GEA Slicing Guide

engineering for a better world

Content

ABOUT GEA 3

OUR HERITAGE IN SLICING, LOADING AND PACKAGING 4

AN INTRODUCTION TO SLICING 5

SLICED PRODUCTS 7

PRODUCT PRESENTATION 11

PORTION PRESENTATION CHARACTERISTICS 12

PRINCIPLES OF SLICING 16

PRODUCT PREPARATION 18

OPTIMAL PRODUCT TEMPERATURE 20

CHALLENGES OF SLICING 21

SELECTING THE RIGHT BLADE SHAPE 22

SELECTING THE IDEAL TOOTHING PROFILE 25

BLADE CHARACTERISTICS 26

FLEXIBILITY VERSUS CAPACITY 28

GEA SLICER RANGE 31

GEA LINE COMPETENCE 40

ADDITIONAL EQUIPMENT 42

ADD-ON OPTIONS 45

LOADING DEVICE 47

A-TO-Z OF SLICING TERMINOLOGY 50

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2

ABOUT GEA

GEA is one of the largest suppliers of process technology for the food industry and for awide range of other industries. As an international technology group, the company focuseson world-leading engineering, equipment and components for sophisticated productionprocesses.

GEA takes you forward with performance-focused solutions, from single machines to completeproduction lines for the preparation, marination, processing, slicing and packaging of primarily meat,poultry, fish, seafood, confectionery, lettuce, fresh and frozen vegetables and cheese-basedproducts. Our equipment helps you meet today’s operational challenges such as product variety,process flexibility, uptime, reducing the cost per kilogram and per pack, food safety and theenvironment. From standard plant systems to customized solutions, all GEA food technology isdesigned to meet optimum hygiene and quality standards, while operating efficiently and sustainably.Our technical expertise is complemented by project management, planning and cost control servicesto help our customers achieve flexible and cost-effective food production.

3

OUR HERITAGE IN SLICING, LOADING AND PACKAGING

It all began in 1953, when Herbert Jacobowitz and Otto Koetzsch started

a factory in Kempten, Germany that was later became Dixie Union. It

started with the first semi-automatic thermoformers in the fifties, slicers in

the sixties and packaging materials in the seventies. In particular, the

multi-faceted slicer family has proven itself for over 50 years with entry-

level devices, as well as mid-range and high performance solutions for

customers worldwide.

Milestones include the high-speed Dixie EuroSlicer, Dixie UniSlicer and NovaSlicer, followed by theMegaSlicer. The Evolution packaging machine was a well-established worldwide success because ofits uncompromising reliability and safe machine design. After joining Convenience Food Systems(CFS) in 2000, the high-speed, high capacity GigaSlicer slicing machine was introduced - a benchmarkin the industry to this date. Vast growth of the Slicers activity led to the commissioning of a brand new,state-of-the art production facility in Kempten in 2006. The GEA Group acquired the company in2011. Further developments and technical innovations lead to the introduction of the GEA DualSlicerin 2013.

Nowadays, GEA offers a complete portfolio of equipment, systems and solutions for the preparation,marination, processing, slicing and packaging through to the handling of the finished packaging.Fully automated production lines with integrated automatic loading continually prove themselves in avariety of applications. In addition to the line solutions, the highly flexible Delta robot-based systemsare also part of the loading portfolio. GEA contributes to its customers’ success with technologies thatmaximize product utilization, optimize output, enhance product safety with hygienic machine designand increase operational flexibility. By ongoing innovations, GEA continuously pushes back the limitsof feasibility.

This guide presents an introduction to slicing and loading technology made by GEA.

4

AN INTRODUCTION TO SLICING

Mechanized food slicing first started around 1900, although the last 60

years have seen the most progress in industrial machines to slice meat and

cheese. As the retail food industry moved from specialist butcher’s and

cheese shops to supermarkets, the emphasis shifted from smaller slicers at

the point-of-sale to industrial slicers for pre-packaged portions. GEA’s

slicers and packaging machines serve this segment, where consumers

continually change the way they view, interact with and discard

packaging.

Five trends can be identified in today's market:

1. SustainabilityAwareness of global environmental issues is influencing buying habits accordingly and consumerslook for signs on packaging that manufacturers have a green conscience. Sustainability is no longer anoptional add-on, it is essential future business planning for the packaging industry. The completestory of a product is important in purchasing decisions - where does it come from, how was it made,what are its recycling credentials?

2. Healthy livingThe health and wellness sector is a key packaging industry trend, reflecting the public’s desire tounderstand what is and isn't good. Consumer packaging displays health credentials of the productboth quickly and concisely allowing consumers to make informed choices. Regulations often stipulatehow this information must be displayed, and packaging must balance these needs.

3. ConvenienceBusy lifestyles mean that consumers look for ease of use and convenient transportation frompackaging. Smaller portions (for one- and two-person households), easily disposable, easily openedand reclosable packs are examples. Increased visibility of the product also influences buying decisions.

4. AuthenticityThere is greater demand for transparency from manufacturers. Origins of products need to betraceable back throughout the supply chain to their source. Advertising on packaging increasescredibility and authenticity, and reassures consumers of high quality and honest produce.

5. Cost consciousnessPeople don't want to pay any more than they have to for packaged food, so cost remains a key markettrend. Consumers increasingly purchase a product when they are running out of rather than stockingup in a 'pantry-loading' approach. Consequently, smaller and easier-to-carry types of packaging isinteresting for money-conscious, last-minute shoppers.

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Our world is changing rapidly

Consumer behaviorSmaller households require smaller pack sizes, while busier lifestyles pose a need for both convenienceand quality. Next to this, environmental footprint is highly monitored and represents a key factor forpackaging innovation and development.

Retail requirementsRetailers and discount supermarkets demand just-in-time delivery of fresh natural and processedproducts in a very wide range of pack sizes, and suppliers must meet the highest possible standards interms of quality and product presentation. As a result, manufacturers strive to improve theproductivity and adaptability of their production and packaging processes in order to enhance theirposition in the market. Considerations such as increasing the range of packaging formats and offeringa variety of portion sizes are two of the ways they differentiate their products. To help them do this,GEA develops slicing and packaging machines that give manufacturers the flexibility they need.Important parameters here are reducing tooling times (for new packages) and offering more slicedproduct presentation formats. And because cost is always a key consideration, factors like on-weightportions and low give-away (waste) are drivers in product development.

