Control in the Food Industry

AG/RCP–006_2
using the C1960

C1960 C1960
Controller/Recorder Controller/Recorder

C360
11.35 Multi-Recipe
Current to Profile Controller
Pressure
Converter
Gauge Current to
Pressure Pressure
Transmitter Converter

Pressure
Control
Valve
Pressure
Control
Valve
Steam

Current to
Pressure
Converter

Steam
Control Current to
Valve Pressure
Converter

Steam
Steam Control
Valve

Fig. 1 Horizontal and Vertical Retorts

Retort Control in the Food Industry using the C1960
AG/RCP–006_2

Why Use a C1960? The C1960 ensures high quality retorting and productivity. Features making it ideal for
retorts include:

▲ ▲
Automatic temperature control for increased production and operational efficiency.
Up to ten set point profiles, including guaranteed ramp and soak with individual
hysteresis for precise temperature profiles and improved product quality.

▲ ▲
Dedicated front panel for Ramp/Soak profile applications.
Three displays showing target set point, time remaining in segment and current
segment running.

▲ ▲ ▲
Fast startup with self-seeking set point.
Direct-connected RTD and/or thermocouple inputs reduce installation costs.
Easy-clean NEMA4X/IP66 front face.

Features and Benefits Precise Set-Point Profiles Improve Quality, Consistency and Yield
▲

The C1960 features a Ramp/Soak set point profile generator with configurable
hysteresis. It can be programmed with up to 10 temperature profiles and has a
maximum of 99 segments that can be distributed throughout the programs.
▲

Configurable hysteresis provides the flexibility to set the upper and lower limits of
both ramp and soak segments to achieve a particular process requirement.
▲

A guaranteed process ramp is provided as part of the C1960 profile. This feature
is useful in situations where steam fluctuations may occur. For example, when
ramping the process to the desired temperature set point, the guaranteed process
ramp tries to ensure that the process keeps pace with the rising set point. If it
cannot, the set point ramp is delayed until the process is within the specified
hysteresis band.
▲

The guaranteed soak ensures that the temperature and duration of the soak are
held to the configured set points.

Comprehensive Displays for Improved Operation

▲

The large, dedicated ramp/soak front panel display of the C1960 allows the
operator to see displayed information from a distance. This information includes
the target set point, time remaining in main soak segment and the segment running.
▲

The controller also includes status indicators to show if the profile is in a ramp or
soak segment. Dedicated keys allow simple control of the profile. The keys are:
• Run
• Hold
• Stop
• Increase Time/Temperature
• Decrease Time/Temperature

Direct Connecting I/O Reduces Installation Costs

▲

With the C1960, RTD or thermocouple inputs are connected directly to the
instrument. Linearization and ranging are automatic. This not only simplifies
installation but also reduces installation costs by eliminating the need for special
termination panels or conversion equipment.

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Retort Control in the Food Industry using the C1960
AG/RCP–006_2

The Application Much of the food consumed each year is preserved by packaging it in hermetically-
sealed containers in a process known as canning.

One of the most important steps in the canning of foods is 'thermal processing', more
commonly referred to as the retorting operation. In this operation, strict specifications
concerning both time and temperature must be adhered to and repeated batch after
batch to obtain sterile product and uniform quality.

Processing is done in batches using a cylindrical, pressurized vessel called a retort.

Retorts are classified as either vertical or horizontal, depending on the position of its
long axis. A vertical retort is loaded from the top whereas a horizontal retort is loaded
from one end.

In either retort type, the canned product is cooked by one of two processes:
▲ ▲
Steam cooking for product stored in metal containers
Water cooking for product stored in glass jars

Steam cooking is done in a steam atmosphere devoid of air, and water cooking is done
in steam heated water.

C1960
Multi-Recipe
Profile Controller

Current to
Pressure
Converter

Pressure
Control
Valve

Fig. 2 Loading a Vertical Retort

3
Retort Control in the Food Industry using the C1960
AG/RCP–006_2

The Retorting The cooking sequence is similar in both vertical and horizontal retorts:
• Load retort with canned product
Process – • Lock cover or door
Steam Cooking • Vent the retort
• Raise to cooking temperature
• Cook product for a predetermined period of time
• Either cool with water under pressure. (normally used for large cans)
or pressure relieve (Normally used for small cans)
• Water cool at atmospheric pressure
• Unload retort
Loading, locking the cover or door and unloading are strictly manual functions.

▲ Venting Period
Venting the retort is the first step in the cooking cycle and takes place after the door,
or cover, is screwed down tightly on the loaded retort. Its purpose is to eliminate the
air in the retort. Steam is used to purge the air from the retort in order to obtain a
steam-only atmosphere. It is important to get the air out of the retort before the
cooking period starts because air, due to poor heat conductivity, acts as an insulator
preventing the canned product from being adequately cooked. Proper venting is
achieved by purging for a preset time period and to a desired temperature - there
are no shortcuts.
▲

Raise-to-Cook Temperature Period

This period occurs after the completed vent period and is the interim period from
the vent temperature to cook temperature.

