Tunnel Pasteurizer
TUNNEL PASTEURIZER
Custom tunnel pasteurizer | post-fill pasteurization for cans and bottles | energy-efficient beverage pasteurization
Custom tunnel pasteurizers for cans, glass bottles, and PET
CODI tunnel pasteurizers provide controlled post-fill thermal processing for beverage packaging lines from 50 to 600+ containers per minute. Each system is engineered around your target Pasteurization Units (PUs), line speed, container, available utilities, and floor space.
Multi-zone water recirculation provides controlled heating, holding, regeneration, and cooling, while flexible heating configurations allow the tunnel to work with existing plant steam or hot water, or a CODI-supplied gas-fired instant hot water system.
Because CODI also manufactures conveyors, fillers, depalletizers, packaging equipment, and palletizing systems, the pasteurizer can be engineered as part of the complete packaging line rather than as a standalone machine.
Custom tunnel pasteurizers for cans, glass bottles, and PET
CODI tunnel pasteurizers provide controlled post-fill thermal processing for beverage packaging lines from 50 to 600+ containers per minute. Each system is engineered around your target Pasteurization Units (PUs), line speed, container, available utilities, and floor space.
Multi-zone water recirculation provides controlled heating, holding, regeneration, and cooling, while flexible heating configurations allow the tunnel to work with existing plant steam or hot water, or a CODI-supplied gas-fired instant hot water system.
Because CODI also manufactures conveyors, fillers, depalletizers, packaging equipment, and palletizing systems, the pasteurizer can be engineered as part of the complete packaging line rather than as a standalone machine.
PRODUCT FEATURES
Regenerative Energy Recovery
Regenerative tunnels transfer thermal energy between heating and cooling sections rather than continually adding and removing heat.
• Recovers up to 70% of thermal energy
• Reduces heating and cooling utility demand
Precision PU Control
Each tunnel is engineered around the required time-temperature profile for your product.
• PLC-controlled thermal zones
• Independent recirculation pumps and spray systems
• Variable conveyor speed
• Continuous temperature monitoring
Sanitary, Serviceable Construction
Designed for continuous beverage production and straightforward cleaning and maintenance.
• 304 stainless steel construction
• Stainless steel spray headers and removable spray nozzles
• Inline screening and filtration options
• Accessible basins, pumps, piping, and valves
Engineered Container Handling
The tunnel and conveyance are configured around the actual package being processed.
• Aluminum cans, glass bottles, and PET
• Multiple container sizes and formats
• Custom lane and conveyor configurations available
PRODUCT INFORMATION
50 to 600+ CPM
Full conveyance integration
Heating method of your choice
CUSTOM TUNNEL PASTEURIZERS
Tunnel Spray Length: 15 to 50+ ft (excludes infeed, discharge, and blower sections)
Thermal Zones: 3 to 10 independent thermal zones
Belt Widths: 2.5 ft (Slim) and 5.0 ft (Standard)
Throughput: 50 to 500+ containers per minute (12 oz cans)
Deck Height: 40" nominal conveyor height with adjustable leveling
Construction: Heavy-gauge AISI 304 stainless steel throughout
Thermal Recovery: Regenerative heating recovers up to 70% of thermal energy
Line Integration: Custom infeed, discharge, and single-filing conveyance built to fit your facility
UTILITY REQUIREMENTS
Engineered around your facility’s existing utilities or configured with self-contained heating solutions.
Steam Heating (Boiler Source)
Operating Pressure: Low-pressure saturated steam at ≤ 15 PSI constant. (Facilities with high-pressure boilers [100–125 PSI] require an upstream customer-supplied Pressure Reducing Valve [PRV] station stepped down to 10–15 PSI.)
