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CETOTEC
VINEGAR TECHNOLOGYSymposium Modena, Italy
May 21, 2016
Agenda
• About us
• Projects
• Processes
• Products
• A Family company
Founded by Sylvia Sellmer-Wilsberg and
Hans-Werner Wilsberg in 1996
• Research & Expertise
Cetotec has established itself as a Global leader in
vinegar technology - combined expertise in
microbiology, biotechnology, and mechanical
engineering
• Integrated technology and service
Fermenter, aerators, foam system, process control,
on-line alcohol measurement, microfiltration systems,
Consulting, engineering and training
CETOTEC.COM 3
About us
20 years of Vinegar Expertise
• Our Base
We are located in Bad Honnef, Germany
close to Cologne
• International reach
Cetotec’ s equipment has made it to each of the
world’s continent – we have installations in
China, Japan, US, South America, Australia,
Russia, Africa, and all over Europe.
CETOTEC.COM 4
About us
20 years of Vinegar Expertise
Agenda
• About us
• Projects
- Burg Group
- De Nigris
- Mendes Goncalves
• Processes
• Products
Some of our recent projects
Vinaigrerie Fuchs (Burg Group)
La Tremblade, France What does it take to build an industry-leading partnership ?
Flexibility and curiosity
• Together with Europe's leading alcohol vinegar producer Burg group,
we have pushed the boundaries of high-concentration vinegar
production
• Since almost 20 years De Burg and Cetotec are working in close
cooperation to develop solutions for the optimization of vinegar
production processes
• In cooperation with Burg group, we’re already working on producing
vinegar with 25 percent acidity
Acetificio M. De NigrisCaivano & San Donnino, ItalyCan tradition and innovation go hand in hand ?
Yes, and they must, as our partnership with DeNigris
shows
• San Donnino plant equipped in 2011 with new
fermentation and filtration equipment
• Key element is a Fermenter F600 with 60m³ working
volume
• New DeNigris plant in Caivano equipped with Cetotec
fermenters F600 and F250 in 2015
• The factory is almost completely automated –
visualization and remote control via computer
or smartphone
Mendes Gon�alvesGolega, PortugalCustomized technology and efficient fermenters for the
smallest production batches
• Mendes Gonçalves produces sauces, spice mixes and gourmet
vinegars from a variety of exotic ingredients
• Cetotec has provided Mendes Gonçalves with lab equipment &
Fermenters (Fermenter SF6, SF600 )
• They are using the ACETOSCAN for measurement of alcohol and
acidity in less than one minute
Agenda
• About us
• Projects
• Processes
– Flow sheet semi-batch process
– Flow sheet fed-batch process
• Products
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Semi-batch processfor wine, cider and specialty vinegars
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Defined
mixture of
raw material
(6-14%
alcohol) and
nutrients
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��������The Semi-Batch-Process is a
fermentation process at which
1/3 of the fermentation liquid is
discharged when reaching a
residual alcohol content of
~0,3% and replaced by
charging fresh mash.
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Flow-sheet Semi-Batch process
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Fed-batch process (for alcohol vinegar with more than 20% acidity)
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The Fed-Batch-Process is a
fermentation process at which
2/3 of the fermentation liquid is
discharged when reaching a
residual alcohol content of
~0,3% and replaced by slowly
recharging the respective
ingredients.
During the ongoing batch,
alcohol and nutrients are
apportioned in a certain
quantity so that the total
concentration increases slowly.
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Nutrient mixing /
dosing (nutrients
in concentrated
vinegar 15-20%)
Water
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Agenda
• About us
• Projects
• Processes
• Products
– Installations
• Fermenter
• Aerator
• Foam system
Type
Volume
[l]
Diameter
[m]
Total height
[m]
Vinegar
[l10% / year]
SF6 6 0,16 0,57 1000
SF15 15 0,22 0,78 2000
SF25 25 0,27 0,99 4 000
SF50 50 0,34 1,07 8 000
SF100 100 0,43 1,31 16 000
SF150 150 0,50 1,47 24 000
SF200 200 0,55 1,67 31 000
SF300 300 0,64 1,89 47 000
SF600 600 0,85 2,02 94 000
SF1000 1000 1,05 2,16 157 000
Lab Fermenter - ranging from 6 to 1.000 l working volume -
Type
Volume
[l]
Diameter
[m]
Total height
[m]
Vinegar
[l 10% /
year]
F30 3000 1,50 3,2 470.000
F60 6000 1,85 4,2 940.000
F90 9000 2,15 4,6 1.420.000
F120 12000 2,40 5,0 1.900.000
F200 20000 2,80 5,8 3.100.000
F250 25000 2,85 7,4 4.200.000
F300 30000 3,20 7,7 5.000.000
F400 40000 3,55 8,4 6.600.000
F500 50000 3,80 9,2 8.200.000
F600 60000 4,00 9,7 9.900.000
F750 75000 4,35 10,1 12.300.000
F850 85000 4,65 10,1 15.400.000
F1100 110000 4,80 11,2 21.000.000
Industrial Fermenter - ranging from 3 to 110 m³ working volume -
• High quality stainless steel tank with cooling coil
inside
• Aerator with highest possible oxygen enrichment
and optimal mixing results of fermentation liquid
• Efficient and energy-saving foam system
• Proven vinegar process control using SIEMENS
PLC and touch panel
• Alcocontrol / Acetoline for the on-line measurement
• Reliable, stainless steel charge and discharge
pumps
Fermenter components
• High quality stainless steel tank with cooling coil
inside
• Aerator with highest possible oxygen enrichment
• Efficient and energy-saving foam system
• Proven vinegar process control using SIEMENS
PLC and touch panel
• Alcocontrol / Acetoline for the on-line
measurement
• Reliable, stainless steel charge and discharge
pumps
Fermenter components
• High quality stainless steel tank with cooling coil
inside
• Aerator with highest possible oxygen enrichment
• Energy-saving foam system
• Proven vinegar process control using SIEMENS
PLC and touch panel
• Alcocontrol / Acetoline for the on-line
measurement
• Reliable, stainless steel charge and discharge
pumps
Fermenter components
• High quality stainless steel tank with cooling coil
inside
• Aerator with highest possible oxygen enrichment
• Energy-saving foam system
• Proven vinegar process control using SIEMENS
PLC and touch panel
• Alcocontrol / Acetoline for the on-line
measurement
• Reliable, stainless steel charge and discharge
pumps
Fermenter components
• High quality stainless steel tank with cooling coil
inside
• Aerator with highest possible oxygen enrichment
• Energy-saving foam system
• Proven vinegar process control using SIEMENS
PLC and touch panel
• Alcocontrol / Acetoline for the on-line alcohol
measurement
• Reliable, stainless steel charge and discharge
pumps
Fermenter components
• High quality stainless steel tank with cooling coil
inside
• Aerator with highest possible oxygen enrichment
• Energy-saving foam system
• Proven vinegar process control using SIEMENS
PLC and touch panel
• Alcocontrol / Acetoline for the on-line
measurement
• Reliable, stainless steel charge and discharge
pumps
Fermenter components
• Customized design for nearly every fermenter size
• Hydrodynamic optimized rotor and stator
design to give a maximum mass transfer and best
mixing results between fermentation broth, air and
substrates.
