424 e fruitjuice

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Process Technology or theFruit Juice and Primary Industries

Innovative Engineering –

Quality in Line.

Process Engineering

GEA TDS GmbH



GEA TDS …

… is established on an interna-

tional level as a specialist or

technically and economically

optimised process technology

in the treatment o milk prod-

ucts, ood and juice.

GEA TDS possesses the necessary know-

how or the design and manuacture o

hygienic, aseptic and sterile plants or

the production o liquid products. Forproject engineering and customer

service, GEA TDS oers international

attendance and short reaction times

by local presence and, o course, Ater-

Sales-Service. Experienced and compe-

tent expert teams deliver technical

solutions tailored to the customer’s

needs.

Product programme for the fruit

juice and primary industries

complete process lines■

short time heaters■

valves, pumps, components■

deaeration technology ■

mixing plants■

tubular heat exchangers■

plate heat exchangers■

CIP plants■

homogenisers■

process automation and integration■

engineering, implementation and■

service



Process technology for the fruit juice

and primary industries

concentrate cooling■

heating o mashes■

tank arm equipment■

evaporation plants■

aroma extraction■

Plate Heat Exchanger VARITHERM® N40,

capacity 24 m3 /h

CIP Plant

STH Plant (RWT) or ruit juice,capacity 20 m3 /h

In-line dosing

32



Process Engineering

Are you planning a complete

ruit juice plant or a new pro-

cessing room or an extension?

Whether your project is a new

’greeneld’ plant, conversion

or modernisation o an exist-

ing process plant, GEA TDS

engineers, with their complex

know-how, are there to back

you up with excellent service.

From isometric drawings to pipe class

specications, rom detailed engineer-

ing to project management, GEA TDS

takes charge o the projects on site, onthe client‘s premises or in our technol-

ogy centre. GEA TDS is now part o the

international systems engineering

sector o the GEA Group. This provides

access to a variety o components and

units made by members o the group

which can be integrated to create high-

quality processing systems.

The use o modern CAE tools or detailengineering is common throughout the

company.

Concentrate

Liquid sugar

Crystal sugarPasteurisation

Dissolving

Reception

Transport

Storage

Storage

Storage

Filter

Dissolving

Minor ingredients

Concept map or continuous blending



Heating plant / deaeration / homogenisation

Pasteurisation

Steriletank

Filler

Pasteurisation

Blending

Premix Ready-to-drink Product

Carbonation

Deaeration o water

MixerHomogeniser Deaeration

Storage

Detailed engineering

layout planning and detailed■

coordination/clariication o details

inventory taking on site■

design o pipe layout and■

instrumentation

arrangement o components■

calculation o material requirements■

and technical speciications

deinition o interaces■

coniguration and dimensioning■

o instrumentation and control

equipment

technical description o the■

processes

quality assurance and■

quality control

monitoring o time schedules■

cost control■

supervision o construction and■

installation work

commissioning o plant components■

supervision o commissioning■

technical support or production■

process optimisation■

documentation■

For project planning and engineering

the main focus points are:

preliminary design■

support in approval planning■

preliminary planning and layouts■

selection/dimensioning o ■

process equipment

production o tender documents■

or process plants

54



Mix-Processing

One o the key production

steps in the ruit juice and

primary industries is product

mixing. In the mixing process

the individual raw materials are

blended in exact proportions

with each other, and mixed to

orm a marketable product.

Basic mixing takes place in batch

mode, i.e. a particular quantity o

a certain product is manuactured.

For exact determination o the weighto the individual components either

scale balances or mass ow meters can

be used as required – in the ruit juice

industry today it is normally mass ow

meters that are used. Product mix-

ing using scale balances is normally

used in mixing processes where there

are many components and the quan-

tities involved are small. GEA TDS

oers the ideal equipment or prod-uct mixing using mass ow meters in

the orm o the GEA Varimass System.

With the Varimass System the various

components are integrated at a valve

matrix using a varying number o mix-

ing lines, according to their mixing

duty. Their quantities are registered by

means o mass ow meters.

The raw materials are introduced to

the valve matrix either individually or

rom a storage tank, depending upon

the customer’s requirements. Smallquantities prepared in advance (solids,

avourings, etc.) are similarly intro-

duced to the mixing matrix exactly in

accordance with the recipe, as are the

container materials rom the container

station.