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SLICED PRODUCTS

GEA slicers are primarily used for pork, beef, poultry and cheese. Some of

these products have a natural shape like bacon, while others are

processed as round, square or rectangular logs or blocks, such as cheese.

Below is an overview of the main categories of sliced food products.

Pork

Cooked hamCooked ham is made from pork that has beenbrine cured in a liquid solution of water, nitrite,curing salt and spices. After curing, the still rawmeat is placed in a round, oval or angular moldand is heat treated in hot water, steam or hot air.

BaconBacon is made from pork belly, which has beenpreserved (cured) in a salt solution or brine. Aftercuring and trimming, the bacon is smoked usingwood chippings. Bacon that has been cured andsmoked needs to be frozen or refrigerated untileaten.

Raw hamThe first step for making raw ham is dry curingwhere the surface is rubbed in with nitrite curingsalt (further spices and herbs can be added to thesalt). After salting, the ham is left to rest for a fewweeks in climatic rooms. The conditions set in theclimatic rooms determine how mature, firm anddry the ham is to be.

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Cooked sausageCooked sausages such as mortadela areproduced from blanched or pre-cooded meat.Besides meat and back fat, certain other meatraw materials such as liver, tongue and blood canbe used. The pre-cooked material is ground,salted and spiced and cooked again after beingput into natural or artificial sausage skins.

Beef

Raw beefThe raw beef typically used for carpaccio is beefsirloin. It is partially frozen before slicing to allowvery thin slices.

Dried beefDried beef such as bresaola is air dried, saltedbeef that has been aged over two or threemonths until it becomes hard and its colour turnsdark red, almost purple. It is made from thecow's rear leg, lean and tender, with a sweet,musty smell.

Dry / fermented sausageDry / fermented sausage is a cured sausage,consisting of fermented and air-dried meat,typically beef or pork. Countries and regionsacross Europe make their own traditionalvarieties.

8

Poultry

Cooked poultry ham (turkey bacon)Made from poultry that has been processed in aliquid solution (water, nitrite curing salt andspice). After this so-called curing, the still rawmeat is placed in a round, oval or angular moldand is heat-treated in hot water, steam or hot air.

Cheese

Rigid natural cheeseExamples of rigid natural cheese include Swisscheese like Gruyère, as well as Old Amsterdam,Leerdammer, etc. To produce natural cheese,milk is heated slightly before lactic-acidproducing bacteria and rennet are added. Themilk coagulates into a single huge curd, which issubsequently heated to remove whey. The curdcan then be molded and shaped into a cheese.Salting takes place, and the cheese is matured ina cool, well-ventilated space.

.

Processed cheeseProcessed cheese typically comprises two orthree cheese types blended together. It is madefrom unfermented dairy ingredients, plusemulsifiers, extra salt, and food colorings. It doesnot develop the characteristic flavor of naturalcheese because the micro-organisms that createthe individual taste are effectively killed off.

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Fish & Vegetarian products

FishFish is very sensitive to temperature and it needsto be sliced at quite a low temperature of around-8° to -7°C. It is even easier to slice with frozencrust on the surface.

Vegetarian aspicIngredients such as vegetables are set into agelatin mix made without stock or consommé.Sliceable aspic is made in an aspic mold. To slicesuch a demanding product, a frozen crustsurface is indispensable.

Processed tofuTofu is made by coagulating soy milk and thenpressing the resulting curds into soft whiteblocks. Apart from fresh tofu, there are manydifferent processed varieties, such as picked,dried, frozen etc. in or to match the textures andflavors to the likes of cheese, eggs, bacon, etc.

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PRODUCT PRESENTATION

The appearance of a product in the package contributes to consumer

buying decisions. So the more attractive and appetizing a product is, the

more it stands out on crowded supermarket shelves. GEA slicers arrange

sliced products in a variety of visually appealing, space-saving and

consumer-friendly ways.

Portion presentation forms in the packageThe way sliced products are presented and packaged have visual and functional characteristics. Forexample, presentations like shingles allow consumers to see more of what they are buying. Shingledproducts can be arranged in various configurations, such as circular, oval and linear. Interleavedproducts have a paper sheet between each slice to make it easier to take one slice from the stack, andthis is particularly useful with very thin slices or products that tend to stick together.

The examples on the next page show what is possible. The more basic formats, like folded ham can bemade on every slicer whereas some of the more complex forms require options to be specified andfitted.

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PORTION PRESENTATION CHARACTERISTICS

ShingleThe shingle provides the most extensive presentation of a product and gives optimum separation ofthe slices. It is a consumer-oriented presentation suitable for all kinds of products.

StackThe stack is the most space-saving packaging format for efficient use of the space on the supermarketshelves or cooling cabinets. It is a low value-oriented presentation and is well suited for bulkpackaging.

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Zig ZagThe zig-zag variation of the stack enables easy separation of the slices without an interleaved papersheet. It saves the initial investment for an interleaver and reduces the amounts of consumablematerial required. It is a medium value-oriented presentation for slightly sticky products.

InterleavedInterleave provides safe and easy separation of slices, and is typically used for high quality and/or stickyproducts. It is a premium value-oriented presentation for products. The interleaved sheets are insertedbetween each slice during the slicing process.

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ShavedA shaved presentation helps create ‘high-volume’ portions. It is a presentation that reveals theproduct‘s aroma to its fullest as well as making it easier to take a single slice from the portion.

ChunksChunks are the basic format for single thick slices or pieces. It is a common portion form in the baconand cheese industry.

FoldedThe folded portion form is an appealing and distinctive presentation to draw the customer's attentionand arouse his appetite, and make the product stand out on the supermarket's cooling display.

SpecialsSpecial portion forms include custom configurations such as meander, oval and trendy or seasonal /themed (such as Chistmas trees). Additional equipment is needed for these particular portion forms.

