Process Engineering

GEA Powder Handling, Packing and Components Technology

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GEA Powder Handling, Packing and Components Technology

Powder HandlingPowder Ingredient Unloading Systems . . . . . . . . . . . . . . . . . . . . . . . . . .7Pneumatic Conveying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7Powder Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8Sifting & Blending Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8Batching and Weighing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8CIP Cleanable Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9Powder Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

25kg Bag FillingTwo Brands – one source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Avapac™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Li Range - Limited Intervention Range . . . . . . . . . . . . . . . . . . . . . . . . . . 12RBF Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12IBF Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12SmartFil™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Line Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Bulk Container fillingAutomated Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Manual Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Retail Container FillingAccuracy is the Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Integrated Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20Vacuum Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20Auger Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20Specialist Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22Sanitation & Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22Controls & Integration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Packaging FormatsRigid Containers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25Multi-wall Kraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25Big Bags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25Boxes & Drums . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25Boss Pak™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Modified Atmosphere Packing (M.A.P.) for PowdersPre-gassing of Powders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27Pre-gassing for Retail Containers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28Continuous Gassing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29Post Gassing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

ComponentsManufacturing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31Rotary Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31Central Vacuum Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31Blower Packages for Powder Conveying . . . . . . . . . . . . . . . . . . . . . . . . . .31Dust Collection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31Product Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

AftermarketGlobal Service Organisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35Spares Packages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35Product Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35Plant Optimisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35Upgrades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

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Introduction

GEA Systems CapabilitiesYou might recognize our company and our brand names already . We are GEA Avapac and GEA Nu-Con, and we represent the brands of:

• Avapac™• Colby™• Albro™• Nu-Con™• SmartFil™

Collectively, we come together as GEA Powder Systems .

GEA Powder Systems is dedicated to the world-class design and manufacture of Powder Handling including:

• DryBlendingSystems• IngredientUnloadingSystems• 25-kgBagFillingandPowderPackagingSystems• RetailContainerFillingSystems• InertGasandModifiedAtmospherePowderPackaging

Systems• BulkBag(SupersackorFIBC)PowderFillingSystems• IntegratedAutomationSystems

The service we provide is unique . In fact, as our clients in the Americas, Europe, Africa, the Arabian Gulf, South and East Asia and Australasia will attest, there is nothing like it in the world .

GEA is the only supplier capable of meeting the full spectrumofpowderfillingandpackingrequirementssavingthe need to search the world for specialised machinery . Whether purchasing an individual machine or a fully integratedsystem,allclientsbenefitfromourunderstandingof the exacting requirements of the powdered food industry .

We know that our chosen industries can demand very high quality, reliability and sanitary standards, so we do everything with these requirements in mind .

Integrated SystemsA system is more than just the sum of the partsSuccessful design involves the translation of good ideas into practical solutions . GEA approaches a solution by looking at the entire process . We work with our customers to ensure that the solution we provide is properly integrated within their plant . We look for synergy in our solutions and this is whereourcustomerswillseetherealvaluethatGEAoffers.

• Batch&PlantControl• AutomatedControl• SmallestPlantFootprint• LowestEnergyConsumption• In-builtSafety

ComponentsThe difference is in the detailThe team at GEA knows that the quality of every component is vital to the overall performance of the system . Our purpose built manufacturing facility is set up to produce highqualitycomponentswhicharenotonlyofferedaspartof our turnkey systems but which can also be provided as discreet, stand-alone products that can be integrated into an existing plant .

Our aftermarket support for spares and service ensures that our customers receive expert attention throughout the life of our products .

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Meeting Customers’ Needs

Corporate Social ResponsibilityOur customers are an integral part of our businessThesolutionsthatGEAprovides,whilstdesignedtomeetspecificbusiness objectives, also enable our customers to maintain a sustainable and reliable plant operation with minimal downtime .

Our leading edge engineering is helping our customers, throughout the world, to reduce waste and power consumption and to increase the overall yield of their plants thereby contributing to a sustainable industry .

Safety and HygieneSafety and hygiene are at the forefront of our design philosophy . GEA solutions are helping our customers to feed the world and as a world leader in the manufacture of systems for the food and dairy industry we do not cut corners when it comes to safety and hygiene .

It is our goal to not only ensure that our customers have a safe plant but that the products they manufacture are also of the highest quality for the consumer .

Standards ComplianceDelivering high quality systems and components to the global powdered products industry demands a strong focus on international standards and directives . Our team of experienced engineers has automated real time access to the latest directives to enable them to carry out detailed risk assessments and thereby ensure compliance with the applicable standards in each of our key markets .

ReliabilityReliability is not just a word – it’s a philosophy.Our customers need to have a trouble free plant for the lifetime of the equipment and it is our goal to ensure that they do!

This is why our teams of engineers painstakingly select components which have a high service life to give trouble free operation for many years with minimal downtime .

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Integrated Powder Systems Solutions

GEA has the experience, resources and components required to deliver state-of-the-art powder handling systems anywhere in the world .

By coupling our Core Technology Centres in New Zealand with GEA’s strong local market focus, we can deliver local market support and service on a global scale .

All GEA systems are distinguished by their unrivalled engineering and manufacturing quality,sanitarydesign,efficientinstallationandcommissioning complete with a comprehensive maintenance and service support to ensure a long and trouble free life .