A very high level o exibility is

achieved by constructing the valve

matrix using VARIVENT® Mixproo Valves that are secure against impact

loads. By means o this design, and by

the valves’ integrated liting actuators,

cleaning o the component and mix-

ture lines can take place in parallel

with the mixing process.

For product mixing using weighing

technology the individual component

lines, contrary to the GEA Varimassprinciple, are not integrated at a valve

matrix, but at one or more weighing

tanks. In the weighing tanks the

individual components are weighed

one ater another and conveyed to the

appropriate mixing tanks. In a variant

o the mixing process, using weighing

technology, the mixing tanks are

directly tted with load cells.

Dissolving station

Manual addition

Storage tanks

Mixing valvearrangement

Water

Optional

Mixer Pasteuriser Filler

Sugar syrup

Reception

Water

Water

Scale

Minor ingredients

Blendingtanks

Container

Blending concept map



A urther variant o the prod-

uct mixing process is provided

by continuous in-line mixing

technology.

In this procedure we blend the indi-

vidual components or a prepared

premix direct prior to the ollowing

processing. Using this technology the

available capacity o the ingredients

or nal product can be increased.

A mixing plant that is optimised andmatched to customer requirements

increases the efciency and reliability

o the product mixing process. This

enables customers to react with a high

degree o exibility to the rapidly devel-

oping requirements o the market and

to achieve considerable cost reductions.

Our aim is to create and oer optimised

plant designs to meet individual cus-

tomer requirements.

Tank arm Small volume mixing system

Valve matrix or mixing

In-line dosing

76



Pasteurisation plant

Fruit juices as well as beverage

bases require a long shel lie.

Conservation o the product

shall be achieved by ecient

processing without aecting

the product quality.

This task is achieved by thermal

treatment o the product using a

pasteuriser. In a short time heating

plant (STHT plant) the product isheated or a short time to the required

temperature and rapidly cooled down.

Plate or tubular heat exchangers at

choice are used to heat the product

to the required pasteurisation temper-

ature.

The heat treatment system to be used

depends rst o all on the properties o

the product to be treated. The correct

design o the pasteuriser as well as theselection o appropriate components

allow the treatment o the ollowing

products:

Smoothies■

ruit juices and drinks with and■

without cells, pulp and CO2

vegetable juices■

primary products■

mashes■

Vacuum Deaeration

For not aecting the quality

through oxidation, the product

undergoes a vacuum-deaera-

tion which partly takes place

during the pasteurisationprocess.

Via an especially designed cascade valve,

the product is conveyed at a temperature

between 55° and 60° C into the deaerator

vessel where the major part o the total

gas amount is removed rom the product.

The aroma substances entrained by the

degassing procedure are recovered in a

tubular heat exchanger and returned to

the product.

Heating plant 30m³/h capacity



Homogenisation

The GEA Niro Soavi high-

pressure homogenisers and

microsizers refect the latest

innovative developmentsand show excellent results

in respect to capacity and

reliability.

The capacity ranges rom 10 l/h to

50,000 l/h at an operating pressure

o 1,500 bar max. For special appli-

cations, a homogenising pressure o

2,000 bar max. can be achieved. The

Ariete series are capable o process-

ing products at temperatures up to

180° C. Special operating conditions,

e.g. adherence to hygienic and aseptic

requirements or treatment o abrasive,

viscous or corrosive liquids, can be

ullled with the standard treatment

programme.

In aseptic process technology,

product saety takes top

priority. Food processors use

sterile tanks as storage or

buer tanks.

When producing beverages

containing CO2, carbonation

is integrated into the overall

line concept.

Aseptic storage prevents recontamina-

tion o the product and helps to ensure

a long shel lie and stability.

Ater pasteurisation, hygienic treatment

o the product is required. Sterile tanks

can perorm a buer unction in the

process upstream o the lling line.

GEA TDS oers carbonation o bev-

erages. Gaseous CO2 is added to the

product. This continuous process can

be integrated into the overall processeither upstream or downstream o the

thermal treatment.

Sterile tank

Carbonation

98

Sterile tank

Carbonisation system

Homogeniser



VARITHERM®

Plate Heat Exchanger

The core piece in process

plants are heat exchangers– they are used or cooling,

heating, pasteurising or UHT

heating. GEA TDS use plate

and tubular heat exchangers

depending on the plant

conguration.

