GEA Procomac in Dairy

Transcription

GEA Process Engineering / GEA Procomac
The GEA Group in Summary
The GEA Group is one of the largest providers for equipment and process
technology particularly for the food and energy industries where it ranks
among the market and technology leaders.
The GEA Group focuses on demanding production processes and supplies
its customers with efficient solutions in various end markets.
In 2012 the GEA Group employed over 24,500 people who generated
revenue of more than EUR 5.7 billion.
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Group Structure
GEA Food
Solutions
GEA Farm
Technologies
GEA Heat
Exchangers
GEA Mechanical
Equipment
GEA Process
Engineering
GEA Refrigeration
Technologies
Bowl Choppers
Milking & Cooling
Finned, Shell & Tube
Separators
Spray Drying
Compressors
Cooling Towers
Decanters
Aseptic Filling
Packages and Skids
Spiral Cookers
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Slicers
Farm Services
Plate Heat Exchangers
Homogenizers
Brewery & Dairy
Systems
Ice Machines
Thermoformers
Farm Equipment
HVAC Systems
)
Valves
Pharma Systems
Freezers
GEA Procomac vision & mission
Vision:
Mission:
• A company that is identified as the
• NO PRESERVATIVES
market leader for sensitive
beverages filling and generally the
best option for those markets that
require a clean filling environment
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TO PRESERVE NATURAL
LIVING
155 Aseptic filling lines installed worldwide
(December 2013)
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429 filling lines (December 2013)
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Complete Aseptic filling lines for
LA and HA products
•
•
•
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•
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Juices with pulps and fibers
Iced teas
Sport drinks
Functional drinks
Soy milk
Milk-based low acid
beverages
• Aseptic CSD
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Complete milk filling lines
• Fresh milk
• ESL milk
• UHT milk
• Milk based products
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New possibilities for milk in PET
• Growing trend for packaging milk
in PET containers.
PET containers offer production,
logistics and environmental
advantages.
PET containers are light,
re-closable, unbreakable, carryable
and cost effective.
PET bottles are very flexible in term
of design, shape, engravings, neck
finishes.
High product visibility and brand
identity.
New technologies allow UHT milk
filling in PET bottles.
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•
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•
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First PET bottle user in India for milk products
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What means DAIRY? PRODUCTS
UHT
(Ambient)
FRESH / ESL
(4°C)
Probiotics
(High Acid)
Up to 50 d
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Drinkable
Yogurt
(High Acid)
Up to 50 d
Milk Based
(Low Acid)
Up to 30 d
Milk Based
(Low Acid)
Up to 30 d
Milk Based
(Low Acid)
Up to 12 m
White Milk
(Low Acid)
Up to 12 m
Shelf life and technologies
Shelf life
7 days
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14 days
21 days
120 days
Up to 12 months
Pasteurized
ESL
UHT
Cold chain distribution
Cold chain distribution
Ambient temp.
distribution
2-4°C filling
2-4°C filling
15-30°C filling
CLEAN
ULTRACLEAN
ASEPTIC
No container decontamination
Container decontamination
Up to 3 Log
Container decontamination
Up to 6 Log
-
Aspergillus niger
ATCC 16404
Bacillus atrophaeus
ATCC 9372
Range of machines and speed
FRESH or ESL (cold chain)
For PET, PE, HDPE bottles with
cap and/or Foil application
• Output range for pasteurized
and ESL products in cold chain:
from 6.000 bph to 36.000 bph
ASEPTIC (Ambient distribution)
For PET bottles
• Output range for UHT products
from 6.000 bph
to 72.000 bph
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Filling technology for pasteurized dairy products
SAFE AND HYGIENIC FILLING
• No movable parts in contact with the product
except for sanitary membrane valve.
• All filling valves cleaning controlled through flow
meters.
• Standard automatic cleaning cycles available (CIP).
• Complete automatic foaming cycle available (COP).
ENVIRONMENTAL CONTROL
• HEPA filtration units to ensure air curtain over
bottle neck.
• Hood version and Laminar flow (HEPA filter H14).
• Clogging detection of HEPA filters.
EASY TO MANAGE
• Fully automated machine with integrated and online
HMI interface.
• Full control of Filling and Cleaning automatic
cycles.
• Glass protection for easy accessibility to the bloc.
