WELCOME Trends & technological innovations changing the face of food & beverage processing

GEA Africa (Pty) Ltd

26 October 2017

JACO COETZEE

GEA at a Glance

GEA is one of the largest suppliers of process

technology for the food industry and a wide range of

other industries.

The international technology group focuses on process

technology and components for sophisticated

production processes in various end-user markets.

The company is listed on the German MDAX stock

index and included in the STOXX® Europe 600 Index.

In addition, the company is listed in selected MSCI

Global Sustainability Indices.

GEA – “engineering for a better world”

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Order intake (EUR)

4,674 million

Employees (FTEs)

16,937

Operating EBITDA (EUR)

566 million

Operating EBITDA margin

12.6%

Revenue (EUR)

4,491 million

Earnings per share (EUR)

1.48

GEA Africa (Pty) Ltd

GEA Africa (Pty) Ltd

Source: GEA LIFE

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South Africa

Angola

Kenya

Tanzania

Lybia

Nigeria

Ghana

Cameroon

Congo

Algeria

Morocco

Tunisia

Cote d'Ivoire

Egypt

Mozambique

Madagascar

Zambia

Zimbabwe

Botswana Namibia

Somalia

Ethiopia South Sudan

Northern Sudan

Uganda

Rwanda

Burundi

Eritrea

Djibouti

Central African

Republic

Chad

Niger Mali

Mauritania

Western

Sahara

Senegal

Guinea Bissau Guinea

Sierra Leone

Liberia

Burkina

Benin

Togo

Equatorial

Guinea

DRC Gabon

Malawi

110 FTE

130 FTE

11 FTE R & C: 272 FTE

BA-S_APC Uilities: 22 FTE

BA-S_APC Cross: 9 FTE

BA-S_SER: 1 FTE

GCC-FIN: 22 FTE

GCC-HR: 3 FTE

Total in Cluster: 329 FTE

Our applications – in touch with GEA every day

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Approx. one quarter

of processed milk

comes from GEA

production systems

Around every third

process line for

instant coffee was

installed by GEA

Every third chicken

nugget is produced

by GEA technology

Approx. every second

liter of beer is brewed

with the aid of systems

and process solutions

from GEA

Every second

container ship in the

world sails with GEA

marine equipment on

board

Each industry we serve

utilizes GEA’s industrial

refrigeration technologies

Every fourth liter of

human blood is

handled by GEA

equipment

More than one third

of all polymer

producer are using

GEA Drying

technology

Dairy Farming

and Processing

Food

Beverages

Pharma

Chemical

Utilities

Marine

GEA at a Glance

Our ambition – be your no. 1 choice

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We strive to be the

world’s leading global

technology group in

supplying smart solutions

for sophisticated process

industries. Our goal is to

be the customer’s

preferred partner in the

industries we serve.

GEA at a Glance

Megatrends – understanding and taking advantage of opportunities

GEA at a Glance 6

GREATER FOOD SAFETY AND

QUALITY

Readiness of industry to invest

more for greater process reliability

certified hygienic/aseptic processes

and components to meet the strict

standards of the industry

GEA offers

ENERGY SCARCITY AND

STRICTER ENVIRONMENTAL

REGULATIONS

Greater interest in efficient and

resource-saving production

processes

intelligent engineering processes

for resource-economical

technologies, energy-saving

machines and processes, as well

as heat recovery

GEA offers

URBANIZATION WITH GROWING

MIDDLE CLASS

Growing demand for processed

food and medication

components and process

technology for processed food,

ready meals, fortified lifestyle

beverages and food, medications

GEA offers

Groundbreaking innovations – recent examples

GEA at a Glance 7

GEA ColdSteam

• A controlled process for fast thawing of

meat by means of low pressure steam and

indirect heating in order to reduce

defrosting time and improve hygiene,

logistics, shelf life and increase yield in

consumer prod.

ColdSteam Defroster

GEA prolong

• High heating of milk leads to a more or less

significant loss of organoleptic and

nutritional quality of the milk

• Elimination of undesirable constituents like

dirt, blood, somatic cells, bacteria and

spores

multiple use means cost benefit

• GEA has been researching alternatives to

state of the art clarification

Alternative sugar clarification

process

GEA Sugar Clarification

Dairy Farming Food Beverage

GEA prolong – multiple use means cost benefit

Bacteria removal

Some microorganisms are forming heat resistant spores that can survive higher heating

processes than other microorganisms.

Thus the use of Bacteria Removing Separators is necessary especially for products that

require low heat processes such as some cheese milks.

