GEA TDS Process Technology for the Food Industry

GEA Process Engineeringengineering for a better world

GEA TDS ...

GEA TDS delivers the necessary know-how for the design and manufacture of hygienic, aseptic and sterile plant for the production of liquid and paste-like products. With short reaction times and experts present on site we provide worldwide customer support for project construction, maintenance services and, of course, after-sales programs. Our experienced and competent teams provide technical service tailored to your needs.

Your products for the food industry: ■ Margarine, fats and oils ■ Tomato ketchup, mayonnaise, mustard ■ Red sauces, dressings, marinades ■ Egg products ■ Soya liquid products ■ Fruits, jam ■ Convenience food, soups ■ Liquid food additions

… is established internationally as a specialist for technically and economically optimized process technology for the treatment of food, milk and juice products. 150 years of tradition and experience in engineering of food and dairy plant are the basis.

■ Bakery products, liquid yeast ■ Honey ■ Gelatine ■ Ice cream

Our processing technology for the food industry: ■ Complete process lines ■ Valves and components ■ Plate heat exchangers ■ Tubular heat exchangers ■ UHT plant ■ Membrane filtration ■ Homogenization ■ Separators ■ Evaporation systems ■ Deaeration technology ■ Mixing and weighing ■ CIP systems ■ Process automation and integration ■ Tank farm equipment ■ Engineering, assembly and service

Sauce processing plant

Tubular heat exchanger VARITUBE® Cooling plant

UHT plant / deaeration / homogenization

Process lines from a single source for hygiene and efficiency.

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Process Technology for the Food Industry

Whether your project is a new plant or an extension, conversion or modernization of an existing process plant, GEA TDS engineers, with their complex know-how, are there to back you up with excellent service.

Process Engineering

From isometric drawings to pipe class specifications, from detailed engineering to project management, GEA TDS takescharge of the projects on site, on the client’s premises or in the GEA TDS technology center. GEA TDS is part of the Process Engineering sector of the international GEA Group. This provides access to a variety of components and units produced by members in that group, which thus can be integrated to create high-quality processing systems. The use of modern CAE tools for detail engineering is common throughout the corporation.

For project planning and engineering the main focus points are: ■ Preliminary design ■ Support in approval planning ■ Preliminary planning and layouts ■ Selection/dimensioning of process equipment ■ Preparation of tender documents for process plant

Detailed engineering ■ Layout planning and detailed coordination/clarification ■ Design of pipe layout and instrumentation ■ Arrangement of components ■ Calculation of material requirements and technical

specifications ■ Definition of interfaces ■ Configuration and dimensioning of instrumentation and

control equipment ■ Technical description of the processes ■ Quality assurance and quality control ■ Monitoring of time schedules ■ Cost control ■ Supervision of construction and installation work ■ Commissioning of plant components ■ Supervision of commissioning ■ Technical support for production ■ Process optimization ■ Documentation

Tank farm Fruit mixing station Pasteurizing unit

Central product inflow from the top via an adjustable cascade valve

Concept map

Central and gentle product inflow from the bottom over a cone

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Herbal & fruit

preparations

Powder dosing

Buffer

Liquid ingredients Mixing module

Mixing module

Heating plant

Cooler

Homogenization

Filling

CIP plant

Fruit crushing and defrost

Process steps:1. Intake of water and paste-like basic

ingredients (tomato puree, mustard, liquid seasoning) and powdery basic ingredients (starch, spices, binding agents)

2. Blending and homogenization3. Heating the sauces and addition of

pieces of vegetables (peppers, sweet corn, mushrooms)

4. Buffering the prepared sauces5. CIP cleaning

The plant is processing batches from300 – 1,500 l within 20 – 30 min., withtemperatures between 15 and 90 °C.

The ideal solution for the economical production of smooth sauces and sauces containing particles in the delicatessen industy.