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Powder Handling

Our understanding of our customers’ needs to control the flow of materials in their plants has resulted in some ground-breaking innovations.

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Our experience, resources and high quality components coupled with our extensive knowledge of powder packing equipment enables us to provide genuine ‘turnkey’ solutions to meet and even exceed our customers’ requirements .

Powder Handling in a Hygienic Food Processing Environment covers a broad range of expertise . GEA delivers that expertise to your doorstep in one complete package of

• ProcessEngineering• ProjectManagement• EquipmentSupplyandInstallation• ControlSystemIntegration• OnsiteCommissioning• AfterSaleServiceandSupport

Powder Ingredient Unloading SystemsUnloading Systems are used to empty materials from bags, bins and other containers into a production process . GEA has a wide range of solutions that can be easily integrated to provide a complete tipping system suitable for the customers’ requirements .

GEA systems frequently include additional features for the safety and comfort of operators and to eliminate labour requirements such as lifting devices, dust extraction systems, empty bag compactors, and automated cutters, shakers and sifters .

Pneumatic ConveyingGEAhastheknow-howandbroadrangeofcomponentsrequiredtoconfigureclean,efficientandcosteffectivepowderconveyingsystemsformanyapplications .

Because the product is transported pneumatically in stainless steel tubes and vessels, the systems supplied by GEA meet all sanitary standards . Where necessary, the entire system can be atmospherically sealed, evacuated and filledwithaninertgas,readyforfinalpackaging.

From non-friable and non-sanitary powders to high-value, fragile pharmaceuticals, we can supply all the components and systems required .

Both standard products and fragile powders can be transported under lean-phase or dense-phase, using pressure or vacuum .

Ourmethodforconveyingagglomerated(fragile)productsusesproventechnology to provide the most gentle and reliable means yet developed for conveying a broad range of powdered products, most notably dairy powders .

Low product velocity means minimal damage for fragile powder particles . Becauseonlysmallquantitiesofairorgasareused,filtersaresmallandeasytoservice.Thesystemsweofferareeasytoinstallandsimpletouse,cleanand maintain .

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Powder StorageGEAoffersawiderangeofbulkstoragesolutionsforbothrawmaterialsandfinishedgoods.Weunderstand”Bulk“ineverysense of the word – our experience includes a high level of design competence in powder storage silos and hoppers .

Our proven understanding of our customers’ needs to control theflowofmaterialsintheirplantshasresultedinsomeground-breaking innovations .

Every storage solution we recommend demonstrates our awareness and knowledge of bulk storage issues, including loading and feeding, internal and external silos, hoppers and day-use bins, flexibleintermediatebulkcontainers(FIBCs)andrigidintermediatebulkcontainers(RIBCs).

GEA can design the most practical solution to all your bulk powder storage requirements .

Sifting & Blending SystemsGEA can engineer and supply a wide range of sieving and blending techniques to suit many industries .

Weoffercost-effectivemeansoffinescreeningdrypowdersand granular products such as milk powders, food additives, pharmaceuticals, chemicals and other high value products .

ThesanitarysievesthatGEAoffersaremanufacturedfromarangeof stainless steel and food-grade materials to ensure the most suitable contact surface for each product . Sieves can be supplied with a wide variety of throughput rates and aperture sizes .

Sieves can be operated as stand-alone units, or can be integrated into complete GEA powder processing systems .

GEA has extensive experience with all types of blender units, ranging from simple batch units to multiple units providing continuous output . Our experienced system integration engineers can advise the correct solution for your application, whether it be asimple‘tumble’blender,high-efficiencyribbonblender,paddlemixer or vertical ribbon blenders .

OurclosetieswithblenderOEM’salsoallowforcosteffectivespecialblenderconfigurationstosuitthemostdemandingrequirements . We can provide the technology required for high throughputs, high levels of accuracy and high sanitation standards .

Batching and WeighingMany powder handling systems require bulk weighing of large volumes of materials for the preparation of product batches for ingredient formulations . Typical applications are for food mixes, soupsandflavourings,pre-mixedbakingrecipes,infantformulas,drinks, sauces, health and nutritional supplements, breakfast cereals, confectionery, pharmaceuticals and many others .

GEA has a wide range of equipment suitable for systems from 100 tonne silo weighing to micro ingredient systems dosing a few grams .

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Typical Features include:

• Highaccuracyload-cellsandweightcontrolelectronics• Major,minorandmicroingredientdosing• Safe,sanitaryanddustfree• Multipleingredient• Gain-in-weight,loss-in-weightandcontinuousweighing• Fast/bulkfillandslow/tricklefillingwithself-tuningpre-act• Automatictop-up• Maximisedflexibilityforvariablerecipes• StateoftheartcontrolsystemsandrecipemanagementusingSCADA/HMIsoftwareforprocessvisualization,inventorycontrol and reporting functions for management information systems .

CIP Cleanable SystemsGEA is a world leader in the design of completely CIP Cleanable Powder Systems for the most stringent hygiene requirements.When your hygienic requirements demand that batch separation is absolutely assured, GEA can provide completely CIP cleanable powder handling systems for particularly critical applications such as pharmaceutical and infant formula manufacture . Conveying, storage and mixing systems can all be CIP cleaned for minimum downtime with approved designs and components .