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PRINCIPLES OF SLICING

The process is basically similar on most slicing machines, although it

depends to some degree on the application and machine set-up.

The product – either a processed log with a consistent cross-sectional area and density or a natural cutlike bacon – is fed at a very controlled speed into a cutting area where a rotating blade produces slices.These are fed in portions into a packaging machine, so slicing intermittently stops after a presetnumber of slices to separate each portion. The thickness and number of slices determine the portionweight, so in order to make consistent portions of the same weight, it may be necessary to vary thethickness of one or more of the slices.

Working principle (4 steps)1. A product in single or multiple lanes (side-by-side or with a determined space in-between) is fed

into the slicer, either via an infeed conveyor for automatic loading solutions or directly on theproduct bed of the slicer for manual loading solutions.

2. Product grippers grip the rear end to clamp and stabilize the product during slicing, which isespecially important for the last few portions. For safety and loading reasons, a shutter ispositioned in front of the blade, which swivels down to allow the product to enter the slicingarea.

3. The grippers move the products towards the slicing area, in which a blade (either a circular or aninvolute blade) is rotating. The blade slices the product and the portions are arranged on theportioning conveyor.

4. By movements of the belts the finished portion is transported to the next aggregate in the lineuntil it is loaded into the packaging machine.

Working principle (simplified)

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IndicatorsResults in slicing are influenced by several factors. The two main aspects on which slicing resultsdepend are technical aspects and the product. From a technical point of view, the blade, machineparameter setup, and machine configuration can influence the slicing result. Product related factorsinclude the consistency of the product, temperature during slicing and the calibration. Let us have acloser look at the product related factors first.

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PRODUCT PREPARATION

To slice products perfectly, it is not only necessary that the mechanical

set-up of the slicer is correct, the preparation of the products is also very

important. The consistency of the product determines the preparation for

cutting.

In addition to setting up the machine regarding pressure on the product and length of the logs forexample, it is important to have the product at the right temperature. This can be achieved using acooler, or for even lower temperatures, a freezer.

Cooling a soft sausage (boiled sausage), makes the product relatively stiff, which enables betterslicing.

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Meat preparation

• Core temperature of the sausage should be less than 2 to 3°C above the crystallization point of theproduct.

• The crystallization point can be lower than 0°C as it depends on the product character (salinity).

• Core temperature should always be the same or higher than the surface temperature.

• Surface temperature can sometimes be lower than the temperature of crystallization point.

• Lower surface temperature will mostly be achieved with shock freezing, which only cools thesurface, to get required stiffness.

• It may be necessary to slice the sausage warm, for example dry salami, although meat should not besliced above +4°C, in order to avoid bacterial problems.

Cheese preparation

• The temperature of cheese for slicing is not as critical as for meat products.

• The temperature is typically around 4°C.

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OPTIMAL PRODUCT TEMPERATURE

The product is too warm:• irregular, wavy slices

• irregular portions

• visible product shavings

• product tends to get a cutting-beard

• product may be pulled off from the gripper

• fatty traces on the slicer blades

• for products with hard ingredients, some pieces will pull off during slicing

The product is too cold:• Slices roll in easily (chips effect)

• Slices are unstable during transportation

• Within the portion, slices do not adhere (ice on ice), so proper portioning is virtually impossible

• portioning of the slices is not possible

• portions will not stay together as they transport over the gaps between conveyor belts

Products Core temperature (°C) Surface temperature (°C)

Smoked BaconBaconCooked HamCooked SausageSalamiMeat (i.e. Carpaccio)AspicNatural cheeseLight CheeseSoft CheeseFish (pressed)Black Forest HamParma Ham

-3-120-24-60

6 to 100 to 104 to 10

-6-4-8

-3-120-44-8-4-----7

-12

Based on averages. Our GEA specialists can advise you on your specific application.

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CHALLENGES OF SLICING

During slicing, the blade heats up and the cutting edge can reach

temperatures over 120°C. Protein in the product will coagulate at approx.

73°C. Because of this, a sticky crust will adhere to the blade's cutting

edge, thus affecting the slicing result negatively (particularly with dry,

protein containing products such as cheese). As brief contact as possible

between the blade and the product minimizes temperature, and special

coatings such as Teflon help to minimize adhesion of protein to the blade.

MeatSlicing meat or sausage requires a sharp cutting edge otherwise the product will be wrenched outmicroscopically. If the cutting edge of the blade is no longer sharp, the structure of the product will bedamaged and the slice quality will decrease. The guiding of the product is also essential for perfectslicing results. These can be achieved by shear edges, which are perfectly adapted to the product.

CheeseFor cheese products, a sharp cutting edge is also required. But since cheese contains a highpercentage of protein which tends to stick to the cutting edge, fully coated blades are a necessity. Theblade’s coating does reduce the sharpness of the knife.

How to overcome these challenges?

Distance adjustmentFor perfect slicing results, it is important tooptimally adjust the distance to the cutting bar. Ifthe distance is too big, the product cannot besliced properly. To increase the product's stabilityin the slicing process, a downholder system isused. Downholders are mainly used in circularblade applications. For higher speeds andinvolute blades, product stability during slicingcan only be achieved by using a traction beltsystem.

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SELECTING THE RIGHT BLADE SHAPE

The blade is an integral part of the slicer. Using the right blade for a

particular application helps to achieve outstanding accuracy per slice,

optimum line performance and the most attractive appearance of the

sliced portion within the pack. Two different types of blades are typically

used: circular and involute blade. And both blade types are available with

or without coatings, all for a variety of applications.

Circular blade

• GEA circular blades are available withdiameters of 420, 440, 460 and 480 mm

• Universally applicable for a huge range ofproducts

• Product preparation is less intensive than forslicing with involute blades

• Slicing speed up to a maximum of 750 rpm

Blade movement during slicing

Circular blade slicers include a rotor with planetary movement. With every rotation, the circular bladerotates seven times on its own. Thus, a high draw is generated, allowing the product to be sliced in thecentre and in the lowest position (low overlap). With a transmission ratio of 1:7, the maximum speedfor circular blade slicers is 600 rpm. A maximum speed of 750 rpm is feasible if the transmission ratio isadjusted to e.g. 1:5.6, however, the draw ratio will start to decrease. Circular blades are veryconvenient for slicing up to 400 rpm, without a need for idle cuts. Temperature regulation is not ascritical as with involute ones, which is another advantage.

