CHOOSING TECHNOLOGY

ESADA, September 2015

Hendri Downing

CHOOSING TECHNOLOGY

Process Engineering / GEA TDS GmbH

General Considerations

2

• What Product/s do you want to produce?

• What will your capacity be?

• Milk Quality/Juice with preservatives?

• How Flexible do you want to be?

• Will you contract pack?

• Product Shelf Life/cold chain

Aseptic CSD Isotonics Juices LA drinks Water CSD

HOT

FILLESLASEPTIC FILLING TRADITIONAL FILLING


Plate VS Tubelar HX

3

Performance• Viscosity• Particles• Fibers

10

1

3

5

Price

SSHE

THEFF

PHE

• Price / Performance - Relationship

Basic Process Equipment


Overview

4

Technological Aspects - PHE

Plate Heat Exchangers • small gap

• forced turbulence flow

• good mixing effect

• high k-Values at low p

• for smooth products (VT)

• for products with small

particles and fibres ( FF )


Overview

5

• wide gap

• small mixing effect

• high k-Values only at high p

• high operation times

• for middle viscous products with

fibres and particles

Tubular

Heat Exchangers

Technological Aspects - THE


Overview

6

Technological Aspects - SSHE

Scraped Surface

Heat Exchangers

• wide gap

• good, mechanically forced

mixing effect

• high k-Values via

surface scraping effect

• avoidance of fouling

• for high viscous products

with and without particles


Packaging technology

• It was found out in a study, that the highest recontamination in a

process line of pasteurised fresh milk is caused in a filling machine

(Process line: From raw milk to the packed final product)

That implies:

• Sterile air blanketing of filling elements or an aseptic filling machine

have generally been accepted in the market as basic requirements

for the production of ESL/UHT milk.

• Another important aspect is the integrity and proper decontamination

of package material.

Shelf life

7


Continuous cooling chain:

• For each 2°C increase of the storage temperature,

the shelf life of milk will decrease by approx. 50 percent.

That implies:

• A temperature below 8° C until the date of consumption must be

maintained during storage and transportation.

General shelf life extending factors

8


• Cost of Packaging (cartons/HDPE/PET)

• OPEX vs CAPEX of the equipment

• Product Change-over times

• Format change-over times (30min – 3 days)

• Label vs printed Cartons (contract packing)

General Considerations for Packaging

9


• Line Flexibility

• Line Speeds

• Format Sizes (150ml – 2000ml)

• Water/Electricity Usage

• Chemical Usage

General Considerations for Packaging

10


Depending on the product recipe different technologies cane be

used:

• High Shear mixers

• Inline mixers

Mixing Technology

11


High Shear Mixer in Operation

12


Choosing the Right Technology

13

• There are many more technologies involved:

• Seperators/Decanters

Spray Drier for WMP


Choosing the Right Technology

14

• Deaeration

UHT Plants

Filtration Plants


Choosing The Right Technology

15

In Conclusion - To understand what you are getting/paying for:

• Understand the Technologies

• Understand WHY some cost more/less

• Understand what you are gaining/giving up

• Be clear of what you want to Achieve.

• Thanks for your attention!