System features include:

• ProvenCIPresistantvalves,diverters,mixers,vesselsandothercomponents,CIPcleanablefiltrationandisolationsystems

• Hotairdryingandreticulationequipment• USDA/3AacceptedCIPnozzlesandsprayballs–hydraulic,

pneumatic or removable• Water/acid/causticsupplysystemsandcontrols• Wasteliquiddrain/recoverysystems• Automatedandsemi-automaticPLC

Powder TestingPowder handling and packaging is an increasingly complex business . Customers are demanding ever higher levels of performance and service . GEA is meeting their demands by using advanced tools and systems to deliver products of superior design and performance .

GEA understands the advantages of powder testing . Prior to designing mechanical or pneumatic handling systems, GEA typically tests for a wide range of powder properties including sieveanalysisforparticlesizedistribution,bulkdensity,flow-ability,mechanicalstabilityandfluidisationindex.Eachoftheseparameters is carefully taken into account in the development of the design and the execution of the project .

With the results of powder tests we can utilise our extensive in-house knowledge base and experience to design a system with guaranteed performance .

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25kg Bag Filling

GEA can now proudly offer two brands of filling system to offer even greater choice to our customers.

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GEA Filling Lines - the heart of the operation

Two Brands – one source“Our success is often limited by the choices available to us”GEAnowproudlyofferstwobrandsoffillingsystemtoprovide an even greater choice to our customers .

Thetworangesoffillerhavebeencarefullyselectedfromouroriginal Avapac™ and SmartFil™ machine brands to ensure that GEA has a system to meet most of our customers’ needs and preferences .

From a basic but elegant manual system to high output and high accuracy systems and even an almost completely unmannedsolution,GEAhasasolutiontofitthemostdemanding powder packing requirements .

Avapac™

TheAvapacbrandoffillersiswellknownthroughouttheworld and is synonymous with high quality and reliability . Our experience with many and varied powdered products meansthatwehaveasolutiontofitmostpackingneeds.

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Li Range - Limited Intervention RangeTheflagshipoftheGEAAvapacrangeistheallnewLi(LimitedIntervention)bagfillingsystem.Thistechnologysetsanewbenchmarkinautomatedpowderpacking and bag handling .

Reliablebagfillingandclosing,combinedwithanautomatedbagde-stackingsystemhasresultedintheworld’sfirsttrulyautomaticpackingsystemwhicheliminates the need for an operator inside the packing room .

Starting at the optional fully automated bag de-stacking system, bags are deliveredtothefillingsystemandloadedontothefillingheadreadyforfillingand closing .

Multiple independently controlled bag stations are combined into a carousel to performbagfilling,preparationandclosingwhilstthebagisfullyheldensuringfault free operation and thereby maximising throughput of the bag packing plant .

Well proven GEA Avapac bag sealing and closing technology has been integrated intothefillingsystemtoprovideaverycompactoperationwhichsignificantlyreduces the space required for production .

An optional wireless operator panel can be used to monitor the packing process from a central location - which was previously only possible for large automated processing plants .

Ethernet connectivity enables both local and remote monitoring and data analysis using the customer SCADA system .

RBF RangeTheGEAAvapacRBF(RotaryBagFiller)rangeisdesignedtopackawidevarietyofproductsathighfillingrates.

TheRBFrangefeaturesabottom-upfillingsystemwhichmaintainsaconstantdistancebetweentheoutletofthefillertubeandthetopofthepowderinthebag.By doing this, the displacement of air is kept to a minimum and the resulting dust emissions are dramatically reduced over more conventional systems .

ThismakestheGEAAvapacrangeoffillersverycleanandsafeinoperationand the reduction of product losses, through better dust control, means greater product yield for our customers .

PLC with touch-panel operation allows complete control of the packing line fromthefiller,whilstmultipleproductconfigurationsheldasrecipe’stakecareof a wide variety of packing parameters for multiple products . All RBF product contact parts are constructed of stainless steel, making them ideal for both dairy and food ingredient products .

IBF RangeTheGEAAvapacIBF(lnlineBagFiller)rangeisdesignedtopackawidevarietyofproductsatlowtomediumfillingrates.

Featuringthesamebottom-upfillingsystemasthelargermodels,theIBFrangeoffersgreatvalueandflexibilityformediumpackingrates.

AllIBFfillersareconstructedofstainlesssteelwhichmakesthemidealforbothhigh hygiene and corrosive products . Change parts are available for customers wishing to pack a variety of products on the same machine, and options include CIP cleaning .

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RBF800LiRBF1200Li

IBF800 IBF600 IBF45025

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SmartFil™TheSmartFil™brandoffillershasbeendevelopedtoprovidecustomerswithaflexibleandcosteffectivefillingsolutionforlowerthroughputs or where there is a requirement for frequent cleaning .

25-200DTheSmartFil™model25-200Dbagfillerisdesignedtofill25kgbagswith powdered products .

Theeasy-cleanhorizontalaugerfeedfillingsystemisideallysuitedtofood and dairy applications where there is a requirement for accurate andhygienicfilling.

The removable auger is also well suited to plants where there is a need to pack a wide variety of product and where frequent cleaning is a key requirement . To further enhance the capability of the SmartFil™ system, an innovative fully CIP’able option is available .

