Winegrowers Supplies  - Operating Instructions for the KTM Pasteuriser THA-100

1. Water container.
2. Juice container.
3. Bottle filling nozzle-valve (2 or 3 nozzles according to model).
4. Digital thermometer (shows the juice temperature at point of filling).
5. Thermometer for water bath temperature; the temperature control thermostat for the water bath is initially set at 92 C, this can be adjusted by opening the electrical box between the two switches (6&9, undoing one small screw) and altering the setting.
6. On/off switch and indicator for the water bath heating (press the green indicator).
7. Tube for ventilation of the filling valve.
8. Hose connection from juice container to the heating tube (inside the water bath). Use the white-spiral polythene tube with DN25 stainless steel connectors.
9. Unit switched 'ON' indicator; green light; as 6.
10. Heater 'ON' indicator; white light at the bottom.

Preparing the Pasteuriser for operation:-
Fill the water bath with clean water (pre-heated warm water enables the water bath to heat up to the required temperature more quickly) up to the level 'MAX'. If the water level is below the float-valve then the electrical supply will not come on.
Ensure the upper juice container is clean and fix it in place with the clips.
Connect the small ventilation tubes to the upper container.
Connect the hose between the juice container and the heating tube (which goes inside the water bath).
Set the bottle height on the filler platform:
  a. Put a bottle on the filling valve and adjust the height position of the platform.
  b. Put a suitable number of black rubber spacers on the nozzle so that the filling valve opening is visible - as per the diagram.
Put 2 or 3 litres of cold water in the juice container.

Fill some bottles for a trial:-
Check the level against that specified for the bottle, see bottle filling.
Hot juice reduces in volume as it cools down to 15 C, so the fill level must be higher than that specified on the bottle. Some experience must be gained initially to set this level for each particular size bottle used, it may drop by about 10 mm for a 75 cl bottle, in which case the fill height should be adjusted (with the black rubber spacers) to be 10 mm higher than that specified for the bottle.

Important Notes:-
While in operation the parts of the machine become very hot and could cause skin burns. Protective insulated gloves must be worn, so that hot bottles can be handled; i.e. removed from the filler to the capper, and then layed down. The gloves should be thick enough so that no liquid can penetrate them if a bottle with hot juice were to break. Rubber outer gauntlets and Kevlar inner gloves are ideal; available from etc.
Suitable shoes must also be worn, not Wellingtons where it would be possible for hot juice to run down inside. Protective glasses and clothing should also be worn.

Filling into cold bottles increases the risk of glass breakage, so warming the bottles to 40 C or more is advantageous.
As long as the bottles (or plastic containers) are clean inside it is not necessary to sterilise them with wine sulphur before use, since the pasteurisation will achieve this.

Filling the bottles:- 
Plug in the 5-pin 3-phase electrical plug; a large 32 kWatt socket is needed and all 5 wires (the 3-phases, Earth and Neutral) need to be connected in the supply to the socket, in order for the Pasteuriser to work), then switch on.
Press the green light at the bottom until it lights up, the white light also comes on. The white light stays on as long as the water bath is being heated.
Fill the upper juice container with liquid; the maximum level is 2 cm below the top of the small ventilation tube. There is a " BSP ball-valve on the side which can be used to fill the container; either by gravity from a tank higher up, or by pumping.
Switch on the digital thermometer with the small switch on the top. The temperature shown on the digital thermometer is the temperature of juice when filling.
Use the blue-handled ball-valve to control the speed of filling so that the temperature is maintained at the required level (82 C for cider or apple juice; 85 to 87 C for grape juice or sweet wines); slowing the flow will increase the temperature.

When the white light goes out the filling can begin.
Place bottles on the filler heads and wait for them to fill to the preset height.
Empty the contents of the first few bottles back into the juice container, to ensure that the filling nozzle is fully up to temperature.
When a bottle is filled satisfactorily and to the correct level, fit a cap and lay the bottle on its side so that the cap heats up and itself is pasteurised; it is very important to do this.

Finishing off:-
Switch off the electrical supply.
Let the water bath cool to 50 C.
Clean out the juice container, filling valves and tubes, with water.
It is important to use 3 special 25 mm orange rubber balls (in line together) to thoroughly clean the inside of the spiral stainless-steel tube which is inside the water bath; these are propelled through the tube by tap water from the mains or from a pump.