Flow & Boiler Horsepower Demand:CTP-15S & CTP-20S: 1.0 to 1.35 MBTU/hr (840 to 1,170 lbs/hr of steam | ~25 to 40 BHP)
CTP-40S & CTP-50S: 3.0 to 3.25 MBTU/hr (2,500 to 2,750 lbs/hr of steam | ~75 to 95 BHP)
Connection Sizes: 2" FNPT inlet (15S/20S) or 3" FNPT inlet (40S/50S); dedicated condensate return.
No Boiler? Tankless Instant Hot Water Option
Fully skid-mounted, modulating on-demand water heater rack (Natural Gas or LPG/Propane).
Eliminates the need for a dedicated facility steam boiler while delivering precise, on-demand thermal modulation.
Facility Water Supply
Pressure & Flow: City water at 40+ PSI; 20 to 30 GPM peak for initial basin fill, reducing to 5 to 12 GPM steady-state during continuous production.
Water Quality: Softened water recommended (4–6 °dH, pH > 7, conductivity > 50 µS/cm, chlorine 0.2–2.0 ppm).
Drainage: 2" Tri-Clamp gravity drain connections (floor drain rated for up to 15 GPM @ 100°F+ recommended).
Compressed Air
Demand: 5 to 7 CFM @ 90–110 PSI (clean, dry air meeting ISO 8573-1 Class 2).
Connection: 1/2" ID dedicated air drop to FNPT inlet coupler.
Electrical
460V / 3-Phase / 60 Hz: ~68A to 75A Full Load Amps (FLA) on 15S/20S models; ~73A to 100A FLA on 40S/50S models.
208–240V / 3-Phase / 60 Hz: Available upon specification.
Controls: 110V internal control transformer; Schneider Electric PLC & 15" touchscreen HMI.
Final utility submittal packages and P&ID drawings are confirmed during the engineering and approval phase.
SYSTEM OPTIONS & CONFIGURATIONS
Heating Systems
Natural Gas On-Demand Instant Hot Water: Skid-mounted, modulating tankless water heater rack; provides instant, precise thermal control without requiring an on-site steam boiler.
LP / Propane Instant Hot Water: High-efficiency modulating tankless water heating designed for facilities without natural gas service.
Facility Steam (Plate & Frame Heat Exchanger): Heavy-duty sanitary plate heat exchanger rated for low-pressure saturated steam (≤15 PSI), complete with an automated proportional modulating control valve and condensate return.
Facility Hot Water Loop: Direct integration with existing facility hot water systems via a dedicated closed-loop heat exchanger.
Electric Instant Water Heating: High-efficiency electric heating systems available for all-electric, boiler-free production environments.
Cooling & Energy Recovery
Regenerative Thermal Recapture: Cross-zone energy recovery loops that reclaim up to 70% of thermal energy by using warm exit cans to preheat incoming cold cans.
Auxiliary Glycol Heat Exchanger: Closed-loop glycol chilling in final cooling zones to bring cans down to packing temperature (below dew point) and prevent can sweating before labeling or shrink-sleeving.
Container Handling & Conveyance
Sure Dry Air Knife / Blower System: High-velocity centrifugal air knife drying system at discharge to eliminate water droplets from lids and sidewalls before date-coding, sleeving, or packing.
Single-Deck or Double-Deck Layouts: Choose standard single-deck conveyance or double-deck conveying (which doubles thermal dwell surface area on the same physical footprint).
Integrated Infeed & Discharge Conveyance: Custom mass accumulation tables, 90-degree transfers, bi-directional accumulation, and single-filing systems tailored to your packaging line.
Conveyor Belt Widths: Available in 2.5 ft (Slim 30" belt) for compact floor plans or 5.0 ft (Standard 60" belt) for high-speed lines.
Water Management & Filtration
Inline Water Filtration: Sanitary stainless steel basket strainers and continuous multi-stage filtration to protect spray nozzles and extend recirculated water life.
Automated Water Level Control: Continuous reservoir level sensing, automatic make-up water fill, and overflow protection across all water basins.
Chemical Dosing Ports: Built-in connection ports for automated biocidal treatment, anti-foaming agents, and scale inhibitors.
