Pasteurizer Tunnel
TUNNEL PASTEURIZER
Custom tunnel pasteurizer | post-fill pasteurization for cans and bottles | energy-efficient beverage pasteurization
CODI tunnel pasteurizers are custom-built thermal processing systems that deliver precise PU control for beverages in aluminum cans, glass bottles, and PET. We build each one around your PU requirements, line speed, container type, and available floor space. PLC-controlled zoning and variable belt speeds hold exact temperature. Optional regenerative thermal zones recover up to 70% of energy by redirecting heat from cooling containers to warming zones. Systems run 15 to 80+ feet long with 3 to 10+ zones, heated by steam, hot water, or electric immersion.
CODI tunnel pasteurizers are custom-built thermal processing systems that deliver precise PU control for beverages in aluminum cans, glass bottles, and PET. We build each one around your PU requirements, line speed, container type, and available floor space. PLC-controlled zoning and variable belt speeds hold exact temperature. Optional regenerative thermal zones recover up to 70% of energy by redirecting heat from cooling containers to warming zones. Systems run 15 to 80+ feet long with 3 to 10+ zones, heated by steam, hot water, or electric immersion.
PRODUCT FEATURES
Regenerative Energy Recovery
Don't pay to heat water twice. Our "Regen" zones capture heat from cooling bottles and transfer it to the warming zones. This drastically reduces boiler load and water usage, often paying for the efficiency upgrade in under 18 months.
Precision PU Control
Over-pasteurization kills flavor; under-pasteurization kills your brand. Our PLC-controlled zoning and variable belt speeds ensure every can hits the exact target PU—preventing "cooked" flavors in delicate IPAs or fermentation in sugary RTDs.
Sanitary "Open" Design
Microbes hide in shadows. We build with 304 Stainless Steel and feature full-length removable side panels and targeted spray headers. This ensures 100% spray coverage during operation and zero blind spots during CIP (Clean-in-Place).
Smart Water Management
Our active water filtration and cascading reservoir system keeps spray nozzles free of debris, reducing maintenance downtime and keeping water usage to an absolute minimum.
PRODUCT INFORMATION
50 to 600+ CPM
Water recirculation
Steam, Gas, Electric
CONTACT CODI FOR SPECIFIC TUNNEL PASTEURIZER SPECIFICATIONS
Certification
UL
Voltage
380-800 / 3 PH
200-240V / 3 PH
Heating Method
Navien LP
Navien NG
Instant HW
Steam NX
Zones
To 8
Hold Zones
Specify
Blower Dry Off
Yes/No
CPM
Specify
PU
Specify
Thermal Processing & Heating
Supports multiple heating methods to match plant utilities and ensure consistent thermal control.
Compatible with steam (shell & tube), boiler hot water, or electric immersion
Designed for stable, repeatable temperature control across the tunnel
Suitable for a wide range of beverage types and processing requirements
Zoned Thermal Control
Multi-zone design enables precise control of heating, pasteurization, and cooling stages.
Configurable from 3 to 10+ thermal zones
Dedicated stages for heat-up, hold, regeneration, and cool-down
Controlled temperature transitions protect product quality
Energy Efficiency & Regeneration
Engineered to reduce energy consumption while maintaining performance.
Regeneration system recaptures up to 70% of thermal energy
Standard on tunnels over 20 ft
Reduces overall utility demand and operating cost
Throughput & Scalability
Designed to scale with production requirements and line speeds.
Throughput from 50 to 600+ CPM (12 oz cans)
Configurable tunnel length and zone layout
Supports continuous, high-volume operation
Container Handling
Handles a range of container types while maintaining stability through the process.
Compatible with aluminum cans, glass bottles, and PET
Gentle conveyance through all zones
Supports multiple container formats on a single system
Line Integration
Built for straightforward integration into beverage packaging lines.
Configurable belt widths from 4’ to 12’
Standard 40” deck height with adjustable leveling
Positioned between filling and downstream packaging
Utility Requirements
Optimized for efficient operation with minimal facility demand.
Low compressed air consumption (~5 CFM @ 110 PSI)
Supports multiple heating infrastructures
Designed for long-duration continuous operation
Tunnel Pasteruization basics
Pasteurization is a thermal process used to stabilize beverages by controlling microbial activity and extending shelf life after filling. By carefully applying heat for a defined time and temperature, pasteurization protects product integrity while maintaining flavor, carbonation, and package quality. In modern beverage operations, pasteurization is applied after filling and sealing — ensuring the finished package is microbiologically stable before labeling, packing, and distribution.
A tunnel pasteurizer delivers consistent, measurable pasteurization across every container passing through the line. The process is quantified in Pasteurization Units (PUs), which express cumulative thermal exposure as a function of temperature and time. PU control is preferred over simple temperature control because it targets the process outcome — consistent microbial stability — regardless of changes in line speed, ambient conditions, or product temperature. Warmers and coolers address adjacent needs: reducing condensation for labeling, preventing thermal shock, and stabilizing product for downstream operations.
Containers enter the tunnel and pass through a series of temperature-controlled spray zones: pre-heat, heating, holding, and cooling. Hot water is applied through overhead spray nozzles in each zone. The time-temperature relationship is exponential — small increases in temperature dramatically reduce the time needed to achieve the same level of microbial control. This is expressed as: PU = t × 1.393^(T − 60), where 1 PU equals holding product at 60°C for one minute. Regenerative systems recapture heat from holding zones and transfer it to pre-heat zones, reducing energy demand by up to 60–70%.
Key variables when sizing a tunnel pasteurizer include target Pasteurization Units (determined by product acidity, alcohol content, and microbial profile), required throughput, available floor space, container type and size, heating method (steam, tank-based hot water, or on-demand hot water), and target product temperature at discharge. CODI engineers work through these variables with your team to develop an optimal temperature ramp curve for your specific beverage and production requirements.
Each CODI tunnel pasteurizer is engineered around your specific beverage and production requirements. We begin by working with your team to understand the product, target PUs, and line conditions — then configure the pasteurizer to deliver the required thermal load at your desired throughput. CODI's systems are constructed from 304 stainless steel and purpose-built for direct integration into packaging lines. Warmers and coolers in the CODI lineup address condensation control, label adhesion, and post-fill temperature management for any container type.
ACCESSORIES
FAQ
What is a pasteurization unit (PU) and how do I get it?
One PU equals holding product at 60 degrees C for one minute. The relationship between time and temperature is exponential rather than linear, expressed as PU = t x 1.393^(T - 60), so a small temperature increase sharply reduces the time required. Target PU depends on your product's acidity, alcohol content, and microbial profile. You will need to work with your local process authority to determine the PU for each product you wish to pasteurize. A good place to locate your process authority is the ADFO Directory. Once you have the PU, and some product details, CODI's engineers can recommend a suitable product configuration.
How much energy do regenerative zones, like the ones that CODI provides, actually recover?
Optional regenerative thermal zones capture heat from containers in the cooling zones and redirect it to the pre-heat zones, recovering up to 70% of energy. On a tunnel running continuously, that is the largest single operating cost lever available.
What size tunnel will my line need?
Systems range from 15 to more than 80 feet with 3 to more than 10 zones, covering 50 to 600+ CPM. Length follows from target PU and line speed together, since holding time at temperature sets the required dwell. Available floor space usually constrains the answer as much as the process does.
What heating methods are available?
Steam, gas, and electric, with specific options including Navien LP, Navien NG, instant hot water, and Steam NX. The choice follows your plant utilities. A blower dry off can be integrated at the discharge so containers leave dry and ready for labeling. Warming and cooling tunnels are covered on the pasteurizing category page.