The mechanical separation of spores and somatic cells is based on the different

densities:

• whole milk 1,011 g/ml

• skim milk 1,016 g/ml

• vegetative bacteria cells 1,070 g/ml – 1,115 g/ml

• aerobic spores 1,130 g/ml

• anaerobic spores 1,132 g/ml

Bacteria removing can be done in skim milk, standardised or

whole milk and in skim whey.

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Advantages of bacteria removal vs. heat treatment

• Heat destroys bacteria cells but not spores

when cell wall breaks enzymes, inhibitors and spores come into product

Cells remain in product

Still negative influence on product, reinfection possible!

• Separators remove cells and spores

no reinfection

enzymes and inhibitors are removed with the cells

no flavor or vitamin losses

inhibitors

enzymes

spore

ESL-Milk and UHT-Milk

High heating of milk leads to a more or less significant loss of organoleptic

and nutritional quality of the milk like:

• Cooking flavour (in connection with serum protein denaturation)

• Loss of vitamins (thiamine – B1 / riboflavin – B2)

• Colour change because of Maillard – reaction (browning)

• Reduction of nutritional usability of the essential amino acid lysine

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Elimination of undesirable constituents

like dirt, blood, somatic cells, bacteria and spores!

• Bacteria removal clarifiers are used for the clarification of cheese milk since 1970

• GEA offers bacteria removal clarifiers from 3.000 l/h - 60.000 l/h.

Bacteria Removal Clarifiers

Ecoclear CSE 140 CSI 500

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Safe and gentle double bacteria removal with GEA prolong

Inflow – first bacteria removing separator

Raw milk contains bacteria and spores (even heat resistant

ones) which have to be removed with respect to the shelf life of

milk.

Recirculation for

renewed bacteria

removal

Inflow – second bacteria removing separator

During the first stage of bacterial removal a reduction of the total

bacteria count of about 90 percent and of Bacillus cereus of

about 80 percent is achieved.

First bacteria removing stage

Second bacteria removing stage

All-in-all a reduction of the total

bacteria count as well as

removal of Bacillus Cereus by

about 99 percent is achieved.

The minimum storage life of

fresh milk is prolonged to a

minimum of 21 days.

Recirculation for

renewed bacteria

removal

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High efficiency of the bacterial clarifiers from GEA

GEA prolong – Efficiency

Germ count Germ gram negative Spores

Reduction

Reduction

(overall)

Reduction

Entero- bacteria

Reduction

Pseudo-

Monades

Reduction

Bacillus Cereus

Bacterial Removal

Clarifier I

96.9 %

99.6 %

99.2 %

99.7 %

80.0 %

Bacterial Removal

Clarifier II

99.5 %

99.9 %

99.8 %

99.9 %

> 99.0 %

Conclusion: If there is a need for the most efficient bacteria removal two bacterial clarifiers

have to be installed.

GEA prolong

0 10 20 30 40

GEA prolong

ESL Milk MF

ESL Milk directly heated

ESL Milk indirectly heated

pasteurised drinking milk

Shelf Life

days

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GEA prolong – Advantages

Proof of heat treatment

0 1000 2000 3000 4000 5000

whole milk

pasteurized milk

prolong milk

micro filtrated milk

heated direct

heated indirect

whole milk

pasteurized milk

prolong milk

micro filtrated milk

heated direct

heated indirect

ß-Lactoglobulin (mg/kg)

As an amino acid, ß-lactoglobulin has an essential nutritional significance.

For vitamin A and selenium it is an important transport protein.

0 5 10 15 20 25 30 35

wohle milk

pasteurized milk

prolong milk

micro filtrated milk

heated direct

heated indirect

wohle milk

pasteurized milk

prolong milk

micro filtrated milk

heated direct

heated indirect

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GEA prolong – Advantages

Proof of heat treatment

Lactulose (mg/kg)

A high lactulose value due to the heat treatment of the milk has a negative influence on

the sensory acceptance.

Higher contents in lactulose cooks’ taste is possible.

No organoleptic or nutritional impairment of quality due to

additional heating

Gentle treatment maintains the authentic fresh milk flavour

Multiple use of double bacteria removing separation

Lower operating costs

Clearly extended shelf life of natural fresh milk

Easy integration into existing plants

Benefits of GEA prolong

Essential nutrients and vitamins remain in the product

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GEA DEFROSTING with ColdSteam T

• Defrosting in open vats with running water

• Long defrosting time

• Loss of meat juice (yield loss)

• Food safety issues

• Drain / sewer issues

• Defrosting cabinets with hot air fans

• Long defrosting time

• Loss of meat juice (yield loss)

• Uneven defrosting temperatures

• Low guarantee of food safety

• Microwave tunnels with radio frequency waves

• Only suitable for tempering (max. -2.0 C)

• Difficult to defrost uniformly (above +0.0 C) - product heat spots

• High cost of ownership and maintenance

Defrosting/tempering solutions in the market

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• Time (quick)

• Space

• Production planning

• Price

• Availability

• Price

• Shelf life

• Logistics

Considerations we make every day:

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… still a contradiction?