Sauce Processing Plant

Plant description:Insulated stainless steel tanks are filled with a preselected quantity of water via a recipe management system. When the specified quantity of water has been supplied, the basic paste-like and powdery ingredients are introduced into the circulating water stream by a blending table, a self-priming centrifugal pump and a homogenizing pump. In the homogenizing pump, the components are finely blended in the shear gap between rotor and stator, thus preventing agglomeration, lump formation and cross linking. The homogeneous blend is circulated until the entire supply of basic ingredients on the blending table has been introduced into the sauce tank. Homogeneity of the sauce, which at this stage is still cold, is maintained by agitators. A positive-displacement pump transfers the tank contents to a VARITUBE® M tubular heat exchanger by GEA TDS.

The tubular heat exchanger type M consists of several inner tubes surrounded by hot water, which flows in the shell. The tube bundles are mounted in a “floating” manner so that the complete bundles can be removed for inspection purposes. The modules of the tubular heat exchanger also contain specially designed flow devices which keep the heat exchanger free from deposits when processing products containing fibres or particles. Once the specified heating temperature has been reached and cold vegetables have been added (optional), the prepared sauce is automatically kept warm. A push-out program conveys the prepared sauce to the buffer tanks or the filling system.

Stirring unit Powder entry Tubular heat exchanger

Mixing processes are necessary when: ■ Dry substances or paste-like media are

to be added to a liquid phase. ■ Several liquid phases or paste media

are to be blended to form a final product.

■ Products are made from different components in a batch process.

■ Basic products are varied by adding ingredients prior to filling.

Mixing Plant

Some products require these processes to run under ultra-clean and aseptic conditions. Sometimes additional thermal process steps are required during the mixing phase. The use of volume and mass flow meters or weighing systems allows mixing processes to be semi- or fully automated and recipe-controlled.

By the way, we are supplying mixing plant as ready-to-connect pre-assembled units.

Powder mixing stationIn-line dosing

With GEA TDS mixing plant the mixing of components for the production of dairy products is made easy, whether they are liquid, paste-like, or powdery. GEA TDS plans and delivers mixing plant for a variety of processes.

Basic layout scheme, process tank weighing system

BATCH FORMULA™ mixer

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Filling and dosing valves

Motor with variable speed

Jackated shell

Heater/cooler

Condensate

Ice water

Scraper agitator

Decentral weighing control

Load cells

CIP booster pump

Tank bottom valve

Product pump

Steam

Ice water

Compact CIP system

Orbital cleaner Rotating jet cleaner Orbital cleaner Roating spray head

Single-use CIP system with ECOCIP

CIP (cleaning in-place) is the commonly used method for plant cleaning during the production process where hygiene is, of course, of paramount importance. Using a modern CIP system enables optimum quality assurance and increases product quality. GEA TDS is always striving to find the perfect balance of chemicals, mechanics, temperature and residence time, with additional focus on environmental protection and downtimes.

CIP recovery systemsThese CIP systems consist of various tanks for drinking water, cleaning solution and return water. The system or tank size is adjusted to the required cleaning procedures. The systems are technically equipped and configured to meet the cleaning objectives defined.

Single-use cleaning system with ECOCIPThe system consists of a detergent tank for the ready-made cleaning solution, pre-assembled on a base frame. The cleaning solution is circulated and heated up to the operating temperature. Conductivity measurement and in-line concentrate metering ensure that the required amount of detergent is added. The detergent flow rates are adjusted by the cleaning program.

The diversity of products and processes calls for different methods for cleaning process plant.

CIP Systems

VARICIPIn the VARICIP automation system, cleaning objectives are translated into recipes.

The recipes contain target-dependent parameters: ■ Start-enabling and cleaning-monitoring tasks ■ Conductivity limit values ■ Temperature limit values ■ Turbidity-monitoring tasks ■ Flow-rate set points ■ Rinsing interval chains

as well as step-dependent parameters: ■ Step function as a selection of configured steps ■ Run and monitoring times

These blocks can be used to configure cleaning sequences freely. A water blocker considerably reduces the water consumption during CIP. Trend curves are recorded to document the cleaning process. An event log in table form is created as a file for quality management purposes.

