In-Line UV-C Tunnel for High-Speed Sterilization of Transparent Food Packaging

1. Composition of Production Line

A complete integrated sterilization solution includes:

1. Infeed Conveyor: Synchronized stainless steel mesh or belt conveyor.

2. UV-C Irradiation Chamber: Enclosed housing with high-output UV-C lamp arrays and optimized reflectors.

3. Exhaust System: Gentle extraction to manage ozone (if generated) and heat.

4. Outfeed Conveyor.

5. Control Cabinet: Houses power supplies, PLC controller, and UV intensity monitor.

6. User Interface: Touchscreen HMI for operational control and data logging.

2. Product Description

This In-Line UV-C Tunnel is engineered for the high-efficiency, non-chemical sterilization of transparent food packaging containers and lids immediately before filling. By emitting intense 254nm germicidal ultraviolet light, it destroys up to 99.9% of microorganisms (such as bacteria, molds, and yeasts) on surfaces within seconds. Constructed with food-grade materials, it ensures a hygienic processing environment, enhancing product safety and shelf-life without leaving any residue.

3. Technical Parameters

4. Application

• Pre-fill sterilization of transparent plastic cups, tubs, trays, and bottles.

• Surface disinfection of packaging lids and foil seals.

• Integration into high-speed dairy, beverage, ready-to-eat food, and bakery packaging lines.

5. Customization

This sterilization tunnel is designed for flexibility to match your line exactly:

• Treatment Width & Length: The tunnel's dimensions and UV power can be customized to your packaging size and required microbial reduction level.

• UV Source: Choose between traditional mercury lamps or modern, instant-on/off UV-C LED modules.

• Conveyor System: Customized to match your container type (mesh belt for stability, roller for bottles).

• Integration Interfaces: Customizable electrical and communication interfaces for seamless PLC integration into your existing line.

6. Feature

• High-Efficiency Sterilization: Achieves high log-reduction of pathogens in a compact footprint.

• Non-Thermal Process: No heat damage to heat-sensitive transparent packaging materials.

• Hygienic Design: Smooth surfaces, easy to clean and maintain, complying with food safety standards.

• Intelligent Monitoring: Real-time UV intensity sensors and dose calculators ensure consistent performance.

7. Support and Services

• Process Validation Support: Assistance with microbiological testing protocols to validate efficacy.

• Turnkey Installation: On-site installation, commissioning, and performance verification.

• Comprehensive Training: Training for operators and maintenance technicians.

• After-Sales: 12-month warranty, preventive maintenance plans, and global spare parts supply.

8. Packing and Shipping

• Packing: Fully disassembled major modules are securely packed in weather-proof, shock-absorbent wooden crates.

• Shipping: Shipped via sea freight to major ports under FOB/CIF terms. Air freight is available. All customs documentation is provided.

9. FAQ

Q1: How does UV-C light sterilize through transparent packaging?
A: UV-C light penetrates transparent materials like PET, PP, and glass. However, its germicidal effect is primarily on the inner surface directly exposed to the light. For pre-filled containers, the liquid or food content may shield microorganisms. Therefore, our system is optimally used for empty packaging sterilization before filling.

Q2: Is UV-C treatment safe? Are there chemical residues?
A: UV-C is a physical, non-ionizing radiation process. It leaves no chemical residues, making it extremely safe for food contact surfaces. The equipment is fully enclosed with safety interlocks to prevent any operator exposure to UV light.

Q3: What is the typical maintenance required?
A: Regular maintenance mainly involves periodic cleaning of the quartz sleeves (if applicable) to maintain UV transparency and replacing UV lamps after their rated service life (typically 8000+ hours) to ensure consistent output.

Q4: Can this system handle different packaging shapes and sizes?
A: Yes, the conveyor and irradiation chamber can be customized. For a mix of shapes, customized jigs or fixtures can be provided to ensure consistent exposure. The UV dose can also be adjusted via speed or power to accommodate different sizes.

Q5: Do you provide validation reports for the equipment?
A: Yes, we can provide a third-party validation report certifying the delivered UV-C dose at a specified conveyor speed, which is crucial for your HACCP and food safety documentation.