Automation, Data & Controls
Schneider Electric PLC & 15" Touchscreen HMI: Comprehensive digital control with multi-recipe storage, zone temperature monitoring, and belt speed adjustment.
Batch PU Calculation & Data Logging: Real-time calculated Pasteurization Units tracked per batch with exportable reports via USB or Ethernet for QA compliance.
Remote Diagnostic Support: Network-enabled PLC connectivity for secure remote troubleshooting and software updates.
Electrical & Certifications
UL 508A Listed Control Panel: Built, wired, and tested to strict North American electrical safety standards (cULus available).
Multi-Voltage Compatibility: Configurable for 460V / 3-Phase / 60 Hz, 208–240V / 3-Phase / 60 Hz, or 380–415V / 3-Phase / 50 Hz international power.
CONFIGURABLE SYSTEM PARAMETERS
Throughput Capacity: 50 to 500+ containers per minute (12 oz cans)
Spray Section Length: 15 to 50+ ft active spray sections
Thermal Zones: 3 to 10 independently controlled temperature zones
Target Pasteurization Units (PUs): Custom-engineered to your Process Authority (PA) specifications for beer, cider, seltzers, ready-to-drink cocktails (RTDs), wine, or non-alcoholic beverages
Thermal Processing & Heating
The tunnel operates on a closed-loop recirculating hot water system engineered for maximum temperature stability and fuel efficiency, powered by your facility’s existing utilities or self-contained heating.
On-Demand Instant Gas Heating: Skid-mounted, modulating tankless water heater racks (Natural Gas or LPG/Propane) provide instant, precise thermal control without requiring an on-site steam boiler.
Facility Steam Integration: Heavy-duty sanitary plate-and-frame heat exchanger equipped with automated proportional modulating control valves and dedicated condensate traps, engineered for low-pressure steam (≤ 15 PSI).
Facility Hot Water Integration: Seamless connection to existing central boiler loops or plant hot water manifolds.
Independent Closed-Loop Recirculation: Each zone maintains its own recirculating reservoir, delivering stable, repeatable temperature control completely isolated from building utility fluctuations.
Zoned Thermal Control & Precision PU Management
Independently controlled temperature zones systematically build, hold, and ramp down the precise thermal curve required for your beverage chemistry.
3 to 10 Independent Thermal Zones: Dedicated warming, holding, regenerative, and cooling stages eliminate thermal spikes and protect delicate flavor profiles.
Dedicated Pumps & Spray Manifolds: Every zone features its own independent stainless steel centrifugal pump, pressure regulating loop, and high-coverage spray nozzle grid.
Decoupled Dwell & Temperature Control: Variable Frequency Drive (VFD) conveyor belt control allows operators to adjust container dwell time independently from zone water temperatures.
Live Batch PU Calculation: Integrated PLC algorithms continuously calculate and log accumulated Pasteurization Units, with exportable reporting via USB or Ethernet for QA compliance.
Energy Efficiency & Regenerative Heat Recovery
Cross-zone regenerative loops capture heat from exiting warm containers and transfer it directly to incoming cold containers instead of rejecting it as waste.
Up to 70% Thermal Energy Recovery: Dramatically slashes utility consumption by recycling energy internally across the heating and cooling zones.
Dual Utility Demand Reduction: Simultaneously cuts boiler/gas fuel consumption while reducing cooling water or glycol load.
Thermal Shock Mitigation: Gradual, balanced temperature transitions protect can seam integrity and eliminate thermal breakage risks for glass bottles.
Primary Operating Cost Reducer: Serves as the single largest operating cost lever over the lifetime of a continuously running packaging line.
Throughput, Scalability & Deck Configurations
Every tunnel is sized specifically to your product's thermal curve, container geometry, and target line speed rather than forced into a rigid standard frame.
Throughput from 50 to 500+ CPM: Scaled to match production speeds across 12 oz, 16 oz, sleek/slim cans, glass bottles, and PET containers.