Detergent concentrate storage A CIP station needs detergents. As a certified specialist company in accordance with § 19i WHG (federal water resources law) GEA TDS is authorized to install concentrate storage tanks that conform to all legal and environmental requirements. The company has extensive experience in this field for designing concentrate draw-off and exhaust-air cleaning and when calculating caustic, acid and additive metering rates – this also includes the generation of the necessary balance sheets.

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Depending on the product to be treated, product quality and required effi ciency, three different types of UHT processes are at your disposal.

UHT Plant for Aseptic Product Treatment

UHT plant, type IThis type of product treatment plant works according to the indirect heating principle. Its great benefit is very high production safety. This process technology has proved successful for many years. UHT plant enable optimum flow conditions which produce good deliver quality and high efficiency, with a heat recovery rate of up to 90 percent.

UHT plant, type PIn comparison with the indirect UHT plant type I, the UHT plant type P is widely based on the same process technology but uses tubular heat exchangers. This makes the indirect heat transfer circuit between product to be heated and product to be cooled dispensable. The advantage is that the plant type P achieves even higher efficiency and improves product quality without the need of expanding the heat exchange surface.

UHT plant, type DThe direct heating method used in this type of UHT plant offers a very high product quality. The integral steam injector or infusion system and a flash cooler provide very short dwelling times in the temperature intensive zones.

UHT plant, type P

Membrane fi ltration unit

Membrane filtration is specifically used for mass transfer at low temperatures and/or ambient temperatures in special applications.

Reverse osmosis, nanofi ltration, ultra-fi ltration and microfi ltration

Membrane Filtration for Liquid Separation

These methods are used to separate liquid components or to concentrate solids without thermal or mechanical treatment. The filtration plant are equipped with membranes made of organic polymer or ceramics.

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The VARITUBE® tubular heat exchanger is specifi cally designed for the thermal treatment of low- to high-vis cosity products as well as products containing particles, pulp and fi bres.

VARITUBE® Tubular Heat Exchangers

The VARITUBE® system is mainly used in heating, cooling, and aseptic systems.

Application-oriented technology According to the required production capacity and the physical properties of the product, the most appropriate design can be selected from numerous versions of our VARITUBE® heat exchangers. Depending on the area of application, customized designs can also be developed and installed. Our VARITUBE® range is used for many products that need to be heated, cooled, pasteurized, and UHT treated.

Technical concept The VARITUBE® tubular heat exchanger is a straight-tube heat exchanger with one or more inner tubes situated in a shell. The inner tubes can either be straight or corrugated. Corrugation and the optimized product/media volume ratio increase the thermal efficiency of our heat exchangers.

Their modular design allows for easy installation and easy extensions or future modifications.

VARITUBE® modules are TÜV-approved and manufacturedfrom 1.4404/1.4571 (AISI 316 L/Ti) material. A sanitary sealing system and product flow paths without “dead zones” ensure highest production reliability and product quality. Easy maintenance and inspection and low service costs are further features of our heat exchangers.

VARITUBE® S – Singletube for indirect heat treatment of products containing pieces. Product recovery is possible using pigging technology. This is a tubular heat exchanger in which the product flows in one straight inner tube, while a heat-carrying medium flows around it in an external shell. The inner tube is mounted in a fixed or floating manner to compensate for the different thermal expansions caused by high temperature differences between shell and inner tube.

VARITUBE® M – Multitube with indirect heat exchange, which is also suitable for products containing particles of approx. 18 mm diameter. The product flows in several straight inner tubes while a heat-carrying medium flows around it in a shell. The inner tube is mounted in a fixed or floating manner to compensate for the different thermal expansions caused by high temperature differences between shell and inner tube.

Further characteristics of VARITUBE® S and M ■ Modular design with 2 or 4 modules ■ Fixed or removable inner bundle ■ Straight or corrugated inner tubes ■ Lengths of 3 or 6 m ■ EHEDG approved and certified

VARITUBE® S and M Straight and corrugated inner tubes

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VARITUBE® P – used for the direct product/product heat recovery with smooth, fibre-containing and viscous products. In this tubular heat exchanger the product is guided through several straight inner tubes surrounded by the same product, which flows in a counter-current direction in the shell. The inner tubes are mounted in a floating manner and can be removed as a complete bundle for inspecting the product flow path.