Fresh Frozen ColdSteam

Flexible

Easy logistics

Low space

Frozen Rates

No protein loss

(drip)

Natural quality

ColdSteam T

A controlled process for fast thawing of meat by means of

low pressure steam and indirect heating in order to

reduce defrosting time and improve hygiene, logistics,

shelf life and increase yield in consumer products

Let’s bring you back to reality again…

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Note: An improve yield will be expected, as protein will be kept in the meat, during the ColdSteam process. This will improve the water holding capacity ! (proteins can hold 3.3 times their own weight)

Product Process Yield %

Examples on overall process gain

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90%

95%

100%

105%

110%

115%

120%

125%

Frozen Thaw Drip Injection Curing Filling Cook andChill

ColdSteam

Traditional

Earnings

Taste

Quality

• Product: Beef Cuts

• Process time: 8 hours

• Added steam: 5 %

• Product: Beef Knuckles & Topside

• Process time: 8 hours

• Added steam: 3 %

Defrosting of beef products

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• Product: Chicken Wings

• Process time: 5 hours

• Added steam: 5 %

• Product: Chicken Breast

• Process time: 5 hours

• Added steam: 5 %

• Product: Whole Chicken

• Process time: 6 hours

• Added steam: 3 %

Defrosting of chicken products

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• Increased capacity compared to conventional defrosting techniques

• Gentle defrosting technology with elimination of purge (no drip loss)

• Substantial reduction of manual handling. Limiting the “Human Factor”

• Verified food safety by TNO (Institute of Applied Scientific Research)

• Small blueprint

• Short, automatically controlled process

• High food safety and traceability

• Low cost of ownership (no yield loss, low operating costs)

• High end product quality (bacteria killing process)

Benefits to remember

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Non-alcoholic beverages processing

GEA Sugar Clarification

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Sugar clarification - general

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• Sugar clarification for non-EU projects

EU sugar clarity regulated by Council Directive 2001/111/EC

Sugar clarification is planned for non-EU projects – no regulation

Costumers require colourless and odourless sugar (<35 ICUMSA Units)(International Commission

for Uniform Methods of Sugar Analysis Ltd)

• Possible processes

Ion-exchanger

Membrane filtration/Separator

Activated Carbon (AC) with Kieselguhr as filter aid

Activated Carbon (AC) without Kieselguhr GEA DI SUGAR CLEAR

Refined sugar sugar appr.

100 ICUMSA

sugar appr.

1000 ICUMSA

• GEA has been researching alternatives to state of the art clarification

• Analysis of sugar and AC to optimize the use of AC

• Method of clarification without activated carbon and kieselgur

• Separator and microfiltration

• clarification achievable,

• high CAPEX (separator and filtration)

• high OPEX (electrical consumption)

• Method of clarification without kieselgur (preferred)

• Special filter solution

• Very good clarification

• Moderate CAPEX

• Low OPEX

Alternative sugar clarification process

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Sugar clarification – Proven Technologies

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AC press

AC Filter 2

AC Filter 1

• Analysis of Sugar and AC

• Optimization of AC usage depending on sugar impurities

• No Diatomaceous earth

• Save OPEX

• Less handling

• Activated carbon can be re-used partly

• Re-dosing with fresh AC

• Processed for other uses (palletisation – heat generation)

Sugar clarification – Benefits of new development

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GEA offers a solution to clarify sugar with the lowest running costs. No other system on the

market from other suppliers are able to follow.

Combining proven technologies

OPEX saving of 199.680 EURO/year NET

Basis of the calculation:

13 t/h, 24 hours/day, 5 days/week, 50 weeks/year

63°brix, appr. 0,2% adding of Kieselguhr+pre-coating

Saving: appr. 2,56 Euro/tonne clarified sugar

Sugar clarification – Why GEA?

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Very high heat recovery, more than 80%

Almost no product losses

Highest usage of syrup due high accuracy of Brix

Environmental friendly: less waste, CO2 savings

Excellent cleaning, hygienic design according EHEDG

Low usage of activated Carbon, can be used more times

Low maintenance and operation costs

Long running time between cleaning of filters (depends on sugar quality)

Optional Activated Carbon press and dryer for optimum usage of sugar

Independent cleaning of filter during production: 24/7

Sugar clarification – Why GEA?

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