As a central module in thermal processtechnology, the plate heat exchanger has

always been the cornerstone in systems

engineering: design and development are

continuously adapted to the needs o the

changing market and trends in product

specications.

The advantages at a glance:

thermal treatment o products■

containing cells and ruit pulp

eicient heat transer, i.e. small heat■

exchange area and thus low

investment costs

high degree o heat recovery (up to■

96 %), this means low energy costs

low space requirements due to large■

heat transer surace in a compact

assembly

easy adaptation to changed capacity ■

parameters by expansion or reduction

o plates, i.e. high-lexibility

short dwelling times in the heat■

treatment section, thus gentle product

treatment

Type VARITHERM®

VARITHERM®

plates are used or thethermal treatment o:

clear or turbid products with and■

without CO2

Products containing ibres with a max.■

edge length o 0.5 mm to 1 mm.

You can choose between various types

o heat exchanger plates with dierent

embossed proles:

Plate type H with horizontal■

chevron pattern or high thermal

eiciency

Plate type V with vertical chevron■

pattern or lower pressure drops

Plate type M and P with V-shaped■

chevron pattern or highest dieren-

tial pressure resistance

Type Freeflow NThe Freeow N plate is the right

choice or:

clear or turbid products and products■

containing ibres

up to a length o approx. 5 mm and■

1 mm in diameter

Type H

Type V

Type M/P

Type Freelow N



VARITUBE®

Tubular Heat Exchanger

VARITUBE® S – the single-tube heat

exchanger or indirect heat exchangeor the treatment o products contain-

ing pieces. Product recovery is possible

using pigging technology.

VARITUBE® M –the multi-tube heat

exchanger or indirect heat exchange

is also suitable or products containing

particles o approx. 18 mm length.

VARITUBE® P – or the direct prod-uct/product heat exchange in all appli-

cations.

VARITUBE® SK – or the direct prod-

uct/product heat exchange o bre-

containing products up to a length o

30 mm.

Functional principle: Patented ow

devices installed on the bottom plateprovide additional acceleration and

generate a transverse ow, ensuring

that no bres collect on the tube

bottom. Longer production cycles

are thus achieved.

VARITUBE® HS – the multi-tube heat

exchanger or indirect heat exchange,

suitable mainly or hot water genera-

tion and heating o CIP media.

VARITUBE® E – Multitube with indi-

rect heat exchange, suitable mainly or

hot water generation and heating o

CIP media or medium thermal out-

puts and volume ow rates o up to

165 m3 /h.

The VARITUBE® Tubular Heat

Exchanger is specicallydesigned or the thermal

treatment o low- to high-

viscosity products and or

products containing particles,

pulp and bres. The VARITUBE®

system is mainly used in

heating, cooling and aseptic

systems.

VARITUBE® S and M, corrogatedand plain inner tubes

VARITUBE® P

VARITUBE® SK

VARITUBE® HS

VARITUBE® E

Profle o VARITUBE® SK

1110



Process Automationand Integration

Quality assurance and

increased productivity drivethe steadily increasing auto-

mation o plants and produc-

tion processes. The advan-

tages are obvious: labour and

production downtimes are

reduced and operator error

is saely ruled out. The plants

are upgraded so that all essen-

tial parameters relevant or the

production processes are auto-

matically controlled, monitored

and documented.

GEA TDS oers a wide spectrum o

innovative process automation systemsand services that range rom the provi-

sion o electronic process control up to

integrated, company-wide network

systems complete with the correspond-

ing management inormation systems.

Machine control systems, or separators,

homogenisers or lling machines or

example, can be homogeneously

integrated into the overall automation

system through the bus network.

GEA TDS uses the latest industrial stan-

dards or all automation projects. In this

respect batch processes are automated

in accordance with ISA-S88a as an

essential actor or a transparent, trace-

able production.

To adapt existing production plants to

new generations o automation systems(e.g. when replacing the visualisation

system or upgrading rom S5 to S7)

migration strategies will be developed

or you that allow sae conversion while

production continues to run.

Operation and Process Visualisation

All operator interaces are designed with

logical menu structures that allow intui-

tive operation o the plant. The operator

is comprehensively inormed at a glance

and guided progressively through the

system.