• No base frame for ideal cleanibility and absence of
stagnation points.
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HDPE / PET bottle for pasteurized product
in cold chain
GEA
Procomac
Ecoflux
Alu foil application
Filling
Alu Foil Welding
(or Capper)
Bottle sterilization
H202 + Steam
No
waste
product
change
Bottle outlet
Bottle intlet
Alu foil
sterilization
Alu foil press
Specific integration with
GEA Process Engineering
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Filling technology for ESL dairy products
ULTRACLEAN AND HYGIENIC FILLING
FOR COLD CHAIN DISTRIBUTION
• Up to 3 Log reduction efficiency to meet most
demanding quality specifications.
• Automatic cleaning and sterilization cycles
(CIP/COP/SIP/SOP).
• Ultraclean sterilizing, filling and capping bloc
with either DRY or WET bottle/cap sterilization
technology (HDPE and PET).
• Complete isolation of sterile area from
mechanical components and lubrication points.
• Suitable for the more demanding ultraclean
products: no compromise in terms of
cleanliness, hygiene and product safety.
• A microbiological isolator housed around the
filling area to maintain a controlled overpressure
of redundant HEPA filtered air (class 100).
• Slanted base frame for ideal cleanibility and
absence of stagnation points.
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ABF 4C for ESL product in PET
Blower
• Stretching
• Blowing P1 / P2
• Air-recovery (Option)
• Exhaust
Ecoxide
Chiller
CLEAN
Ecoflux
ZONE
Preform sterilizer
Internal and external
preform surface
sterilized at the same
time
Filler
Capper
Oven
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•
•
•
First Reheating
Stabilization time
Second reheating
Inversion time
Preform dedusting
Preform infeed system
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Filling technology for UHT dairy products
SAFE AND HYGIENIC FILLING FOR
AMBIENT TEMP. DISTRIBUTION: Aseptic
• Up to 6 Log reduction efficiency to meet
most demanding quality specifications.
• Up to 3 h for automatic cleaning and
sterilization cycles (CIP/COP/SIP/SOP).
• Up to 120 h of continuous production
without any intermediate SOP cycles.
• FDA approved technology (ECOSpin).
• Residuals below 0,5 ppm as per FDA
regulation.
• Full control of Filling and Cleaning automatic
cycles and CCP (critical control points).
• A microbiological isolator housed around the
filling area to maintain a controlled
overpressure of redundant HEPA filtered air
(class 100).
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Aseptic: GEA Procomac solutions
«WET» technology on bottles
«DRY» technology on preforms
ECOSpin 2
ABF
• Aseptic Filling
• Bottle sterilization
• Spray Liquid Peracetic Acid
• Aseptic Blow-Filling
• Preform sterilization
• Spray H2O2 Vapor
Why and When?
• FDA Approved
• Easy Neck Change (28 - 38 mm)
• Layout Constraints
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No water waste
Reduced Footprint
Reduced Chemical use
Lightweight and Special bottle design
Aseptic: GEA Procomac solutions
«PAA» technology on caps
«VHP» technology on caps
Sterilcap IM
Sterilcap VHP
•
•
•
•
• Suitable for both sport and flat caps
• Compact layout: decontamination and buffer
phases integrated in one unit positioned above
the capper
• Possible retrofit on PAA wet aseptic line for dry
solution and sport caps handling
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Can treat 1-piece caps
Sterilisation in bath of PAA solution
Rinsing with sterile water
Positioned above the capper: sterilised caps are
transferred to the capper by gravity only
ECOSpin 2 - Flow chart: production
Sterilising Solut.
Production
and Recovery
Caps Supply
Caps
Sterilization
and Rinsing
Sterile Water
Production
Bottle Handling
Internal and
External
Bottle Steriliz.
Line
Control
Software
Safety
devices
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Internal
Bottle Rinsing
Bottle Filling
Microbiological
Isolator
Product
Pasteurisation
Aseptic
Air Conditioning
System
Product
preparation
Bottle Capping
Finished
product
6th generation: ECOSpin 2
(in bloc with blower)
Blower
Ecodox
with caustic COP
Sterilizer
Ecoflux with H2O filtration
and CIP on board
Rinser
Filler
Oven
Exit tunnel
Preform inlet
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Caps sterilization unit
Capper
6th generation: ECOSpin 2
(bloc with air conveyor and blower)
Ecodox
with caustic COP
Ecoflux with H2O filtration
and CIP on board
Blower
Pitching starwheel
Sterilizer
Filler
Oven
Preform inlet
Sterile Zone
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Rinser
Exit tunnel
Caps sterilization unit
Capper
ABF - Flow chart: production
H2O2 Sterilising
Solution
preparation
Caps Supply
Caps
Sterilization
Preforms
Supply
Internal and
External
Preform Steriliz.