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Involute blade

• Involute blade with different radius

• High slicing speeds of up to 1500 rpm arepossible

• Works in combination with GEA’s idle cuttechnology to prevent slivers, etc.

• Bigger products can be sliced as involuteblades cover a bigger slicing throat

• Slicing and portioning is more challengingthan with circular blades

• Products require more preparation (well-tempered product)

Blade movement during slicing

With involute blades, the product is sliced by two movements: slicing and pulling. Because of thepulling movement through the product and the logarithmic geometry, the draw ratio is lower butconstant. Due to the rotor’s simple construction, it is possible to slice up to 1500 rpm. But as the drawratio is much smaller compared to circular blades, more pressure is being put on to the product.Therefore, an involute blade must exactly suit each application to achieve optimal slicing results.Slicing with involute blades is more complex and is commonly used for high speed applications ofmore than 600 rpm. Such high speeds require an idle cut rotor to ensure perfect slicing and portioningquality and to allow sufficient time to transport the portion out of the slicing area into the nextaggregate, before slicing the next portion.

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SELECTING THE IDEAL TOOTHING PROFILE

Toothed blades minimize compression of the product. These types of

blades are also used in interleaver applications, to slice both product and

paper leaves simultaneously.

Peak toothed, coated bladeWith these type of blades, the cutting pressure isreduced. Portioning is constant and in goodshape. The cutting, however, is similar to a rasp,creating cutting dust. Toothed blades arecommonly used in the cheese industry only.

Curve toothed (arch toothed), coated bladeCutting pressure will decrease even further whena curve toothed blade is used. With cheese, it willlead to noticeably better results in portioning andquality. Cutting dust is reduced by 50% onaverage compared to peaked toothed blades.Curved toothed, coated blades also reduce theconsumption of power by the rotor drive. Thistoothing type is also used in the sausage industryfor cooked ham and cooked sausage.

Mixed toothed, coated bladeMixed toothed, coated blades are used ininterleaver applications. Whereas the archedteeth slice the product, the peak teeth typicallyslice the interleaver foil or paper.

BLADE CHARACTERISTICS

Various coated and uncoated blade types are available for a variety of

applications. While fully coated blades are mainly used in the cheese

industry, uncoated blades are basically used in meat slicing applications.

The protein in meat would destroy the blade's coating and lead to corrosion of the blade's edges.Consequently, the edge is mostly uncoated in the meat industry because a very sharp blade is neededin these applications.

Uncoated blade: hard-chrome plate

Main advantage of a hard-chrome plated bladetype is that the cutting edge is very hard, becauseno coating was applied in the manufacture ofthis blade. Hard-chrome plates are not indicatedfor slicing products with a high percentage ofprotein, as this would stick to the blade and leavefatty sediments to the sliced product. Theseblades are mainly used for slicing hard productssuch as smoked ham, salami or fresh meat, thatrequire a sharp and stiff cutting edge.

Teflon coated blade

Blades can be coated to reduce friction, toimprove and prolong durability and to protectagainst corrosion. Coated blades with a grindedcutting edge – a so-called blank cutting edge -can be used for cooked ham, sausage and aspic.This blade is fully coated. Its main advantage isthat protein will not clog easily, and fatty tracesto both blade and product is reducedconsiderably.

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Stainless steel, uncoated blades

GEA's newest blade generation made of highquality stainless steel with a hard metal knifeedge provides convincing slicing results. Thebalancing process for involute blades has beenoptimized. The result: no need to adhereadditional counter weights onto the surface,thus assuring highest hygiene standards andlowering noise emission. Because of thematerial's properties, less grinding is needed.The manufacturing process ensures highstiffness of the blade, resulting in consistentslices.

Grinding of bladesAll GEA blades can be sharpened. However, blades with a full Teflon coating need to be re-coated.GEA blades can be sharpened to a maximum of 5 mm less than the original radius. If more millimetreswould be taken off, the weight of the blade will no longer match with the rotor and its counterweight. In time, the rotor will be damaged!

Coated blades in the futureGEA continuously strives to improve coating solutions that will prolong the blade’s lifetime, razorsharp cutting edges and first-in-class anti-adhesion features.

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FLEXIBILITY VERSUS CAPACITY

Sliced meat and cheese manufacturers need to be flexible in terms of the

types of products made and variations in presentation and packaging

without compromising on overall line performance. GEA can advise on

how to meet this challenge.

The priority is to get the best out of products in terms of yield, slice quality and presentation. To dothis, it is necessary to establish whether a limited number of product types will be sliced in very highvolumes or many different products are to be sliced in smaller batches on a more flexible line. Thesecriteria influence the choice of equipment.

Slicing within the target weight to boost yieldYield is influenced by many factors, including slicing within the target weight, increasing thepercentage of on-weight-portions and reducing debris and end pieces to a minimum. GEA coversthese requirements by using innovative scanning systems and blade technology as well asimplementing individually designed grippers and shear edges.

Analyzing irregular and natural productsThe GEA OptiScan is a pre-scanner that uses X-ray technology to determine variations in density alongthe length of a product and then calculate the thickness of each slice and size of each portion prior toslicing. This ensures the portions are within the target weight and is particularly important for slicingnatural products like bacon and cheese with large holes where the variation in density and weight ishigh. After slicing, the portions are weighed on a dynamic scale, GEA Check 4000, and any deviationfrom the expected weight is fed back to the control system to make adjustments for the next portion.Smart software is integral to optimizing yield.

Idle-cut technologyBlade technology plays an important role in reducing debris. GEA employs its unique idle-cuttechnology that moves the blade away from the product between cutting portions to reduce slivers,while the shear-edges are designed to prevent movement of the product and it is fed into the slicer.Using the right blade profile is also critical for reducing waste like slicing dust.