VARITUBE® SK – a specially designed flow device that keeps the heat exchanger free from deposits – it processes products containing fibres with a length of up to 30 mm – and to enable an even distribution of the product to all tubes.

This heat exchanger is available in an M version (VARITUBE® M-SK) and in a P version (VARITUBE® P-SK).

Functional principle Flow devices installed on the bottom plate provide additional, jet-type acceleration of the product in the reducer at the connection bend.

The flow breaks at the outside of the displacement device and generates a transverse flow directly in front of the tube bottom plate. The transverse flow enables that no fibres collect on the tube bottom plate. Much longer production cycles are thus achieved and furthermore the efficiency will be increased.

VARITUBE® HS – Multitube with indirect heat exchange, suitable mainly for hot water generation and heating of CIP media for high thermal performance and volume flow rates of up to 60 m3/h. This tubular heat exchanger features product guiding in several inner tubes which are bent around 180°.

The heat-carrying medium flows in the surrounding shell. This design allows for compensation of the different thermal expansions between inner bundle and shell, which could be caused by high temperature differences.

VARITUBE® E – Multitube with indirect heat exchange, suitable mainly for hot water generation and heating of CIP media for medium thermal outputs and volume flow rates of up to 165 m3/h.

This tubular heat exchanger guides the product through several straight inner pipes surrounded by a carrier medium in a shell. The inner tube is mounted in a floating manner to compensate for the different thermal expansions caused by high temperature differences between shell and inner tube.

VARITUBE® SK

VARITUBE® HS

VARITUBE® E

VARITUBE® P

VARITUBE® SK flow simulation

Our heat exchangers are at the heart of all process plant. Based on more than 70 years of experience, our heat exchangers meet the highest demands with regard to performance and hygiene.

Plate Heat Exchangers

Their extremely compact design enables the plate heat exchangers to fulfill de manding thermal tasks on a relatively small floor space. The modular design of the system allows easy capacity increase or reduction. Easy access for maintenance and inspection is also guaranteed. In our systems we use glue-free seals, a decisive advantage for fast seal replacement and shortest downtimes.

VARITHERM®, NT and FREEFLOW N – These three different plate types enable us to meet the specific requirements of any process application. Multiple plate sizes and embossed profiles provide an ideal combination of efficient heat transfer and gentle treatment for different types of products with different viscosities.

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Type VARITHERM® – VARITHERM® plates are used for the thermal treatment of products with low and high viscosities.

You can choose between three types of heat exchanger plates with different embossed profiles:

■ Plate type H with horizontal chevron pattern for high thermal efficiency

■ Plate type V with vertical chevron pattern for lower pressure drops

■ Plates type M and P with V-shaped chevron pattern for highest differential pressure resistance

Type NT – High-performance plates with optimized wave flow pattern (OptiWave). A wide range of possible sizes and shapes result in a perfect, tailor-made design to fulfill exact operating requirements.

Type FREEFLOW N – A plate with horizontal washboard profile. Vertical caterpillar-shaped reinforcing fins channel the product flow and are continued at the top and bottom as flow distributors directed towards the inlet or outlet. For products containing pieces with a diameter of up to 4 mm and operating pressures of up to 10 bar, the Freeflow N plate is the right choice.

Further characteristics of GEA TDS plate heat exchangers ■ Efficient heat transfer, i.e. small heat exchange area and thus

allowing for low investment costs ■ High degree of heat recovery resulting in low energy costs ■ Low space requirements due to a compact assembly

Type H Type V

Type NT

Type M/P

Type FREEFLOW N

HomogenizerNanoValve™

Homogenization

PrincipleThe product passes the high-pressure piston pump, is then pressurized andre-expands in the homogenizing valve. The associated mechanical energyfed into the product causes the desired product properties and leads to long-term physical stability.