• Intense mixing of alcohol and water
• Low energy consumption due to use of energy
saving motors (IE3)
Aerator
exhaust air
foam collecting
pipe
foam
pump
• Foam in the fermentation of vinegar is built
up by dead cells, their metabolic products
and insoluble extracts from the raw materials
• All these substances are undesired
in the final product and have to be removed
from the fermentation liquid
• The Cetotec foam system performs
exactly this task
Foam system
Agenda
• Introduction
• Processes
• Products
– Installations
– Process measuring & control
• On-line alcohol measurement
• Process control for fermenter
• Visualisation
• Now ethanol and acetic acid can
be measured simultaneously and
fully automated during the
production process
• Measurements can be integrated
to a Siemens PLC for precise
production control
• Up to now it has been possible to
measure only the alcohol
concentration on-line
• Acetic acid could only be measured
by taking samples and testing them
in the laboratory
• Calibration was required more often
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On-line alcohol measurement
• Measurement of the alcohol concentration
in the fermenter
• As consumables only the polymer
membrane is needed
• Long term stability
• Easy installation – only a sensor port is
needed
• Simple to calibrate and operate
• Short response time, high accuracy
Alcocontrol system
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• The measurement functionality is based on NIR
spectroscopy
• Ethanol and acetic acid show specific
“spectral fingerprints“, which is generated by the
adsorption of the penetrating light and thereby
weakened in a characteristic way
• These fingerprints can be used to identify
substances and to quantify the concentration
in a mixture of substances without any
cross-sensitivity
Acetoline - on-line measurement of
acetic acid & alcohol
• Simultaneous measurement of alcohol and acetic acid
concentration in less than 1 minute
• Easy installation beside the fermenter
• Can be integrated to a Siemens PLC
for precise production control
• Automated sampling
• High precision
Measurement range: 0 – 20% Alcohol; 0 – 25% Acetic acid
Acetoline - on-line measurement of
acetic acid & alcohol
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Process control for wine vinegar
using the semi-batch process
The Ceto-SEMI fermentation software
with Siemens PLC controller and
user-friendly colour touch panel controls
the activation of motors, pumps, sensors
and the actual process control.
Operating the software via the touch
panel is comprehensive and logically
structured thus can be mastered efficiently
in a very short time.
Visualisation
• Process Software, being specially designed
for vinegar fermentation
• Fermenter is displayed with filling level,
temperature, air volume, alcohol content, etc.
• With the help of a modern and customized
visualization software, it is possible to directly
monitor and control the PLC via a PC or any
other electronic visualization device
• Several fermenters or filtration systems can
be integrated and therefore centrally
monitored and controlled.
Agenda
• Introduction
• Processes
• Products
– Installations
– Process measuring & control
– Filtration
• Filtration systems
• Filtration modules
Filtration systems
• The filtration step following the storage is
essential in order to produce a micro-
biologically stable product.
• Micro-porous hollow fibre membranes are
used with 0,2 µm
• Our cross-flow filtration systems range from
small plants with capacities of 250 l/h up to
fully automated large-scale plants with a
capacity of 3.200 l/h
Type # Modules Surface
CB 01 1 6,3m²
CB 02 2 12,6m²
CB 04 4 25,2m²
CB 06 6 37,8m²
CB 08 8 50,4m²
Filtration systems - Advantages
• One compact system
• Fully automatic PLC process control
• No consumables are needed
(except for cleaning agents)
• Filtration modules especially designed
for vinegar filtration
• Automatic back-flushing system to ensure
a proper flow and pressure
Agenda
• Introduction
• Processes
• Products
– Installations
– Process measuring & control
– Filtration
– Lab equipment
Acetoscan
• Simultaneous measurement of
ethanol and acetic acid concentration
in less than 1 minute
• Easy installation
• Analysis without any sample
preparation
• No consumables or dangerous
additives necessary
• High accuracy & reproducible results
Measurement range: 0 – 20% Alcohol; 0 – 25% Acetic acid
THANK YOU
FOR
YOUR ATTENTION !
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