Thefullyautomaticoperationofthisfillingsystemprovidesflexibilityfor medium volume, high value packing operations .

25-100DGEArecognisesthatcustomershaveabroadspectrumoffillingrequirementsandwehavedevelopedtheSmartFil™25-100Dtofulfilthe need for low volume or pilot plants where customers wish to have moremanualcontrolovertheirfillingprocess.

Thissimplebutelegantfillingsystemhasgreatflexibilitytohandleawidevarietyoffillingmethods.Initssimplestform,theunitcanbe placed beneath the customers’ existing powder feed system . Alternatively, GEA can supply the 25-100D with a rotary valve, vibratory-tube or screw feed system .

Line EquipmentGEA designed Line equipment includes solutions to meet the varied needs of powder packing facilities .

Oncethefilledbagisclosed,itispassedtotheLineequipmentfor processing and quality checks before being palletised . The Lineequipmentcanbespecifiedandconfiguredtomeetcustomerrequirements, or to suit existing packing facilities .

AlinecontrolMCCcanbeconnectedtothefillertoprovidedistributed control for line equipment . This connectivity enables the line to be monitored and controlled from a single interface thereby providing a user friendly environment .

Optional connectivity of the check-weighing and bag coding equipment enables both local and remote monitoring and data analysis using the customers’ SCADA system .

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Line Equipment

SmartFil™ 25-100D

SmartFil™ 25-200D

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Bulk Container Filling

Our team of experienced engineers work closely with our customers to develop the right solution.

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GEA has a wide range of solutions for packing products into bulk containers including FIBC’s, RIBC’s, Octobins, Tote bins and even Boss Pak™

Asnearlyeverysolutionistailoredtosuitspecificneeds,our team of experienced engineers work closely with our customers to custom design the right solution .

Automated SystemsOurbigbagfillingcustomersaremanyandvariedandwithparticular requirements for safety and hygiene, GEA has responded with several automated solutions .

Therangeincludessafeandconvenientsystemsforfillinghigh value products which can automatically palletise the finishedbagsoutsideofthehighhygienearea.WithourownImpulsesealingsystem,GEAoffersacompletesolutionforinert gas packing of oxygen sensitive powdered products .

Manual SystemsFor lower throughput or alternative packing format requirements,GEAcanofferverysimple,lowcostmanualsolutions which can be easily installed directly below existing powder feed installations .

GEA Filling Lines - the heart of the operation

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Retail Container Filling

GEA retail powder filling lines can fill the widest range of powders including free flow food powders.

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When high hygiene, high accuracy, product safety and fully integrated automationareyourkeyrequirementsforfillinghighvaluepowdersintoretailcontainers, then…

GEAhasacomprehensiverangeofworldclassfillerstocoverthroughputsupto400 containers per minute and container sizes from 200 grams to 2 .5 kilograms .

Our on-going development program means that you will always obtain state-of-the art systems featuring the latest technology .

AsallGEAretailpowderfillinglinesaredesignedwiththecustomer’srequirements in mind, they combine the highest levels of productivity and accuracy with the gentlest product handling, while ensuring that requirements, such as correct spoon placement, are met .

GEAretailpowderfillinglinescansuccessfullyfillthewidestrangeofpowdersincludingfreeflowfoodpowderssuchas:

• MilkPowderandPowderedDairyBeverages• NutritionalPowders• CoffeeandCoffeeCreamer

Dependingontheproducttobefilled,GEAfillingtechnologiessuchasauger,auger/vacuumorvacuumonlycanbeoffered.

Accuracy is the Key‘Nothing Under’ FillingIn many markets, local legislation states that the net content of each and every container must never be less than the declared weight .

Inthese“nothingunder”markets,GEA’sprovenvacuumaugerfillersorthemoregentlevacuumbulkfillandoptionaltop-upsystemcombinesextremeaccuracywith high throughputs to produce average savings of up to 5 per cent compared withotherfillingtechnologies.Dependablehighfillaccuracyisthekeytoproviding minimal product give away .

Rather than giving away large quantities of powder to reduce underweight rejects to a manageable level, GEA has a solution for you .

Wecanprovideeitheraugerbulkfillmachineswithunparalleledaccuracyorvacuumbulkfillmachineswithasinglestationtop-upifrequired.

Whenatop-upsystemisinstalled,theGEAcontrolsysteminstructsthebulkfillertounderfillallcans.Eachcanisthenweighedagain,andtheamountrequiredtobringthecanuptothespecifiedweightispassedforwardtothetop-upsystem.

Average Weight FillingInsomemarkets,itispermissibletounderfillaproportionofcans,providedthatthe complete batch has an average weight which is greater than or equal to the declared weight .

In these markets, GEA utilises a dynamic targeting feedback system that allows clientsthatarefillingtoaverageweightlegislation,toreducegive-awaylevelstoas low as 0 .01 per cent .

Regardlessoffluctuationsinthebulkdensityofthesupplypowder,thefillingsystemcalculatesarunningaverageofallcontainersfilled,andadjuststhedynamictargettomaintaintheaverageat(orslightlyover)thedeclaredweightatall times .