15 to 50+ Foot Active Spray Lengths: Tunnel lengths scale dynamically to provide the exact square footage of treatment dwell area needed for your target PUs.
Single-Deck & Double-Deck Footprints: Choose standard single-deck designs or space-saving double-deck configurations (which double your treatment dwell area within the same physical floor space).
Continuous Industrial Duty: Heavy-gauge AISI 304 stainless steel construction throughout, engineered for multi-shift industrial reliability.
Container Handling & Package Protection
Conveyance, spray manifolds, and thermal ramps are designed to protect delicate container seams, lightweight walls, and printed packaging.
Multi-Format Versatility: Easily accommodates standard cans, sleek/slim cans, glass bottles, and PET bottles with quick recipe changeovers on the HMI.
Balanced Spray Pressure Regulation: Calibrated spray nozzle geometry and pump regulation prevent container tipping, dislodging, or flotation of lightweight cans.
Sanitary Modular Belting: Low-friction, flush-grid Intralox conveyor belting ensures smooth container transfers, rapid drainage, and scuff-free can handling.
Seam & Label Preservation: Controlled temperature curves prevent beverage thermal expansion from doming can lids or wrinkling shrink sleeves.
Packaging Line Integration & Discharge Dry-Off
Engineered to drop seamlessly into your packaging line between the seamer/capper and downstream secondary packaging equipment.
Flexible Belt Widths: Available in 2.5 ft (Slim 30" belt) for compact floor plans or 5.0 ft (Standard 60" belt) for high-speed mass accumulation.
Standard 40" Conveyor Height: 40" nominal deck height with heavy-duty adjustable leveling feet (850 mm to 1,050 mm) for direct alignment with existing lines.
Custom Infeed & Discharge Handling: Options for 90-degree transfers, bi-directional mass accumulation tables, and continuous single-filers.
Sure Dry Air Knife Integration: High-velocity centrifugal air knife drying system at discharge strips residual water droplets from lids and sidewalls prior to date-coding, sleeving, or case packing.
The CTP-20S is a highly versatile 8-zone tunnel pasteurizer featuring a 20-foot spray section, perfect for expanding producers requiring precise PU control and thermal efficiency.
Throughput Range: 50 – 100 CPM
Physical Footprint: 5' Wide x 25' Long Overall (20ft spray section)
Zone Profile: 8 thermal zones for precise temperature transitions
Available with instant hot water heaters and regeneration
CTP-20S
CTP-20S
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Mid-range tunnel pasteurizer for growing food & beverage operations. (shown with Instant Hot Water Heaters)
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The CTP-35S is a 7-zone pasteurizer engineered for medium-to-high speed lines.
Throughput Range: 150 – 300 Containers Per Minute
Physical Footprint: 5' Wide x 40' Long Overall (35ft spray section)
Thermal Design: 7 independent zones with central thermal recovery
Available with instant hot water heaters and regeneration
CTP-35S
CTP-35S
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High-efficiency 7-zone pasteurizer designed for mid-to-high speed beverage packaging lines.
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The CTP-40S is a heavy-duty industrial tunnel pasteurizer with a 40-foot treatment section built to sustain high-volume packaging lines with continuous, multi-shift operations.
Throughput Range: 150 – 300 Containers Per Minute
Physical Footprint: 5' Wide x 45' Long Overall (40ft spray section)
Feature Integration: Heavy-duty, high-flow spray nozzles and industrial pumps
Available with instant hot water heaters and regeneration
CTP-40S
CTP-40S
High-capacity 8-zone pasteurizer engineered for continuous, high-speed industrial canning.
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The CTP-50S is CODI's high throughput tunnel pasteurizer, featuring a 50-foot spray section and 10 thermal zones for products requiring maximized hold times and continuous throughput.
