Extended Life Capabilities
| All Evergreen models can be equipped with ESL features.
Although we market ESL capabilities as options, most of our customers consider
them as requirements. Very few Evergreen machines are shipped without at least
some basic ESL components. ESL (Extended Shelf Life) PACKAGING MACHINE
TECHNOLOGIES While packaging configurations and materials also affect the shelf
life of refrigerated products, machine technology is fundamental for
maintaining product quality: |
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Form, fill and seal environment - Air quality
enclosures of the basic machine are combined with HEPA (High Efficiency
Particulate Air) filtration (to form a cleaner environment) for the form, fill
and seal sections of the machine. The environment is pressurized to assure an
outward flow during normal operations and when doors are opened.
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Metering bowls - ESL machines generally utilize hermetically
sealed metering bowls. The fill valves and both sides of the pistons are
flooded with product, which prevents air from entering the system. HEPA
filtered air occupies head space in the product tank for additional protection.
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Pre-sanitation - The additional ESL measure of pre-sanitation
at 195°-205°F can extend refrigerated shelf life as far as 28 days – the limit
for HTST processed dairy products before they begin to degrade because of
non-microbial factors. (This measure also eliminates the need for chemical
sterilants.)
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Auto sanitization - The auto sanitze system protects against
contamination by periodically spraying sanitizing solution on critical product
contact surfaces. This system can be used in an automatic or manual mode.
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| In addition to machine technologies, to ensure desired
shelf life, the following requirements must be applied: |
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Minimal Process Requirements – HTST processed with SPC to the
filler not to exceed 100. Again, the higher the sanitation standards of the
entire plant, the higher the prospect of ESL success.
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Minimum Packaging Machine Requirements – These also begin with
good sanitary practices, including system CIP and careful cleaning of
product/container contact surfaces according to machine specifications. In
addition, the filler area should be enclosed to reduce potential contamination
via ambient plant air.
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Minimum Distribution Requirement – Maintain product at 45°F
(7.0°C).
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ESL Technology – Features are required that control product
contact surfaces.
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| Evergreen ELL Technology |
| Our Extended Long Life (ELL) machines represent the
ultimate expression of sanitary packaging design. These machines bring together
several technologies to maintain maximum control over potential product
contamination. Evergreen ELL machines begin with hot water pre-sanitation and
auto-sanitizing of surfaces that contact product and carton interiors. Add to
these measures an advanced air quality design incorporating HEPA (High
Efficiency Particulate Air) filtration and, on certain models, a continuous
ultra-violet decontamination of plenum surfaces. This design forms a
self-contained “clean room” within the machine. On some models, a
double class 100 environment, one inside the other is standard. Depending
on application, various package sanitation methods are available. While
packaging configurations and materials do contribute to the maintainability of
product quality for refrigerated products, this discussion of ELL packaging
focuses on machine technology. To achieve the expected shelf life of ELL
machines, the minimal process requirements are UHT processed product with SPC
to the filler of less than one.
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Minimum Packaging Machine Requirements
ELL technologies begin where ESL technologies leave off. There are no
sanitation options; all product quality maintaining enhancements are required.
In order to maintain maximum control over potential product contamination, ELL
machines leave virtually nothing to chance in the packaging environment. The
ELL machines include the following technologies:
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Air quality (laminar flow) enclosures combined with HEPA filtration.
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Hermetically sealed metering bowls (when applicable).
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Pre-sanitation at 250°F minimum.
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Continuous flow of decontaminated air achieved by filtration or incineration.
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ELL Packaged Products
When used to package UHT processed dairy products in standard
packaging, these multiple ELL measures combine to produce refrigerated shelf
life for dairy products of up to 45 days. Selecting advanced packaging
configurations, materials and pretreatments, product quality can be maintained
up to 90 days. For juice, the microbiological quality of refrigerated products
can be sustained beyond 100 days with ELL technology. |
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Benefits of ELL
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Virtually eliminates product returned from expired short-term pull dates.
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Increases sales at retail; studies show longer term pull dates
encourage retailers to increase facings, which boosts consumer purchases.
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Cuts distribution costs with fewer, larger deliveries to more distant outlets.
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Boosts plant efficiency through larger production volumes
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