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Application-specific optionsReducing the size of end pieces, which is typically around 20 mm, is best done by using application-specific grippers for each product type. An application-specific gripper can reduce the end piece to 15to 18 mm, and by ensuring the grippers are quick and easy to change over, the machine’s overalluptime is optimized.

If a very high capacity line is needed, the GEA GigaSlicer that handles up to six lanes of salami forexample, would be the best choice. However, if flexibility is more important, the two-lane GEADualSlicer is ideal. GEA lines can satisfy both flexibility and capacity requirements.

A full product overview is given in the following section.

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GEA SLICER RANGE

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GEA SLICER RANGE

The GEA slicer range offers cutting-edge technology for innovative slicing

applications. Developed to meet tough hygiene and safety standards,

each GEA slicer provides unsurpassed performance and outstanding cost-

saving benefits. Our portfolio also includes smart loading solutions for

fully automated, hands-free production.

Your performance benefits• High performance, due to GEA's application and process know-how over decades

• Flexible production, thanks to easy calibration

• Reduced give-away

• Easy handling and cleaning throughout the entire product portfolio, with minimal downtime

• Full service and spare parts support

• Reliable quality, long equipment lifetime

• Line compatibility: GEA Slicers can be easily integrated into fully automated packaging lines.

FlexibilityDesign your requirements in consultation with us, and GEA will configure the optimal slicer for you.The best of all: our equipment is flexible so you do not need to determine a single configuration for itsentire life. With the modular construction of the GEA Slicing range, you can build a machine which isuncompromisingly tailored to your applications of today - and still remain open to the demands oftomorrow.

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Technical data GEA UniSlicerGEA UniSlicer S GEA UniSlicer L GEA UniSlicer

ContourType of blade circular blade circular blade circular bladeBlade sizes Ø 420 mm Ø 420 mm Ø 420 mmMax. cutting cross-section 135 x 220 mm 154 x 240 mm 154 x 200 mmMachine dimensionsL / L1 x H x W

- / 4.050 x 2.120 x 856 mm

2.620 / 4.580 x 2.120 x856 mm

2.620 / 4.580 x 2.120 x856 mm

Max. blade speed 600 1/min. 600 1/min. 600 1/min.Max. product length 980 mm 980 mm 980 mmProduct loading manual manual manualCheck weigher - i iPortioning conveyor I transfer conveyor as

portioning conveyori -

Contour portioningconveyor

- - I

H

L1

L

1x 150 mm

3x Ø 80 mm

2x 100 x 100 mm

1x bacon / dry-cured ham (70 x 220 mm)

Examples of applications

Out

feed

hei

ght

Uni

Sca

. 120

0 m

m

Out

feed

hei

ght

Uni

L

ca. 9

60 m

m

Power supply (max.): 7kW; compressed air: 6 bar; Noise emission in accordance with EN ISO 11204: 71.5 db (A);Depending on product and application

I available as standardi optionally available

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GEA UniSlicer

The GEA UniSlicer with circular blade technology increases operational flexibility in two ways: it slicesa wide variety of products and produces a range of portion patterns. This slicing machine achieves upto 600 rpm and has a wide product throat, thus combining high throughput with a virtually smallfootprint. Its compact design makes the GEA UniSlicer easy to integrate into existing production lines.The machine can be specified for operation from either side according to the plant layout.

Performance at a glance

• Attractive product presentation: the GEA UniSlicer slices all portion patterns commonlyemployed in the market for sausage, dry-cured and cooked ham, bacon and cheese at a highlevel of quality. Programs for selection of portion patterns.

• Flexibility with regard to portion patterns: functions like contour shingle conveyor andthe folding device mean the GEA UniSlicer can handle a very broad range of portion patterns.

• Fast and easy change-over from one product to another: manual product loading,changing of grippers and new program selection enhance productivity of smaller batch sizes.

• Maximum product utilization: dynamic high-performance weighing equipment and thevariable portion sequence optimize product utilization on the GEA UniSlicer.

• The GEA UniSlicer has an output of up to 450 kg/h.1

1: depending on product and apllication

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Technical data GEA MegaSlicerGEA MegaSlicer S GEA MegaSlicer L GEA MegaSlicer XXL

Type of blade circular blade circular blade involute bladeBlade sizes Ø 440; Ø 460;

Ø 480 mmØ 440; Ø 460; Ø 480 mm

R 415 mm

Max. cutting cross-section 350 x 155 mm 440 x 155 mm 440 x 180 mmMachine dimensions L x H x Wproduct length 1.200

2.830 x 2.370 x 1.200mm

3.920 x 2.410 x 1.200mm

3.920 x 2.410 x 1.200mm

Machine dimensions L x H x Wproduct length 1.850

- 5.225 x 2.740 x 1.200mm

5.225 x 2.740 x 1.200mm

Max. blade speed 600 rpm (750 rpm)* 600 rpm (750 rpm)* 1.500 rpmMax. product length 1.200 mm 1.200 / 1.850 mm 1 1.180 / 1.830 mm 1

Product loading manual automatic automaticInterleaver i up to 3 lanes i up to 3 lanes i up to 3 lanesContour portioning conveyor i i iCheck weigher i i iCamera i i iGEA OptiScan - i iTelemonitoring / RemoteService / PreventiveMaintenance

i GEA UptiFox i GEA UptiFox i GEA UptiFox

MegaSlicer S

Examples of applications

MegaSlicer XXL

2x Ø 135 mm 3x Ø 135mm

3x 100 x 100 mm 3x 150 x 100 mm (upright)

3x 100 x 100 mm

1x bacon / dry-cured ham (100 x 220 mm)

2x bacon / dry-cured ham (100 x 220 mm)

2x bacon / dry-cured ham (100 x 200 mm)

3x Ø 110 mm 4x Ø 110 mm 4x Ø 100 mm

MegaSlicer L

3x Ø 135 mm

GEA MegaSlicer SGEA MegaSlicer L / XXL (product length 1200)

Power supply (max.): 15.5 kW; compressed air: 6 bar; Noise emission in accordance with EN ISO 11204: 65.6 db (A)1 Depends on machine configuration and product features. *Depends on product-special machine execution

i optionally available

34

GEA MegaSlicer

When it comes to high productivity and covering a very wide range of applications, the GEAMegaSlicer offers one of the most efficient combinations available in the market. The choice betweencircular or involute blade technologies allows the machine to be used for a wide variety of applicationsand capacities. Equipped with involute technology, the GEA MegaSlicer can achieve slicing speeds upto 1500 rpm. Thanks to short, automated loading times and high output, the GEA MegaSlicer is idealfor integration into fully automated lines, e.g. in combination with a GEA ShingleLoader and a GEAPowerPak.