Throughput Range: 200 – 600+ Containers Per Minute
Physical Footprint: 5' Wide x 55' Long Overall (50ft spray section)
Advanced Features: Fully CIP-capable, open-frame design with 10 high-flow pumps
Available with instant hot water heaters and regeneration
CTP-50S
CTP-50S
Large-scale 10-zone pasteurizer built for maximum hold times on high-volume production lines.
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TUNNEL PASTEURIZATION MODELS
With nearly every tunnel pasteurizer we sell, customers ask the same question: "how do we integrate it into the rest of the packaging line?"
An advantage of working with CODI is that we have built our own conveyance systems since 1992. We don't resell conveyors from another manufacturer. We design and build them in our own shop.
That means when you order a tunnel pasteurizer from CODI, we can integrate it into your existing line or design a complete packaging line from the ground up.
You send a sketch of your floor. You tell us what the line needs to produce. We come back with a complete layout, including conveyance and how every piece integrates. From there you decide how much of it you want us to build. One machine, a section, or the whole line.
HOW TO INTEGRATE A PASTEURIZER INTO YOUR LINE
Tunnel Pasteruization basics
Tunnel pasteurization is a continuous thermal process applied after the container is filled and sealed. Containers ride a belt through a series of temperature-controlled zones while water sprays over them from overhead nozzles, raising product temperature, holding it, and then bringing it back down before discharge.
The sequence is always the same four stages: preheat, heat, hold, cool. What changes from one application to the next is how long the product spends in each stage and how hot it gets. Because the package is already sealed, the process treats the beverage and the container together, and the product is microbiologically stable by the time it reaches labeling and packing.
Thermal processing is measured in Pasteurization Units. One PU equals holding product at 60°C for one minute.
The relationship between time and temperature is exponential, not linear:
PU = t × 1.393^(T − 60)
That exponent is why PU is the control variable instead of temperature alone. A small increase in temperature sharply reduces the dwell time required to reach the same PU, which means the same thermal result can be achieved by a short hot tunnel or a longer, gentler one. It also means PU stays accurate when line speed, ambient conditions, or incoming product temperature shift, where a fixed temperature setpoint would not.
Here is an example of CODI's calculations for a pasteurization curve:
Target PU depends on the beverage itself: formulation, pH, alcohol content, microbial risk, and the shelf life you need. That number is established by the producer working with a qualified process authority, not by the equipment manufacturer. The AFDO Directory is a good starting point for locating one.
Each zone has its own basin, recirculation pump, and spray headers. Water is drawn from the basin, brought to the zone's setpoint, sprayed over the containers passing beneath, and drained back to recirculate.
Zone temperatures are controlled independently, which is what makes a programmed curve possible. One zone might sit at 100°F while the next holds 145°F and a third runs cool water. Belt speed sets how long a container spends under each one, so dwell time and temperature are set separately.
Water routing is a separate question from temperature control. A standalone zone recirculates through its own basin. A regenerative pair does not: the preheat zone and its matched cooling zone share a water loop, so water that gives up heat to incoming containers is the same water that later absorbs heat from containers on the way out. The two zones still hold different temperatures and are still controlled separately.
More zones mean finer control over the shape of the curve. Gradual transitions matter for glass, which will fracture under sharp thermal change, and for carbonated product, where rapid heating drives internal package pressure.
A tunnel without regeneration spends energy twice: once heating containers on the way in, and again removing that heat on the way out.
Regenerative zones connect the two. Water that has picked up heat from containers in the cooling section is routed forward to the preheat section, where it warms containers entering the tunnel. The heat moves from where it is a problem to where it is useful, and the tunnel supplies only the difference.
The result is lower demand on both the heating utility and the cooling utility at the same time. On a line running continuously, that recovery is the largest single lever on operating cost the tunnel design offers. Regeneration also flattens the temperature curve, which is easier on glass and on carbonated product.
Beverages can be pasteurized before filling, by running product through a heat exchanger on the way to the filler. That approach is faster and uses less floor space, but it only treats the liquid. Anything introduced during filling and seaming, from the container, the lid, or the fill environment, arrives in the sealed package untreated.
