Pasteurization：why tunnel pasteurization is a preferred method for beverages like beer, cider, and other drinks?

In the competitive world of beverage production, ensuring product safety and shelf stability without compromising quality is key. Among the various methods of pasteurization available, tunnel pasteurization stands out as a reliable and widely adopted solution—especially for packaged products like beer, cider, and other ready-to-drink beverages. But what exactly makes tunnel pasteurization the go-to choice? Let’s dive in.

What Is Tunnel Pasteurization?

Pasteurization tunnel is a continuous heat treatment process, warming and cooling tunnel, it is specially designed and used for bottled or can beer/cider/kombucha/other beverages after they've been sealed . Which through sterilization, warm preservation, cooling achieve prolong the shelf life, especially the secondary sterilization equipment for automatic production line. The products pass through a long, temperature-controlled tunnel on a conveyor belt where they are gradually heated and then cooled using hot and cold water sprays. According to users of different products of different heating, sterilization, warm preservation, cooling process requirement, to design a different process, meet the technological requirements, according to user requirements, configuration of the corresponding high precision automatic control system.
Tunnel Pasteurization, pasteurizer, Pasteurizer Tunnel Machine

Tunnel Pasteurization, pasteurizer, Pasteurizer Tunnel Machine

Performance Characteristics for Tunnel Pasteurization

The machine frame is made of stainless steel, the overall structure is compact and the appearance is wholesome and beautiful.
High quality plastic engineering belt chain plate, can be long-term work under the high temperature of 100 ℃;
The solid cone Angle nozzle spray heads, the water flow distribution is uniform and stable, the temperature zone is constant.
The comprehensive utilization of various energy and warm recovery technologies, energy saving and environmental protection;
PT100 temperature sensor, measurement accuracy is high, up to + / - 0.5 ℃;
The multi-process combination, the process is reasonable, can handle various materials.
The pasteurized temperature is controlled by the German Siemens PLC's PLC .
The frequency conversion control can be adjusted according to the production process.
PP bottles, plastic bags, paper boxes, bottles, cans and other products roof the discharged, configuration and automated conveyor line connection transition smoothly; The whole line is smoother.

Different Size for Option

According to the output and temperature zone requirements, the pasterurizer can be designed with 6 meter, 8 meter, 10 meter, 12 meter etc. And the width can also be designed according to the output.

Speed: 1000-1300b/h (330Ml)	Voltage ：3Phase 380V / 50Hz
Bottle inlet temperature: 3℃	Bottle outlet temperature: 35℃
Sterilization temperature: 63℃ (Adjustable)	Can control the temperature accuracy: ±１℃
Speed :	110-553mm/min
Material:	SUS304 Thickness =2 mm. Nozzle is SUS304
Using steam pressure:	0.2-0.4mpa
Heating steam pressure:	0.2Mpa
Heating the amount of circulating water:	6m3
Sterilization length:	2400mm
Sterilization time:	17min (adjustable)
Total Sterilization time:	About 43 min
Sterilization effective width:	920 mm
Warming water pump:	2T/h x 7pcs
Hot water pump :	4T/h x 1pcs
Pneumatic diaphragm valve from temperature control:	DN25
Electrical control box :	PLC control system, 1 set
Into and out of the conveyor belt
Size(L×W×H):	7000×1350×1650mm

Here’s how it works, step by step:

Packaging First: The beverage is first brewed, filtered, carbonated (if needed), and then filled into bottles or cans and sealed.

Conveyor Tunnel System: These sealed containers are then placed on a slow-moving conveyor belt that passes through a long, enclosed structure called a pasteurization tunnel.

Controlled Temperature Zones:
The tunnel is divided into zones: pre-heating, pasteurization (heating), and cooling.

Hot water sprays gradually raise the temperature of the beverage to the pasteurization point—usually around 60–65°C (140–149°F)—and hold it there for a specific amount of time.

The beverage is then slowly cooled down with cold water sprays to prevent heat shock to the packaging.

Pasteurization Units (PUs): The process is measured in PUs—a unit that reflects the time and temperature the beverage is exposed to. The goal is to reach just enough PUs to kill spoilage organisms without damaging flavor or quality.

Why Do Pasteurization After Packaging for Beer, Cider, Kombucha, and Other Beverages?

