GEA Procomac in Dairy. GEA Process Engineering / GEA Procomac

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Tamsin Howard
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2 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. 2

3 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 Spiral Cookers Cooling Towers Decanters Aseptic Filling Packages and Skids Slicers Farm Services Plate Heat Exchangers Homogenizers Brewery & Dairy Systems Ice Machines Thermoformers Farm Equipment HVAC Systems ) Valves Pharma Systems Freezers 3

and generally the best option for those markets that require a

4 GEA Procomac vision & mission Vision: A company that is identified as the market leader for sensitive beverages filling and generally the best option for those markets that require a clean filling environment Mission: NO PRESERVATIVES TO PRESERVE NATURAL LIVING 4

5 155 Aseptic filling lines installed worldwide (December 2013) 5

6 429 filling lines (December 2013) 6

7 Complete Aseptic filling lines for LA and HA products Juices with pulps and fibers Iced teas Sport drinks Functional drinks Soy milk Milk-based low acid beverages Aseptic CSD 7

8 Complete milk filling lines Fresh milk ESL milk UHT milk Milk based products 8

New possibilities for milk in PET Growing trend for packaging milk in PET containers. PET containers offer production, logistics and environmental advantages.

9 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. 9

10 First PET bottle user in India for milk products 10

11 What means DAIRY? PRODUCTS FRESH / ESL (4 C) UHT (Ambient) Probiotics (High Acid) Up to 50 d 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 11

12 Shelf life and technologies Shelf life 7 days 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 C filling CLEAN ULTRACLEAN ASEPTIC No container decontamination - Container decontamination Up to 3 Log Aspergillus niger ATCC Container decontamination Up to 6 Log Bacillus atrophaeus ATCC

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

13 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 bph to bph ASEPTIC (Ambient distribution) For PET bottles Output range for UHT products from bph to bph 13

Filling technology for pasteurized dairy products SAFE AND HYGIENIC FILLING No movable parts in contact with the product except for sanitary membrane valve.

14 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. 14

HDPE / PET bottle for pasteurized product in cold chain Alu foil application GEA Procomac Ecoflux Filling Alu Foil Welding (or Capper) No waste product

15 HDPE / PET bottle for pasteurized product in cold chain Alu foil application GEA Procomac Ecoflux Filling Alu Foil Welding (or Capper) No waste product change Bottle sterilization H Steam Bottle outlet Alu foil sterilization Alu foil press Bottle intlet Specific integration with GEA Process Engineering 15

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.

16 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. 16

at the same time Chiller Oven First Reheating Stabilization time Second reheating

17 ABF 4C for ESL product in PET Ecoxide Blower Stretching Blowing P1 / P2 Air-recovery (Option) Exhaust Preform sterilizer Internal and external preform surface sterilized at the same time Chiller Oven First Reheating Stabilization time Second reheating Inversion time CLEAN ZONE Preform dedusting Filler Capper Ecoflux Preform infeed system 17

18 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). 18

19 Aseptic: GEA Procomac solutions «WET» technology on bottles «DRY» technology on preforms ECOSpin 2 Aseptic Filling Bottle sterilization Spray Liquid Peracetic Acid ABF Aseptic Blow-Filling Preform sterilization Spray H 2 O 2 Vapor Why and When? FDA Approved Easy Neck Change (28-38 mm) Layout Constraints No water waste Reduced Footprint Reduced Chemical use Lightweight and Special bottle design 19

caps Sterilcap IM Can treat 1-piece caps

transferred to the capper by gravity only

flat caps Compact layout: decontamination

20 Aseptic: GEA Procomac solutions «PAA» technology on caps «VHP» technology on caps Sterilcap IM 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 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 20

Handling Internal and External Bottle Steriliz.

21 ECOSpin 2 - Flow chart: production Sterilising Solut. Production and Recovery Caps Supply Sterile Water Production Caps Sterilization and Rinsing Bottle Handling Internal and External Bottle Steriliz. Internal Bottle Rinsing Bottle Filling Bottle Capping Line Control Software Microbiological Isolator Product Pasteurisation Safety devices Aseptic Air Conditioning System Product preparation Finished product 21

22 6 th generation: ECOSpin 2 (in bloc with blower) Blower Ecodox with caustic COP Ecoflux with H 2 O filtration and CIP on board Sterilizer Rinser Filler Oven Exit tunnel Preform inlet Caps sterilization unit Capper 22

23 6 th generation: ECOSpin 2 (bloc with air conveyor and blower) Ecodox with caustic COP Blower Ecoflux with H 2 O filtration and CIP on board Pitching starwheel Sterilizer Rinser Oven Filler Preform inlet Exit tunnel Sterile Zone Caps sterilization unit Capper 23

Bottle blowing Bottle Filling Bottle Capping Line Control Software Microbiological

24 ABF - Flow chart: production H 2 O 2 Sterilising Solution preparation Caps Supply Caps Sterilization Preforms Supply Internal and External Preform Steriliz. Bottle blowing Bottle Filling Bottle Capping Line Control Software Microbiological Isolator Product Pasteurisation Safety devices Aseptic Air Conditioning System Product preparation Finished product 24

25 ABF - Aseptic Blow Fill Blower Ecoflux with H 2 O filtration, CIP on board and caustic COP Ecoxide Chiller Preform sterilizer Filler Oven Capper Preform dedusting Preform infeed system Sterile Zone 25

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

26 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 26

27 UHT Milk bottle solutions: Light Barrier TiO 2 dispersion during Polimerization Step Coloured PET Multilayer TiO 2 PET 27

pieces - Max pulp/fibre size: 3 mm (Ø) x 20 mm (L) - Max pieces size: 5x5x5 mm Fillstar FX P Fillstar

28 Filling flexibility For clear products Fillstar FX STANDARD ASEPTIC FILLERS For still products containing pulps/fibres - 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 Fillstar FX P Fillstar FX C For beverages containing pulps, fibres and pieces with dimensions bigger than 5x5x5 mm DUAL filling 28 S.p.A.

29 Production availability PRODUCT CHANGE Last bottle T = 0 min Filler drainage (5 min) Rinsing with sterile water (0-20min) Filler priming with product (5 min) First bottle T = min FORMAT CHANGE ECOSpin2 Last bottle T = 0 min Blower Change Parts 2 min/mould Filler Change Parts 30 min Bloc setup (*) 30 min First bottle T = min FORMAT CHANGE ABF Last bottle T = 0 min Blower Change Parts 2 min/mould Filler Change Parts 30 min Bloc setup* 30 min Blower SOP 60min (overlapped with Filler activities) First bottle T = min (*) Filler priming with new product, cap sterilizer start up, preform / bottles sterilizer startup 29

Lifetime threshold and automatic communication to headquarter

30 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 30

PLUS : plant management software and database PLUS HD is an integrated Hardware-Software system designed to perform production plant analysis and

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

31 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. 31

32 Thank you for your attention GEA Process Engineering GEA Procomac S.p.A. Via Fedolfi Sala Baganza (PR) ITALY Tel Fax sales.procomac.it@gea.com 32

Aseptic filling solutions. Sensofill FMa Combi Sensofill FMa Combi Predis FMa

Aseptic filling solutions. Sensofill FMa Combi Sensofill FMa Combi Predis FMa Aseptic filling solutions Sensofill FMa Combi Sensofill FMa Combi Predis FMa We know what Sensofill FMa, Combi Sensofill FMa and Combi Predis FMa are Sidel s new aseptic filling solutions for your sensitive