Line
Control
Software
Safety
devices
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Bottle blowing
Microbiological
Isolator
Aseptic Air
Conditioning
System
Bottle Filling
Bottle Capping
Product
Pasteurisation
Product
preparation
Finished
product
ABF - Aseptic Blow Fill
Blower
Ecoflux with H2O filtration,
CIP on board and caustic COP
Ecoxide
Chiller
Preform sterilizer
Filler
Capper
Oven
Preform dedusting
Preform infeed system
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Sterile Zone
Effects of light on milk: new bottle solutions
• Extended exposure to visible light
will initiate photo oxidation of
vitamins B6/B12 and B2 (riboflavin)
• Secondary degradation due to auto
oxidation of lipids results on offflavours and nutrient losses,
especially of vitamins, the so called
«light taste»
• New development of PET (dairy
resin) offers a very high light barrier
(> 99,5%) that may guarantee over
4 months shelf life for UHT milk
(depending of the local laws)
• Virtually total light barrier for very
low wall thickness
• Potential for reducing bottle weight
• Reduced cost
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UHT Milk bottle solutions: Light Barrier
• TiO2 dispersion during Polimerization Step
• Coloured PET
• Multilayer TiO2 PET
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Filling flexibility
Fillstar FX
STANDARD ASEPTIC FILLERS
For clear products
For still products containing pulps/fibres
Fillstar FX P
- Max size: 3 mm (Ø) x 20 mm (L)
For beverages containing pulps/fibres or pieces
- Max pulp/fibre size: 3 mm (Ø) x 20 mm (L)
- Max pieces size: 5x5x5 mm
For beverages containing pulps, fibres and
pieces with dimensions bigger than 5x5x5 mm
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Fillstar FX C
DUAL filling
GEA Process Engineering / GEA Procomac S.p.A.
Production availability
PRODUCT
CHANGE
FORMAT
CHANGE
ECOSpin2
FORMAT
CHANGE
ABF
Î
Rinsing with
sterile water
(0-20min)
Î Change Parts Î
Î
Last bottle
T = 0 min
Î
Î
Last bottle
T = 0 min
Î
Last bottle
T = 0 min
Filler drainage
(5 min)
Blower
2 min/mould
Blower
Î Change Parts Î
2 min/mould
Î
Filler priming
with product
(5 min)
Î
First bottle
T = 10- 30 min
Filler Change
Parts
30 min
Î
Bloc setup (*)
30 min
Î
First bottle
T = 90-120 min
Filler Change
Parts
30 min
Î
Bloc setup*
30 min
Î
First bottle
T = 90-120 min
Blower SOP 60min
(overlapped with Filler activities)
(*) Filler priming with new product, cap sterilizer start up, preform / bottles sterilizer startup
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GEMS - GEA Embedded Maintenance System
• Computerized Maintenance
Management System
• Automatic list of all devices that
exceed the Lifetime threshold and
automatic communication to
headquarter
• Personalized maintenance on the
base of the real life and usage of the
plant
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“PLUS”: plant management software and database
PLUS HD is an integrated
Hardware-Software system designed to
perform production plant analysis and
optimization.
It is the GEA Procomac’s answer to the most
advanced market demands for
interconnecting machine on a production line
and recording production data in order to
controlling systems performance.
•
Real-time monitoring: a global control
over line efficiency from a single location.
•
A tool for statistical analysis of alarms
and machine states to spot critical
points (line bottlenecks).
•
Enabling technology for quick, focused,
and therefore more effective
interventions.
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Thank you for your attention
GEA Process Engineering
GEA Procomac S.p.A.
Via Fedolfi 29 - 43038 Sala Baganza (PR) ITALY
Tel +39 0521 839411 - Fax +39 0521 833879
[email protected] – www.gea.com
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GEA Procomac in Dairy

Transcription

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