GEA Retail Filling Lines - the heart of the operation

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Integrated SystemsA truly integrated filling line is far more than a series of machines running in sequence.It is the product of a clear understanding of throughput, accuracy, shelf life and quality standards . The types of powders to be handled, the variety of container sizes and the frequency of product changeover must also be taken into account .

Successfulfillinglinedesignalsorequiresthecarefulselectionofcomplementary machines and components from all over the world, the provisionofbufferstoensureminimumdisruptiontooperationsandspecialised software which can integrate and control both machine and system performance .

Each of these issues is critical and getting the line right is as much an art as it is a science: an art based on specialist knowledge, experience and expertise .

AllGEAfillinglinesfeatureintegratedcontrolsystemswhichcontinuouslymonitorandadjusttheperformanceofthefillingline.

GEA can link our own machines with other O .E .M . supplied equipment via a number of networked solutions . By carefully specifying such items, we can ensure the supply of an integrated control system where overall plant operation can be monitored on multiple SCADA displays .

TheGEAcontrolsystemwillfacilitaterunningthefillinglineathighefficienciesbybalancingtheflowateachstationthroughtheline.Inaddition, the line operators are given complete visibility of the line operation with graphical displays, allowing for maximum throughput and line uptime .

Vacuum FillingTheGEArangeofretailfillingmachinesnowincludesallnewvacuumandfreeflowmachineswhichhavebeenfullyredesignedfromtheground up . Taking the best of the well-proven Albro and Colby brands of fillingsystems,GEAhascreatedanewrangeoffillersforthroughputsupto 300 cans per minute!

Blendingwellprovenvacuumfillingtechnologywithmoderndesignandmanufacturingtechniqueshasresultedinacosteffectiveretailfillingsystemforhigherthroughputsandhigheraccuracy.ThenewRCF(RotaryCanFiller)andICF(IncrementalCanFiller)rangesarenowreadytobeintegratedintoacompleteretailfillingsystem.

Auger FillingFor customers that require unparalleled accuracy with minimal plant footprintthenourrangeofhighqualityaugerfillers,utilisingprovenColby technology, is the ideal solution .

Our technology ranges from our fully Integrated Filler and Seaming system(IFC-1A)totheclassleading24-Headrotaryaugerfillerwhichiscapableofhighaccuracyfillingatupto300containersperminute.

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ICF-6F

RCF-10V/RCF20V

IFS-1A

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RCF-10A/RCF-24A

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Specialist EquipmentAtGEAwerecognisedthattherangeofmachinerydesignedspecificallyfor the needs of the food powder industry was limited . So we developed a comprehensive range of spoon dispensers, container cleaners and sterilisers,fillers,containergassers,conveyorsandaccumulatorstosuitthe exacting requirements of food powder packaging .

GEA can also integrate any of these single machines into an existing fillingline.

Thosemachineswhicharenotspecifictotherequirementsofthepowder industry such as palletisers, de-palletisers, check-weighers, seamers, case-packers and ink-jet printers are carefully sourced from the world’s best suppliers .

Scoop DispensingInfant formulae and other food powders often require the insertion of a particular type of measuring scoop or spoon .

GEA’sflexiblescoopdispensingsystemautomaticallyhandlesvirtuallyall scoop types with speed and accuracy, eliminating the need for unreliable and labour intensive manual insertion .

Can Handling & Accumulation GEAconveyorslinkfillinglinemachines,preciselymatchingsupplytooperatingspeed.Accumulationtablesprovideabufferbetweenprocesses . Sophisticated, electronically controlled diverters and channelisers reject underweight or overweight containers, enhancing system performance .

Sanitation & CleaningThe highest quality finished product is our goalAll GEA systems can be designed and manufactured to ensure world-class sanitary standards will be met . We regularly supply equipment and systems for use in USDA, MAF and other similarly regulated plants .

Tool-free disassembly allows for easy inspection and cleaning of individual components and machines .

GEA’s main strength however, is the ability to engineer complete systems for use on sanitary products . We understand the need for sanitary, clean roomdesignaswellasHVACsystemsratedforthehighestfiltrationandhumidity control requirements .

GEA can help with your complete sanitary plant design .

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Controls & IntegrationOne of the most important aspects of any modern manufacturing business is the human/machine interface.

Iftheprocessistoworkatmaximumefficiency,theinterfacemust be optimised .

Toofferthemostup-to-datecontrolsolutions,GEAworksclosely with established suppliers of industrial control technology . Our close relationship with these companies gives us a privileged window into the leading-edge advances they are making . It also provides us with valuable access to reference sites across a variety of industries .

Asaresult,GEAofferscontrolsystemswitheasytouseoperator interfaces requiring a minimum of operator training . Automatic monitoring and sequence control ensure our systems runwithminimumstaffandhavehighlevelsofreliability.GEAhastheexperiencetofindtherightbalancebetweeneconomyand sophistication .

On the basis of this experience, we can provide control systems whicharetailoredspecificallytoourcustomers’needs.

GEA also understands the importance of a formal approach to software engineering .

We have developed an extensive library of standard software solutions, which is continually being expanded and updated as we provide new advanced control technology systems worldwide . Disciplined use of this library enables us to continue toprovidecustomisedsolutionswithouthavingto“re-inventthewheel”foreachproject.

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Packaging Formats

GEA is at the forefront of this industry and we work closely with packaging companies to ensure that we stay ahead.