Many products reach optimum quality after single-stage homogenization. Those products containing slow-acting emulsifiers or high-fat products are homogenized in two stages. Products with limited emulsifier/fat ratio are homogenized twice with a lower working pressure. Often the homogenizing follows after the heat treatment under aseptic conditions in order to cut heat-induced fat-protein aggregates.

NanoValve™This homogenizing valve, patented worldwide, is the result of many years of experience in the homogenizing technology. It achieves much finer droplet or particle sizes compared to standard valves at the same homogenizing pressure. Therefore the desired quality can be reached with lower energy consumption. The optimized flow in the valve gap minimizes the wear and tear of all parts as well as the noise level of the machine. The NanoValve™ is also available in aseptic version.

We offer high-quality homogenizing technology for all applications up to a pressure of 1500 bar and flow rates from 10 l/h to 60,000 l/h in different variants and configurations.

Homogenization is an important step in processing dairy products, liquid foods and beverages. It leads to increased physical product stability, prolonged shelf life, and improved taste, color and consistence. Homogenized products improve digestibility. Due to homogenization the amount of product additives can be reduced.

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Assembly and After Sales

Our After Sales program includes continuous support service; taking care of service and maintenance directly after hand-over of the plant.

GEA TDS, as a matter of course, undertakes the task of assembling entire plants. A comprehensive range of further services is available throughout the entire service life of your plant, all designed to achieve maximum productivity and economic efficiency.

Customer support also includes defined maintenance and individual inspection agreements to ensure fault-free and reliable operation and to keep your plant running efficiently for years.

Demounting work prior to leakage testing On-site documentation of tasks performed

Quality assurance and increased productivity drive the steadily increasing automation of plant and production processes. The advantages are obvious: labor and production downtimes are reduced and operator error is safely ruled out. Plant are upgraded so that all essential parameters relevant for the production processes are automatically controlled, monitored and documented.

Process Automationand Integration

GEA TDS offers a wide spectrum of innovative process automation systemsand services that range from providing electronic process control to integrated, company-wide network systems with corresponding MES (Manufacturing Excecution System). We achieve this progress for you using proven modules and technologies and following inter-national standards (e.g. ISA-S88, ISA-S95).

To adapt existing production plant to new generations of automation systems (e.g. when replacing the visualization system or upgrading from S5 to S7) migration strategies will be developed for you that allow safe conversion while production continues to run.

We deliver for the MES level database-based applications for quality assurance, increase in productivity, batch tracking, and verification.

Operation and process visualizationAll operator interfaces are designed with logical menu structures that allow intuitive operation of the plant. The operator is comprehensively informed at a glance and guided progressively through the system.

Documentation and process optimizationThe supervisory control system allows operators to record measured values and switch status, thus creating the necessary transparency for process optimization.

Recording of measured data is supplemented by a database- supported event log with practice-oriented evaluation features. This audit trail allows the tracking of individual batches or an entire production.

Reporting and batch tracking The process data is transferred online to an SQL database, extended with powerful evaluation tools:

■ The report generator can be customized so you can configure your own application-oriented reports.

■ Batch tracking in graphical or tabular form helps you to keep track of your products in accordance with the EU regulation 178/2002. The standardized approach allows you to introduce a batch tracking system in manageable steps at a known cost.

Automated process plant

Control center Batch tracking

Process report with GANT chart Process visualization

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GEA Process Engineering

GEA TDS GmbH

Voss-Strasse 11/13, 31157 Sarstedt, GermanyTel. +49 5066 990-0

Am Industriepark 2–10, 21514 Büchen, GermanyTel. +49 4155 49-0

Kruppstrasse 3, 48683 Ahaus, GermanyTel. +49 2561 8602-0

geatds@gea.com, www.gea.com

GEA Group is a global engineering company with multi-billion euro sales and operations in more than

50 countries. Founded in 1881, the company is one of the largest providers of innovative equipment and

process technology. GEA Group is listed in the STOXX® Europe 600 Index.

We live our values.Excellence • Passion • Integrity • Responsibility • GEA-versity