Performance at a glance

• Attractive product presentation: the GEA MegaSlicer slices all portion patterns commonlyemployed in the market for sausage, dry-cured and boiled ham, bacon and cheese at a highquality level.

• Constant portion quality: the patented idle cut rotor enables constant slice thickness, evenwith soft products such as boiled sausage, and largely eliminates sliver slices.

• Choose your blade technology: involute blades for high output with slicing speed up to1500 rpm; circular blades for flexibility and a wide range of applications.

• Automatic loading from the rear: fast, reliable and protects the product.

• Flexibility thanks to many auxiliary modules: functions like interleaver and a contourshingle conveyor make the GEA MegaSlicer a specialist in every product segment.

• Maximum product utilization: supportive technology such as a dynamic weighing system, acamera unit or the GEA OptiScan secure minimal give away and a very high proportion of on-weight portions.

• The GEA MegaSlicer has an an output of up to 1.600 kg/h.1

1: depending on product and apllication

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Technical data GEA DualSlicerType of blade involute bladeBlade size R470Max. cutting cross-section 500 x 200 mmMachine dimensions L x H x W 2.520 x 2.450 x 1.411 mmMax. blade speed 1.500 rpmMax. product length 1.200 mmProduct loading automaticInterleaver i up to 2 lanesContour portioning conveyor iFolding device iCheck weigher iIndependent drives max. 2GEA OptiScan iTelemonitoring / RemoteService / PreventiveMaintenance

i GEA UptiFox

Examples of applications

2x D-shaped ham (180 x 140 mm)

2x 230 x 100 mm 4x Ø 110 mm 2x 110 x 165 mm

2x cooked ham (240 x 135 mm)

Depends on machine configuration and product features. Power supply (max): 15.5 kW; Compressed air inaccordance wih 7:4:4-ISO8573-1: 6 bar 15NI/min. Cooling water necesssary; Noise emission in accordance with ENISO 11204: 73 dB (A)

i optionally available

36

GEA DualSlicer

The GEA DualSlicer meets very high performance requirements. Benefits include maximum output,with fewer idle cuts, thanks to two independent drives and an adjustable rotor head in combinationwith the 3-stage-portioning conveyor. The independent drives lead to very low give-away, highproduct utilization and a high percentage of on-weight portions. The adjustable rotor head ensuresoptimal positioning of rotor and blade towards the product to achieve optimal results. The GEADualSlicer is ideal for integration into fully automated lines, e.g. in combination with a GEAShingleLoader and a GEA PowerPak.

Performance at a glance

• Low give away and maximum output: thanks to two independent drives and a 3-stageportioning conveyor.

• Smooth slicing, fewer idle cuts and perfect portioning results: due to rotor head design,GEA Idle Cut Technology and dynamic cutting gap setting.

• Easy to operate: machine is set up quickly, with automated control of product specific bladepositioning (touch screen).

• Reduced loading times thanks to automatic loading.

• Flexibility thanks to many auxiliary modules: functions like interleaver and a contourshingle conveyor make the GEA DualSlicer a specialist in every product segment.

• Maximum product utilization: supportive technology such as a dynamic weighing system, acamera or the GEA OptiScan secure both minimal give away and a very high proportion ofon-weight portions.

• The GEA DualSlicer has an output of up to 1.600 kg/h.1

1: depending on product and apllication

37

Technical data GEA GigaSlicerType of blade involute bladeBlade size R 550 mmMax. cutting cross-section 640 x 210 mmMachine dimensions L x H x W 3.080 x 2.585 x 2.040 mmMax. blade speed 1.500 rpmMax. product length 1.250 / 3.200 mm*

Product loading automaticFolding device iCheck weigher iIndependent drives max. 4GEA OptiScan iTelemonitoring / Remote Service / Preventive Maintenance i GEA UptiFox

Examples of applications

Up to 4 x 135 mm slicing area

Up to 6 x 105 mm slicing area

Up to 4 x D-shaped ham

Up to 4 x 110 mm x 150 mmslicing area

Up to 4 110 mm x 165 mm logs

Depends on machine configuration and product features. Power supply (max.): 16 kW; compressed air inaccordance with 7:4:4-ISO8573-1: 6 bar 40NI/min. cooling water necessary; Noise emission in accordance with ENISO 11204: 76.0 db (A). *Option.

i optionally available

38

GEA GigaSlicer

The GEA GigaSlicer is the highest capacity solution within the GEA portfolio. Its large cross-section ofthe cutting throat (640 x 210 mm) enables cutting of up to six sausage logs with a diameter of 105mm, or four cheese logs measuring 110 x 165 mm. Functions like motorized adjustment of the bladeposition in relation to the product and automatic cutting gap setting guarantee constant uniformportioning. The patented idle cut rotor system contributes to consistent slice quality and largelyeliminates sliver slices.

Performance at a glance

• High-quality product presentation: the GEA GigaSlicer slices all portion patternscommonly employed in the market for sausage, dry-cured and cooked ham as well as baconand cheese at a consistent, high quality level.

• Constant portion quality: automated adjustment of blade positioning, dynamic cutting gapsetting as well as the patented idle cut rotor enable constant slice thicknesses, even with softproducts like boiled sausage, and largely eliminates sliver slices.

• High degree of product safety: due to easy accessibility and hygienic design.