Current to
Pressure
Converter C1960
Multi-Recipe
Profile Controller
Pressure
C100 Control
Pressure Controller Valve

Gauge
Pressure
Transmitter

Current to
Pressure
Converter

Steam

Steam
Control
Valve

Fig. 3 Loading a Horizontal Retort

4
Retort Control in the Food Industry using the C1960
AG/RCP–006_2

▲
The Cook Period
This period is essential in order to properly cook the product, thereby destroying
any organisms that could later spoil it. These organisms, called spores, are able to
withstand several hours of atmospheric boiling water temperature, but are destroyed
in a short time at a temperature of 116 to 121°C (240 to 250°F).

The correct temperature and the duration of the cook period are equally important in
achieving the desired objectives. Overcooking not only increases costs, it also causes
loss of taste or appearance of the finished product.

Fig. 4 Sparge Tubes

▲

Pressure Relief Period

The retort pressure, attained as a result of cooking at high temperature in a closed
vessel, must be relieved before the product can be safely removed. If the retort has
been filled with small cans, the pressure can be reduced to atmospheric immediately
in a process known as blowdown.

However, if the retort contains large cans, it is necessary to lower their internal
pressure before blowdown takes place to prevent them from exploding or distorting.
The reduction of internal can pressure is obtained by circulating cooling water through
the retort whilst maintaining retort pressure at the value attained during cooking by
introducing pressurizing air. When can internal pressure has dropped to a safe
value, indicated by the temperature of the cooling water leaving the retort dropping
to a desired value, blowdown can take place without the threat of can damage.
▲

Water Cooling Period

In order to increase retort production, small cans are removed from the retort
immediately after blowdown and immersed in a cooling canal prior to labeling. Larger
cans, after cooling in the retort, may require further cooling in the same manner. The
determining factor is the temperature of the product at the time it is packed in cases.
This temperature is critical because cans that are too cool may rust externally, while
those that are too warm prior to being cased and closely stacked in storage will
cool too slowly and will be damaged by “stack burn”, or spoiled by creating
conditions that encourage the growth of thermophile bacteria.

The cooling canal is a rectangular-shaped, cold-water filled channel near the retort
through which the can-filled baskets are pulled after they are unloaded from the
retort. The length of the canal, the temperature of the water, and the speed of the
conveyor determines the final can temperature. When a cooling canal is used instead
of the retort for final cooling, the reduced retort-time cycle increases production.

5
Retort Control in the Food Industry using the C1960
AG/RCP–006_2

The Retort Process – Product in glass jars is processed in a water-filled retort that is heated with steam. The
topmost jars must be covered by 4 to 6 inches of water throughout the cycle and the
Water Cooking water must be agitated to provide uniform cooking. Good agitation of the heated water
is attained by introducing air into the steam supply line to create a bubbling action.

To ensure that the jar lids remain tightly sealed, the retort pressure is maintained slightly
higher than internal jar pressure. Pressurizing the retort also means that cooking
temperatures in excess of 100°C (212°F) can be achieved.

C1960
Controller

Manual By-pass
Hand Valve

Cooling Water
Fig. 5 Ancilliary Control Capabilities

6
Retort Control in the Food Industry using the C1960
AG/RCP–006_2

▲
Preheat Period
During the first stage, the vertical retort is filled with water prior to loading the jars. On
subsequent stages, the water used to cool down the last batch remains in the retort.

The temperature of this water is too low for the next batch of hot-product filled jars
(glass cannot withstand a thermal shock of more than 50°F) and must therefore be
heated with steam to a predetermined temperature before the jars are immersed.
This operation is called preheat. The preheat water temperature must not be more
than 15°F above product temperature to avoid raising the internal jar pressure which
would cause the jar lids to open and to prevent premature cooking of the product.

Preheating in a horizontal retort is not possible because the jars must be loaded and
the door closed before water can be added. The water used to fill the retort must be
preheated externally.
▲

Raise to Cook Temperature Period

The period in which the water is heated from initial temperature to cook temperature is
referred to as the “raise to cook” period and should be kept to a minimum to prevent
overcooking.
▲

The Cook Period

Both temperature and time are critical for the same reasons as outlined in steam cook.
▲

The Pressure Cool Period

The internal jar pressure must be lowered sufficiently to prevent it from forcing the jar
lids open after cooking. To do this, retort pressure is maintained above jar internal
pressure as cooling water is circulated through the retort to cool the product and
reduce the pressure in the jar. Temperature reduction is done quickly to stop the
cooking of the product.
▲

Pressure Relief Period

After the jars have been cooled sufficiently, the retort pressure may be reduced to
atmospheric (blown down) without danger to the containers.
▲

Atmospheric Cooling Period

After blowdown, and with the retort cover or door open, cooling water can be circulated
through the retort in order to continue the product cooling process. Alternatively, the
jars can be removed and submerged in a cooling canal before labeling.

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 Issue 2
AG/RCP–006
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information contained herein without notice.
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