Tunnel pasteurization treats the finished package. Whatever is inside when the container is sealed receives the full thermal process, which is why it is the standard approach where post-fill contamination is the primary shelf life risk. It is also why the tunnel sits downstream of the seamer rather than upstream of the filler.
The tradeoff is footprint and dwell time. A tunnel is a large machine and product moves through it slowly compared to line speed elsewhere, which is why accumulation upstream and downstream of the tunnel is part of designing the line around it.
The paired piping visible here is the regeneration loop, carrying heat from the cooling zones forward to preheat incoming containers. It recovers up to 70% of thermal energy.
FAQ
Does a tunnel pasteurizer require a steam boiler?
No. CODI tunnels run on hot water, and there is more than one way to make it. Most CODI pasteurizers ship with gas-fired instant hot water, which means the tunnel carries its own heat source and the plant does not need steam capacity for it. If you already have sufficient steam, CODI can put it through a heat exchanger into the pasteurizer's hot water loop instead. Instant hot water usually makes the most sense when the pasteurizer is the only reason you would need to add or expand a steam system.
How does gas-fired instant hot water work on a tunnel pasteurizer?
Multiple commercial gas-fired water heaters run in parallel to feed the tunnel's hot water loop, with total capacity matched to the tunnel's thermal load. The heaters are modular, so capacity scales with tunnel size rather than being fixed to one unit. Natural gas and LP are both available. This is the most common configuration CODI ships.
Is electric heating available?
Electric immersion heating can be incorporated where an application calls for it, but CODI uses it as supplemental heat rather than the primary source on production tunnels. Gas-fired instant hot water or facility steam handles the main thermal load.
How much energy does CODI regeneration recover?
Up to 70% of thermal energy. On a tunnel running continuously, regeneration is the largest single operating cost lever in the machine, and it reduces demand on the heating utility and the cooling utility at the same time.
How fast can a CODI tunnel pasteurizer run?
50 to 600+ containers per minute for 12 oz cans. Actual throughput depends on container size, target PU, incoming product temperature, required discharge temperature, and the dwell time those conditions demand. Two lines running the same CPM can need very different tunnels.
What size tunnel will my line need?
Length follows from dwell time, and dwell time follows from target PU and line speed together. CODI tunnels run 15 to 50 ft of thermal zone length, measured without the infeed and discharge conveyance or blower sections, so plan floor space for more than the tunnel dimension alone. Belt widths are 2.5 ft and 5 ft. In practice, available floor space constrains the answer as often as the process does, which is why CODI engineers the zone layout and temperature curve around the space you have rather than quoting a fixed model.
How many thermal zones do I need?
CODI systems use 3 to 10 zones. More zones give finer control over the shape of the temperature curve, which matters most for glass and for highly carbonated product. The right count depends on your heating curve, hold time, cooling profile, line speed, and how much energy recovery you want.
What containers can a CODI tunnel pasteurizer handle?
Aluminum cans, glass bottles, PET, and other compatible packages. Belt width, rails, spray pressure, temperature ramp rate, and zone configuration are all engineered around the specific package. VFD-controlled spray pumps let water flow be dialed back for lightweight containers, and temperature transitions can be flattened to reduce thermal shock in glass.
Can CODI integrate a pasteurizer into an existing packaging line?
Yes. CODI builds custom conveyance, which is usually where integration actually succeeds or fails. The tunnel can be tied into existing fillers, conveyors, labelers, cartoners, and palletizers, and CODI engineers the infeed, discharge, accumulation, and controls required to make the transitions work at line speed.
Can CODI supply an entire pasteurized beverage line?
Yes. CODI manufactures depalletizers, container rinsers, conveyors, fillers and seamers, tunnel pasteurizers, dry-off systems, packaging equipment, and Flex Stack gantry palletizers. Machines can be purchased individually or engineered together as a complete line, with one supplier responsible for how they hand off to each other.