• Maximum product utilization: depending on the product requirements, the most suitabletechnology can be selected - with the dynamic weighing system or the GEA OptiScan, toensure minimal give away and a very high proportion of on-weight portions.

• The GEA GigaSlicer has an output of up to 2.500 kg/h.1

1: depending on product and apllication

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GEA LINE COMPETENCE

As a single source supplier, GEA offers complete line solutions for a wide

variety of applications to produce attractive, safe and consumer-friendly

packs.

The line concepts range from low to high output, from easy handling and flexible in operation toambitious and sophisticated technology with full automation and synchronized components. It goeswithout saying that the focus for all machine setups lies on efficient production, best possible yieldand user-friendly operation always comprising highest hygienic standards.

Your performance benefits• Single source supplier guarantees performance of complete line concept

• One speaking partner

• Global service and spare parts logistics

• Optional software packages available to increase line efficiency (e. g. GEA LineControl, remoteservices, condition monitoring)

Flexible GEA Line Solutions for every application purpose …

… up to 450 kg output / hour1

... up to 1.600 kg output / hour1

… up to 2.500 kg output / hour1

1: depending on product/application

ADDITIONAL EQUIPMENT

GEA OptiScanThe GEA OptiScan is a pre-scanner system that makes it possible to slice natural products like drycured ham, bacon and cheese with maximum yield and on-weight portions. The scanner literally looksinto the product and determines the density distribution over the length of the product by means ofX-ray technology. In this process, the device detects irregular outer contours as well as holes, underslices and irregular distribution of fat and meat. Disruptive factors, such as reflections on the productsurface, are not a problem. Based on the density distribution, the intelligent software calculates theideal slice thickness for each portion prior to slicing. The result is not only exceptionally low give away,but also an extremely high percentage of correct weight portions, thus minimizing the manual workon a slicing line.

GEA Check 4000The GEA Check 4000 is a high precision weighing system, detecting single weights of sliced portionswhile moving these over the check weigher. The single portion weights are analyzed in the slicer forweight regulation. Thus, the slicer is able to respond to varying product cross sections and optimizethe deviation in average weights over a long period of production time. The GEA Check 4000 isavailable in multiple lane configurations. Weigher programs (recipes) as well as reports are stored inthe controls of the slicer and an external USB interfaces makes reading these out easy. All side panelscan be removed swiftly without tools for cleaning and maintenance. The weighing system iscalibrated for loads between 20 and 5000 g.

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GEA ShingleLoader 600 / 700When it comes to slicing and packaging at a high output, the GEA ShingleLoader is an efficient systemcomponent that feeds the portions fully automatically from the slicer to the thermoformer. TheShingleLoader 600 is economically attractive for automation involving flexible slicing lines in the lowerto medium capacity range while the GEA ShingleLoader 700 often makes operation of highperformance lines possible in the first place thanks to its uncompromising loading capacity. Thereproducible loading precision is a common feature of all members of the GEA ShingleLoader family.This means a wide variety of sliced portions can be fed to the thermoformer via the GEAShingleLoader. In addition to the loading operation itself, the GEA ShingleLoader ensures continuousproduction on the part of the packaging machine, in most cases during the entire loading time at theslicer, by means of the integrated buffer conveyors. The consistent hygienic design and simple, quicklydetachable belts enable a high degree of product safety through effective and economical wetcleaning.

GEA FlexLoaderThe GEA FlexLoader is a user friendly and space saving loading system, ideal for loading thermoformeror bagging machines. With the GEA FlexLoader, a fully automatic loading of thermoformer machineswith sliced portions or pieces is possible. Overlapping or stacking of single products to a completeportion is easily viable. Left-hand and right-hand versions of this machine are available and can beimplemented in existing lines or in production rooms with limited space very easily. In the event ofchanging a format configuration, the operator only needs to select another machine program. Theintelligent distance measurement in combination with servo drives guarantees high positioningaccuracy. GEA FlexLoader is built in stainless steel for easy wash down cleaning and featurespneumatic belt tensioning for fast belt exchange without tools.

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GEA RobotLoaderThe GEA RobotLoader offers outstanding productivity and almost unlimited options for productpositioning. To enable customers to meet these requirements as effectively as possible, GEA hasdeveloped a fully integrated delta robot system to handle sliced products as well as single pieces ofconvenience food.

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ADD-ON OPTIONS

GEA slicers can be equipped with a variety of optional add-ons that

increase the versatility, flexibility and functionality of the slicers. Many

add-ons are also available as field upgrades for existing machines.

GEA InterleaverThe GEA Interleaver allows interleaving film orpaper in-between slices of several applications.Either cheese or expensive products can beinterleaved for a nice appearance in the package.The GEA Interleaver is available for GEAMegaSlicer and GEA DualSlicer. Pre-tensioningof paper for long insert of paper or adapted toproduct contour are optionally available andfacilitates a long insert of paper withoutadditional air support.

GEA Camera SystemThe GEA Camera System is located in theportioning area of the Slicer. It takes a picture ofeach slice and calculates the slice thickness basedon the surface area of the image in order to getcorrect weight of the portion. The camera ismainly used for cheese and bacon applications.

45

GEA Cross-shingle ConveyorThe cross-shingle conveyor is characterized bythe movements the portioning part can fulfil. Bymoving in lateral, forward and backwarddirection, different contours of portions can begenerated. Round circles, overlapped crosswiseor meander forms can be easily built with thecross-shingle (also called x-y) conveyor.

Folding device (pneumatic)For folding portions, GEA has a pneumatically-driven folding device which is located in theslicing area. The slice falls onto the device and byuse of pneumatic air flow and the speed of thefalling slice, it is folded and positioned onto theportioning conveyor.

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LOADING DEVICE

As with our slicing portfolio, our loading portfolio can also be extended

with various options.

Lane diverterThe lane diverter is part of the ShingleLoader anddiverts portions from left to right or right to left.This is needed if the packaging machine’s die sethas more rows than the slicer delivers. The lanediverter makes it possible to divert from 1 to 2, 1to 3, 2 to 4, or 3 to 6 lanes. The Lane diverter canalso be used as a spreading conveyor in order toreach the right distance between the portions forautomatically loading them into the packagingmachine.