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The safe and reliable packaging of food is our business . In order to excel, GEA has had to develop innovative solutions in order to meet the ever changing needs of our customers . New packaging formats and construction techniques drive equipment manufacturers to develop reliable solutions . GEA is at the forefront of this industry and we work closely with packaging companies to ensure that we stay ahead .

Rigid ContainersTheGEAretailfillerrangeisdesignedtoenableourcustomers to pack into a variety of retail format containers .

Oursystemsoffercustomerstheflexibilitytohandlecontainerconfigurations,includingthreepiecetinplate,composite cans, moulded plastic and glass jars . Using quick-releasechangepartsourcustomerscanmodifyourfillingsystems to adjust their packing plants to meet the ever changing needs of the retail marketplace .

Multi-wall KraftPackingintoflexiblemulti-wallkraftpackaging can be a challenging and unreliable process . This is why our team of packaging experts has developed unique technology to ensure the most reliable bag handling foritsbagfillers.

Multi-wall kraft bags come in a large variety of formats, shapes and sizes . Our team of packaging expert will guide our customers through a careful program of packaging and machine selection to ensure that the delivered solution is the most reliable it can be .

Big BagsGEA has a vast amount of experience with big bag formats, including standard woven bags, Gambo style bags and even the latest Boss Pak™ system .

Notwobulkfillingsystemsarethesame.WeatGEArecognise this and we work closely with our customers to deliversolutionswhichnotonlyfulfilthefunctionalandperformance requirements of the process but also ensure thatthesolutionfitswithinthecustomers’existingbuildingconstraints .

Asaresult,ourproductsreflectworld’sbestpracticeforbigbagfillingandhandlingandweareproudtoputtheGEAname to all of our well proven systems .

Boxes & DrumsCustomers that have very exacting requirements for their packing plants look to GEA to provide innovative solutions to meet their needs .

Specialised package handling systems combinedwithflexiblelineconfigurationsenable us to meet the needs of the chemical, pharmaceutical and food ingredient industries . GEAhasdevelopedBag,BoxandDrumfillingextensionstoourexistingrangeofIBFfillers.

These features extend the capability of the Avapac range of fillerstohandlethewidestrangeofpackagingmediainasinglemachine.Withquick-changeparts,thefillercanbequicklyandeasilysetuptofillbags,boxesordrums.

Boss Pak™

Boss Pak™ is a high end big bag system that has been developed to meet the needs of product manufacturers . Itspatentedsystemoffillingusingaspinningheadarrangementensuresthatthepowderflowstoeverypartofthebagduringthefillingprocesstherebymaximisingtheuseable volume of the bag .

Thefilledbagisverystableandhandlingisdoneviabelttype conveyors . An integrated slip-sheet system provides the means to take the bag from the conveyor and place it onto a pallet outside of the high hygiene packing room . The finishedbaglookseverybitashighqualityastheproductcontained within .

GEA has a number of well proven solutions to suit all needs forcustomerswishingtopackintothisflexiblebigbagsystem .

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Modified Atmosphere Packing (M.A.P.) for Powders

GEA can provide a range of M.A.P. systems for all your needs; for both retail and bulk products.

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Preservation of food products is one of mankind’s oldest challenges. In modern manufacturing, high importance is attached to the processor‘s ability to provide extended shelf life for food products; including powdered or granular products . ModifiedAtmosphereProcessing(M.A.P.)Systemsremoveoxygen and replace it with inert gases .

GEA can provide a range of M .A .P . systems for all your needs; for both retail and bulk products . We can apply our proven technology to our equipment or your existing plant . If necessary, we can even produce specialised designs for specificcustomerrequirements.

How do GEA do it?GEA uses two main technologies to provide M .A .P . systems for their customers .

These are commonly know as ‘Post-gassing’ and ‘Pre-gassing’ .

In both methods, oxygen is removed from the product and inert gas introduced as a replacement . The inert gas is typically nitrogen or a mixture of nitrogen and CO2 .

The Traditional Way - Post-GassingPost-gassingistheprocessofgasreplacement‘post’filling;in other words, after the product has been placed into it`s packaging .

This is the most established methodology and GEA has many installations using this system .

The Alternative - Pre-GassingAs the name suggests, ‘pre-gassing’ is the process of atmosphere replacement prior to packaging . This requires the separate treatment of the product and the container prior tofilling.

Evacuation or Flushing?Both methods have advantages and disadvantages; depending on factors such as product type, processing speed and cost of inert gases .

GEA has mastered both and can provide you with the right solution for your needs .

Pre-gassing of PowdersGEAoffersaprovenmethodofremovingoxygenfrombulkquantities of powders and granules before they are packed .

The system achieves extremely low levels of Residual Oxygen(R.O.)atahigherspeedandlowercostthanothersystems . It can be used to extend the shelf life of whole milk powders, baby formulae, nutritional supplements and other powders and granular products .

The highest product quality can be maintained by gassing it immediately after it has been produced . This technique is independent of the next process and can be applied to a wide variety of packaging systems .

How our system worksThe extraction of oxygen and injection of an inert gas has long been recognised as the best way to improve the product shelf life .

Our system uses a vacuum to evacuate the gassing chamber . Nitrogenisthenflushedthroughthepowder.