Documentation and Process

OptimisationThe supervisory control system allows

operators to record measured values and

switch status, thus creating the neces-

sary transparency or process optimi-

sation.

Recording o measured data is supple-

mented by a database-supported event

log with practice-oriented evaluation

eatures. This audit trail allows thetracking o individual batches or an

entire production.

Reporting and Batch Tracking

The process data is transerred onlineto an SQL database extended with

powerul evaluation tools:

the report generator can be cust-■

omised so you can conigure your

own application-oriented reports.

batch tracking in graphical or■

tabular orm helps you to keep

track o your products in accordance

with the EU regulation 178/2002.

The standardised approach allows you

to introduce a batch tracking system in

manageable steps at a known cost.

CIP curve

Signals STH

Track & Trace

Login

Reception

Fruit juice blending

1312



CIP (cleaning in-place) is the

commonly used method or

plant cleaning during the pro-

duction process where hygiene

is, o course, paramount.

Variable CIP systems are available or

dierent cleaning procedures. The diver-

sity o products and processes calls or

dierent methods or cleaning process

plants. Variable CIP systems are avail-

able or dierent cleaning procedures within the production process where

hygiene is paramount.

GEA TDS is always striving to nd the

optimum balance between chemicals,

mechanics, temperature and residence

time, with additional ocus on environ-

mental protection and down-times.

Using a modern CIP system ensures the

optimum quality assurance and increas-

es product quality.

CIP Recovery Systems

These CIP systems consist o various

cleaning medium tanks or drinking

water, cleaning solution and returned

water. The system or tank size is adjust-

ed to the cleaning cycles required. The

number o cleaning systems installed

determines the cleaning requency, the

simultaneous execution o operations

and the number o objects. The systemsare technically equipped and cong-

ured to meet the cleaning objectives

dened.

Single Use Cleaning System with

ECOCIP

The system consists o a detergent tank

or the ready-made cleaning solution,

pre-assembled on a base rame. The

cleaning solution is circulated and heat-ed up to the operating temperature.

Conductivity measurement and in-line

concentrate metering ensure that the

required amount o detergent is added.

The detergent ow rates are adjusted

by the cleaning program. CIP modules

are easy to integrate into the process

and oer the most appropriate clean-

ing even or demanding products.

CIP Plants

CIP batch cleaning assembly

CIP Plant



Aseptic flling system

GEA TDS services also include

the assembly o entire plants.

A comprehensive range o

services is available throughoutthe entire service lie o your

plants, all designed to achieve

maximum productivity and

economic eciency.

With GEA Procomac we

respond to the need o the

beverage market or an overall

solution and can provide com-

petent on-the-spot services.

GEA Procomac based near

Parma in Italy is one o the

world’s leading suppliers o

cold aseptic lling technology.

The GEA TDS Ater-Sales programme

includes a permanent support service:

taking care o service and maintenance

directly ater hand-over o the plant.

Customer support also includes denedmaintenance and individual inspec-

tion agreements to ensure ault-ree

and reliable operation and to keep your

plant running efciently or years.

Their core business is the engineering,

manuacturing and installation o com-

plete lling lines or the beverage indus-

try both or conventional and asepticapplications. The proportion o aseptic

lling lines is about 70 % o all the lines

delivered.

GEA Procomac supplies complete lling

lines or juices, teas, still/carbonated

beverages, dairy products and water,

in a constantly high quality rom the

process technology to the packaging

technology.

Assembly and Ater Sales

Packing technology

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e n t u r . d e

Process Engineering

GEA TDS GmbHVoss-Straße 11/13 · 31157 Sarstedt · Germany

Phone +49 5066 990-0 · Fax +49 5066 990-163

Am Industriepark 2–10 · 21514 Büchen · Germany

Phone +49 4155 49-0 · Fax +49 4155 49-2724

Kruppstraße 3 · 48683 Ahaus · Germany

Phone +49 2561 8602-0 · Fax +49 2561 8602-130

www.gea-tds.com

Innovative Engineering –

Quality in Line.

To nd out more about your particular process

technology application, contact GEA TDS at

www.gea-tds.com

The juice industry produces many dierent products and this

brochure could not possibly describe all the potential process lines

available.

424 e fruitjuice

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