Formatting StationTo overlap 2 to 1 portions with spreadingelements. In combination with a lane diverter, itis possible to distribute portions from 2 to 3lanes.

Aligning rakeThe aligning rake is placed under the aligningconveyor. Pneumatically driven, it is used to alignshaved or stacked portions on up to 5 lanes. Thisshortens portion for increased loading precision.

47

Correction DisplayThe Correction Display is a matrix display used totrace missing or supernumerary slices of aportion on the loading area of the packagingmachine. It shows which portion needs to becompleted manually and with how many slices.

UVC DisinfectionUltraviolet disinfection lamps underneath thebuffer belts reduce the bacterial counts forhigher product safety. Its positioning avoidsdirect contact with the product for an even morehygienic production procedure.

OverlapperA stand-alone overlapping unit positionedbefore the GEA ShingleLoader provides easyportion overlapping from 4 to 1 or 3 to 1.

EasyOverlapperUsed in combination with a GEA DualSlicer only.Overlapping portions from 4 to 2 or 2 to 1 with avery small footprint. The Easy Overlapper iscontrolled by the Slicer.

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49

A-TO-Z OF SLICING TERMINOLOGY

A - I

Blade diameter – Diameter of circular blades. Available in 420, 440, 460, 480 mm.Blade radius – Radius of the involute blades. Available in 394, 415, 470, 505, 550 mm depending onmachine type.Blade surface (coating) – Blades can have different surfaces in order to achieve best slicing results.Coating Teflon or hard chromium, depending on application.

Down holder – A tongue from the top stabilizing the product during slicing (less vibrations).

End piece – Normally between 18 and 20 mm. The last bit of a product log which is held by thegripper. Ejection necessary after finishing the product log.

Folding device – A mechanical device pneumatically driven which is mounted in the slicing area tocreate folded portions.Free angle – A specific angle on the backside of the blade. Minimizes the contact between blade andproduct log during slicing.

Give-away – The percentage difference between the average weight of all packed portions and thenominal weight. Valuable are all sliced portions minus:- First cut- End pieces- Last incomplete portion (in case of not using portion completion). - Portions with incomplete or destroyed slices due to bad product consistency.

100%Nominal Weight* portions simultanously measured

Average weight accepted*2 - Nominal Weight*portions simultanously measuredaway -Give =

Grinding – Process to resharpen all different types of blades.Gripper – Mechanical part to hold the end of a product log during the slicing process.

Idle cut – A blade movement without slicing the product. Conventional technology is to stop andretract the product. For high slicing speeds and involute blades, this technology is no longer workingwithout the undesired effect of sliver slices. The patented idle cut rotor moves away the blade fromthe product, which helps to avoid sliver slices almost completely and to achieve very consistent slicethickness within a portion.Independent drive – Together with a multilanes weigher, this option allows different slicethicknesses for the different logs within the same slicing cycle. Infeed belt – Belt on which product is placed for automatic feeding of the slicer.Interleaver – Add-on device of the slicer which supplies paper or foil in between the single slices of aportion. Possible for portion forms stack and shingle.

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P - T

Portion – Appearance and alignment of slices to a predetermined form. Standard forms are shingled,stacked, zig-zag. Other optional forms can be cross-shingled, piece, meander, circle, folded,interleaved.Portioning belt – Portioning is made on this belt system. It can provide all standard portion stylessuch as shingle, stack (up to 30 mm) and pieces.Press angle – A specific angle on the front of the blade. It accelerates the slice during slicing for betterportioning. Product bed – part of the slicer on which the product is transported and aligned during slicing.Product log– The log is the raw product which is sliced. Normally length of the log is between 350mm and 1600 to 1800 mm or endless.

Shear edge – Guides the product during slicing to achieve best slicing results. Serves as referencepoint for the blade. Can be adapted to the real product form.Slice thickness – Specific, adjustable thickness of the slice within a portion .Slicing angle – A specific angle on the edge of the blade. It influences slicing results; the standard isbetween 20° and 33°.Slicing beard – Frazzled slices with a beard at the bottom side of the slice are mostly caused when theshear edge - blade distance is incorrectly set in combination with a blunt blade.Slicing gap – Distance between blade and shear edge. Variably adjustable. Commonly, the gap is setbetween 0.2 mm (metal shear edge) and 0.5-0.8 mm (plastic shear edge), depending on theapplication. The smaller the distance, the better the scissor process which leads to a higher slicequality.Slicing throat – Also called cutting cross-section. Maximum space in the slicer to slice logs in multiplelanes .Slivers – Small pieces of product which are produced during the slicing process. Spreading conveyor – Device to spread the portion on a predefined distance to make it suitable forthe dieset of the packaging machine.Stacking conveyor– Part to produce stacks on the slicer up to 80 mm in height.

Tooth profile – Used for circular and involute blade. It is a special structure of the cutting edge of ablade which is used for difficult applications e.g. Interleaver as well as for very soft sausage productsand cheese applications.Trim slices – First slices of a log that need to be ejected before starting slicing normal portions.

51

Y-Z

X-Ray Technology – Used in the GEA OptiScan to determine variations in density along the length ofa product.

Yield – Percentage of on-weight portions sliced. 100% is all sliced portions1 minus:- First cut- End pieces- Last incomplete portion (in case of not using portion completion) - Portions with incomplete or destroyed slices due to bad product consistency.

Proportion of on-weight portions = - 100%number of on-weight portions

number of all portions1

1: Portions as defined above: accepted weight range according to the German ready-meals regulations

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Notes

53

Notes

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

GEA Group is a global engineering company with multi-billion euro sales and operations in more than 50countries. Founded in 1881, the company is one of the largest providers of innovative equipment and processtechnology. GEA Group is listed in the STOXX® Europe 600 index.

GEA

GEA Food Solutions Germany GmbH

Ignaz-Kiechle-Straße 40, D-87437 Kempten, GermanyTel. +49 831 512 840, Fax +49 831 512 84 4333info@gea.com, www.gea.com Th

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