Oxygenremovalissoeffectivethatevenafterseveraldaysinbulk storage, R .O . levels as low as 0 .5% are achieved .

Inatypical250kg(550lb)batch,theentiregassingcycletakes less than two minutes .

GEA systems have sophisticated controls that are pre-programmed and easy to use . The whole operation is automatic, so results are predictable and repeatable .

The GEA pre-gassing system is a versatile gassing system thatoffersawiderangeofoptionsforbulkstorageandpacking .

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Pre-gassing for Retail ContainersBy eliminating a number of steps from the inert gassing process and reducing the number of mechanical elements, system reliability and uptime are substantially improved, while the capital costissignificantlylowered.

There are two distinct types of MAP systems, Nitrogen only and Nitrogen plus Carbon Dioxide

Standard technology uses fully enclosed systems that can impede access .

The GEA pre-gassing system for Nitrogen systems uses patented gassing rail technology that removes the requirement for a sealed system around the container conveyors, greatly improving access and line uptime .

TheGEApre-gassingsystemisalsoveryspaceefficient,reducingthe requirement for environmental control and air-conditioning in new installations and freeing up additional space in existing applications .

Pre-gassing involves treating bulk quantities of powder with inertgas,priortofillingandseamingthecontainerinaninertenvironment .

To date, this approach has required all elements of the powder packaging system, from the bulk supply to the seamer, to be completely enclosed in an inert environment .

In addition to requiring large amounts of gas, this approach is prone to delays . Production must stop any time the inert environment is compromised, due to a stoppage or service problem . There are also occupational health and safety concerns associated with oxygen depleted environments .

The GEA system however, is based on a much simpler design, with only the bulk storage hopper being enclosed . The inert environment in the can is maintained by the use of patented gassing rails .

As well as providing greater control over the gassing process and simplifying maintenance and product changeovers, this approach also enables continuous motion processing, resulting in high productivity rates .

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Continuous GassingModernfillingandpackinglinesarefrequentlyhigh speed systems that require radical new MAP technologies .

GEAcanprovidecontinuousor“on-line”gassingwhichcontinuallymodifiestheatmosphereofemptycontainersandfoodproductspriortofillingand closing .

The systems use state-of-the-art PLC and computer controltoachievehighefficiencygasexchangewithunequalled ease of use for the plant operators .

Post GassingThe GEA VacuumasterTheVacuumastercost-effectivelyextendsproductshelf life by removing oxygen from retail containers of oxygen sensitive powdered and granular products .

Your product will remain fresher for longer because the Vacuumaster achieves very low levels of residual oxygen .

The system is economic to buy and run . It is simple and compact . It can be tailored to suit virtually any size range of rigid retail containers and can be designed to suit the throughput rates of virtually any powder packaging system .

Our technology is used by companies all over the world to extend the shelf life of whole milk powders, infant formulae, nutritional supplements and other powdered and granular products .

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Components

GEA Nu-Con recognises that our customers need peace of mind when it comes to handling their valued products.

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ManufacturingGEA proudly manufactures its extensive range of powder handling components in its purpose built centre in New Zealand .

Extensive R&D and pre-production testing has resulted in a rangeofthefinestrotaryvalves,divertvalves,magnetsandother components which GEA is then able to integrate into its powder handling systems .

All components are carefully assembled and tested before being packed for delivery to our customers throughout the world .

Rotary ValvesFor over 40 years, GEA Nu-Con has been manufacturing and installing its rotary valves for applications including dairy, food, pharmaceutical, nutritional products and other ingredients .

From this extensive experience, GEA Nu-Con has developed an impressive range of both standard and customised variants to meet our customers’ exacting requirements .

Whetherrequiredforanisolation/air-lockormeteringapplication, there is a GEA Nu-Con rotary valve to suit most specifications.

GEA Nu-Con recognises that our customers need peace of mind when it comes to handling their valued products . This is why the team at GEA Nu-Con has developed an innovative RotorDetectionSystem(RDS)whichcandetectandalerttheplant operator of a potential metal to metal contact condition within the valve .

The application of our technical expertise and experience has resulted in an RDS system with superior performance even during clean-in-place operation thereby giving extended performance throughout the full spectrum of plant operating conditions .

Central Vacuum SystemsGEA central vacuum cleaning systems are designed to enable the highest standards of cleanliness to be maintained in Food, Dairy and Pharmaceutical plants .

Each system includes a centralised waste receiving hopper and vacuum pump connected to a reticulated pipe network throughouttheplantarea.Inletisolationflapvalvesarelocated at convenient plant locations for localised operation .

Avarietyofhosesandnozzlefittingsareavailabletoenablesafeandeffectivecleaningofallfloors,walls,crevices,pipes,ductwork and machinery .

GEA customers around the world who have selected our central vacuum systems benefitfromitsconvenience– something which is not so achievable with portable vacuum cleaners .

Blower Packages for Powder ConveyingGEA Nu-Con has sourced the mostreliableandcosteffectiveblower packages from around the world . These systems are offeredindependentlyforexistingapplicationsorwecanofferthemaspart of a turnkey plant installation .

Dust CollectionGEAJet-pulsebagfiltersaredesignedforhighperformanceandmaximumefficiency,whilereducingmaintenancecosts and downtime . Typical applications include process air cleaning, silo venting, receiving vessels for pneumatic conveying systems, dust extraction, bag tipping, air slide and fluidiserventing.