Pasteurizing after packaging—like in tunnel pasteurization—offers several key advantages when it comes to safety, stability, and product quality. Here's why many producers choose this method:

1. Prevents Recontamination
When pasteurization is done before packaging (like with flash pasteurization), the product still needs to go through filling lines, which can:

Introduce airborne microbes
Get contaminated by equipment or surfaces
Compromise sterility

By pasteurizing after the product is sealed:
►The beverage is already in its final, sealed container
►There’s no risk of post-pasteurization contamination
►The product stays safe and stable

2. Ensures Microbial Stability Without Preservatives
Beverages like beer, cider, and kombucha often contain:
Residual sugars
Low alcohol (especially in cider or kombucha)
Live yeasts or bacteria (especially in kombucha)
Tunnel Pasteurization, pasteurizer, Pasteurizer Tunnel Machine

These elements can cause secondary fermentation or spoilage in the can or bottle.
Post-packaging pasteurization:
Kills off unwanted microbes
Stops live yeast or bacteria from re-fermenting in the package
Prevents explosions, souring, or off-flavors

3. Extends Shelf Life Without Refrigeration
For beverages that are exported or stored at room temperature, shelf life is critical.
Tunnel pasteurization allows you to:
Extend shelf life up to several months or more
Avoid cold-chain logistics
Reduce product returns from spoilage
This makes it ideal for:
Export markets
Supermarkets
Long-term storage

4. Protects Sensory Quality
Unlike harsher methods, tunnel pasteurization:
Uses gradual heating and cooling
Preserves aromas, flavors, and carbonation
Is gentle on delicate beverages like craft beer or kombucha
So you're getting the best of both worlds—stability and flavor.
5. Works With a Wide Range of Containers
Tunnel pasteurization can handle:
Glass bottles
Cans
PET bottles

This makes it perfect for:
Breweries and cideries scaling up
Kombucha brands with RTD formats
Contract packagers who handle multiple beverages

So doing pasteurization after packaging is like putting a safety seal on your product—not just physically, but microbiologically. It's a smart move for producers who want to offer a stable, shelf-ready, and high-quality beverage without relying on additives or refrigeration.
Let me know if you want to tailor this explanation for a specific audience—like brewers, kombucha makers, or co-packers!
Tunnel Pasteurization, pasteurizer, Pasteurizer Tunnel Machine

Key Advantages of Tunnel Pasteurization

1. Microbial Stability and Shelf Life
The primary goal of pasteurization is to eliminate harmful microorganisms. Tunnel pasteurization ensures:
Consistent thermal treatment of every unit.
Reduction of spoilage organisms like yeast, molds, and bacteria.
Extended shelf life without the need for preservatives or refrigeration.

This is especially important for non-sterile beverages like beer and cider that can harbor live yeasts or bacteria if not properly treated.

2. Post-Packaging Pasteurization
Unlike flash pasteurization (which occurs before packaging), tunnel pasteurization is applied after the beverage is sealed in its final container. This means:

No chance of recontamination.
Safer and more reliable in terms of product integrity.
For carbonated beverages, this is a major plus—it maintains carbonation while ensuring safety.

3. Product Quality Preservation
Tunnel pasteurization uses a gentle heat curve, minimizing the impact on:
Flavor and aroma compounds in beer and cider.
Color, clarity, and other sensory attributes.

Modern systems are finely tuned to deliver the right number of Pasteurization Units (PUs) without overprocessing, preserving both taste and brand quality.

4. Packaging Flexibility
Tunnel pasteurizers can handle a variety of container types:
Glass bottles
Aluminum cans
PET bottles
This makes them ideal for breweries, cideries, and beverage producers with diverse product lines.

5. Sustainability and Efficiency
Today’s tunnel pasteurizers are built with energy and water-saving technologies, offering:
Heat recovery systems
Water recirculation
Smart temperature zoning
This helps reduce operating costs and environmental impact—crucial in a sustainability-focused market.

Who Should Consider Tunnel Pasteurization?

Craft breweries scaling up production.
Cider makers looking to distribute more broadly.
RTD beverage producers with a need for stable, preservative-free products.
If you're moving into wider distribution or export, tunnel pasteurization helps ensure consistency and compliance with international food safety standards.

Tunnel pasteurization isn’t just a heat treatment—it's a critical investment in your brand’s quality assurance, safety, and longevity. Whether you’re packaging beer, cider, kombucha, or other functional beverages, this method offers a perfect blend of science, scalability, and product protection. For any producer aiming to grow with confidence, tunnel pasteurization is a smart move—offering peace of mind in every bottle or can.
Tunnel Pasteurization, pasteurizer, Pasteurizer Tunnel Machine