Design features include modular component design jet pulsedfiltercleaningwithfullyadjustablecontrol.Heavyduty welded steel or stainless steel construction, easy access tofiltersforinspectionandmaintenance,withfilterremovalfrom clean air side as standard .

Dust discharge can be provided via collection bin, airlocks, screwconveyor,flapvalvesorevenflangemountedontopowder storage silos for maximum product retention .

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Product RangeThe GEA Nu-Con brand of components builds on over 40 years of experience in supplying high quality equipment to the food and dairy industries . Our extensive range of components ensures that our customers do not need to scourtheglobetofindacompletesolutionfortheirneeds.

GEAoffersrotaryvalvesforATEXapplications.

Typicalapplicationsincludecreatingaflamepreventionpath to act as a personnel protection device or to protect upstream and downstream processes .

TheinternalcomponentsarecertifiedforuseinZone20environments making them ideal for use in systems which require intrinsic protection within the device .

Rotary Valves

Diverter Valves

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Rotary Sifters

Vibrators and Fluidisers

Air Coolers and Preheaters

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Rotary MagnetsLump Breakers

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Our global service team can deliver parts and service directly where it is needed.

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Global Service OrganisationTheglobalGEAorganisationaffordsustheuniqueopportunity to service our customers locally . With GEA representatives in every continent, we have the ability to provide assistance with all aspects of aftermarket care .

Spares PackagesHaving a global service organisation means that we can supply spare parts where they are needed in each market . As part of our project cycle, our team of engineers work closely with our customers to design a spares package to suit their needs . Based on many years of experience, we are able to provide a recommended spares list with each system to ensure that our customers have the necessary parts on hand when they are needed .

TrainingGEAofferstrainingcoursesforyourplantoperatorsandplant maintenance personnel . We are able to prepare a comprehensivetrainingprogramtobringyourstaffuptodate on how to get the best out of your machinery .

GEA’s training can be tailor made for your equipment or yoursystem.WecoverallGEApowderfillingtechnologiesincluding Avapac, Colby, Albro, SmartFil and Sapac machines.Wealsooffercomprehensivetrainingintheoperation and maintenance of all Nu-Con components and powder handling systems .

Instruction will be given on how to: · operate the equipment correctly · optimise output ·ensurequalityoffinishedproduct· maintain the equipment properly ·troubleshootandfaultfind

MaintenanceMaintenance is essential . If this is not planned it can result in unexpected downtime and increased costs . GEA can help with a variety of programs and support services including:

· Service Contracts and Agreements · Total Preventative Maintenance · Reliability Centered Maintenance · Breakdown Maintenance ·Shutdown/StartupSupport· Product Launch Support · Maintenance Consultation

Product QualityProductqualitycanmeanthedifferencebetweenpoormarket image and increased sales . GEA has always placed great emphasis on the quality of our goods and services . We have the knowledge to assist our customers with their quality problems . Our experience includes:

· Powder Breakdown Reduction · Filling Accuracy Control · Increased Yields · Container Damage Reduction ·ModifiedAtmosphereControl· Process Surveys · Residual Oxygen Levels

Plant OptimisationManyplantscanunknowinglyrunatreducedefficiency.Thecausescanbeineffectivesystems,proceduresanddesigns.Improvement is often achieved by systematic analysis provided you have industry knowledge . We have that knowledge and can help you achieve:

· Production Line Output · Instantaneous Filling Rates · Powder Transport Systems Capacity · Utilisation Improvements · Operational Strategies · Changeover procedures · Inert Gas Consumption

UpgradesImproving existing plant and equipment performance is every bit as important to GEA as providing new technology . GEA recognise that our customers’ needs change with the life of their plant and it is therefore important to be able to modify the plant to meet these changing needs .

Our team of engineers and site service personnel can assist with the evaluation of existing plant and then prepare a comprehensive report to outline upgrade solutions to meet our customers’ requirements .

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GEA Avapac Ltd.

12-18 Foreman Road, PO Box 10266, Te Rapa, Hamilton 3241, New ZealandTel: +64 7 849 3414, Fax: +64 7 849 3494info.avapac.nz@gea.com

GEA Nu-Con Ltd.

8 Fisher Crescent, Mt Wellington, PO Box 12-264, Penrose, Auckland 1642, New Zealand Tel: +64 9 276 2388, Fax: +64 9 259 0172sales.nucon.nz@gea.com

GEA Process Engineering B.V.

Munsterstraat 5, 7418 EV DeventerPostbus 2064, 7420 AB Deventer, NetherlandsTel: +31 570 663 366, Fax: +31 570 663 377info.gpnl.nl@gea.com

GEA Process Engineering Inc.

1600 O’Keefe Road, Hudson, Wisconsin 54016, United States of AmericaTel: +1 715 386 9371, Fax: +1 715 386 9376gea-pe.us@gea.com

GEA Group is a global engineering company with multi-billion euro sales and operations in more than 50 countries. Founded in 1881, the company is one of the largest providers of innovative equipment and process technology. GEA Group is listed in the STOXX® Europe 600 Index.

We live our values.Excellence • Passion • Integrity • Responsibility • GEA-versity