THE MAGAZINE OF tHE GEA GROUP

ISSUE 16

FEBRUARY 2013

THE RISE OF THE CITIES TACKLING DIABEtES SPORt GOES HIGH-tECH

The group generates about 70 per cent of its revenue from the food and energy industries. The rapid pace of urbanization is one of the most significant megatrends facing the world today. Manufacturing it is almost an art form and there are different processes depending on the product. GEA Group is a market and technology leader in its business areas. Our main feature looks at the rise of urban living and how it can continue to grow more sustainably. Supporting this growth now and in the future is a challenge for all of us.com www. published by GEA Group Aktiengesellschaft. Our membership of Blue Competence. it has had a negative impact on the environment. The article on page eight looks at how GEA is helping the Indian dairy industry to improve its productivity. Listed on MDAX stock index. improved the quality of life for many and encouraged innovation. Increasing affluence in urban areas brings with it a demand for more and different foodstuffs. from bottles and drinking glasses to windows and mirrors. +49 211 9136-0 generate@gea. both of which have long-term growth prospects. Jürg Oleas Chief Executive Officer GEA Group Aktiengesellschaft UrBaNIZatIoN Is InCreasIng rapIdLy and aChIevIng It sUstaInabLy Is One OF the wOrLd’s bIggest ChaLLenges FEATURE STORY GEA Farm TeChnOLOgIes GEA innovation aids insulin manufacture The FIght agaInst dIabetes Star gLaZIng A bright future for a versatile product HOW TO DO IT Manufacturing flat glass GEA Heat EXChangers GEA MeChanICaL EQUIpment IndIan daIry IndUstry Satisfying the growing thirst for milk CIty LIvIng Expanding the urban landscape sustainably OUt OF thIs wOrLd Get ready for space-age tourism GEA PrOCess EngIneerIng Q&A Green engineering WInnIng perFOrmanCe How technology provides the sporting edge COnFeCtIOnery ChampIOn The continuing popularity of the lollipop GEA ReFrIgeratIOn TeChnOLOgIes Contact GEA Group Aktiengesellschaft Peter-Müller-Str. Dear Readers. 2012. Thomas Schräder from the VDMA.000 employees serving customers in 50 countries. one of the largest system providers for food and energy processes with about EUR 5.7 billion revenue in 2012. One of the world’s most familiar substances is glass. GEA’s Head of Corporate Organizational Development. You can read all about Blue Competence in our question and answer session with Dr. GEA is a world leader in the development of production facilities for the manufacture of insulin. consumption of milk and milk products is on the rise. the internationally operating technology group had a workforce of about 25. In India. a sustainability initiative of the VDMA – the German Mechanical Engineering Industry Association – is an indication of our commitment in this area.com 2 A DAY IN THE LIFE Nobue Beate von Wurzbach. it can be kept under control with the right treatment. While the development of cities has brought prosperity. GEA FOOd SOLUtIOns Welcome to the sixteenth issue of GENERATE. Also in this issue we look at diabetes. on diversity and values Art In engIneerIng Shaping milking equipment Last wOrd Global news from GEA GENERATE MAGAZINE ISSUE 16 1 . At GEA we take our environmental responsibilities seriously and we constantly seek to develop better engineering solutions that use resources more efficiently. As of December 31. an illness that is occurring at an alarming rate. 12 40468 Düsseldorf Germany Tel. the company focuses on process technology and components for demanding production processes in various end markets. for example. Its uses are many.gea.GENERATE is published by the GEA Group Aktiengesellschaft. Our ‘How to do it’ article reveals the process for making plate glass. While there is currently no cure for this disease.

Around 20 per cent of people in the Middle East are diabetic. GROwING At AN EPIDEmIC RAtE AND IN 2011 KILLED mORE tHAN 4. and Barbara Young. purify the output and concentrate the insulin crystals following their precipitation. clinical insulin was mainly derived from the pancreases of cows and pigs as insulin from these sources is almost identical to that of humans. as a result of rapidly increasing urbanization. an estimated 183 million people – or 50 per cent of the global total – are unaware of the fact that they even have the disease. produce a synthetic version of human insulin. worryingly. In Type 1. state-of-the-art manufacturing plant built by Julphar (Gulf Pharmaceutical Industries) in the United Arab Emirate of Ras Al Khaimah. The plant has 5.500 kilograms of product a year. However in 1982. diabetes deaths will have increased by two-thirds. They are also often required in the later stages of Type 2 of the illness. and. was also closely involved in the project. filtration and freeze drying. coli bacteria from the fermentation broth. India and the USA – are also forecast to be the top three in 2030. increasing supply will surely follow. Its GEA Westfalia Separator centrifugal technology is central to the production process. AND tHE SCALE OF tHE PROBLEm IS HUGE. Life-saving Injections of insulin are the main form of treatment for Type 1 diabetes. 80 per cent of diabetics are undiagnosed. it is the world’s biggest countries that have the most diabetics. growth and repair. Diabetes is a group of incurable diseases in which the sufferer has high levels of blood sugar as a result of disruption to the production. GEA Niro Soavi very high pressure homogenizers from GEA Mechanical Equipment offer a quick and effective method of disrupting the cells that can be reproduced on an industrial scale. But the prevalence of diabetes – the proportion of a population that has the disease – paints a very different picture. of the hormone insulin. The five separators installed at Ras Al Khaimah are used to recover the E. or produces it in wholly inadequate quantities. Perhaps unsurprisingly. eat higher calorie diets while doing less physical activity. there was no insulin manufacturing anywhere in the region. the first biosynthetic ‘human’ insulin was produced using genetic engineering techniques and recombinant DNA (r-DNA) technology. recently warned that “we face the real possibility of diabetes bankrupting the National Health Service within a generation”. This type is often inherited and/or genetic. GEA Mechanical Equipment. It IS wIDESPREAD. However. This is the process being used at the brand new.000 square meters of clean rooms and more than 17 kilometers of clean pipework. where they are life-saving. In simple terms. GEA Process Engineering. 80 per cent of diabetics actually live in countries that are classified by the World Bank as low-or middle-income: and. And. harvesting. Yet until late last year. delivery and commissioning of the entire sterile pharmaceutical production system. It is from these poorer countries that the bulk of the epidemic increase will come as people live longer and. Insulin in the diabetes war DIABEtES HAS BEEN DESCRIBED AS ONE OF tHE mOSt CHALLENGING HEALtH PROBLEmS OF tHE 21St CENtURY. The International Diabetes Federation (IDF) estimates that by 2030 there will be in excess of 550 million – or ten per cent of all the adults on the planet. by Transparency Market Research in the US. Yet the health systems in many of these impacted countries are not currently equipped to meet the rising demand. But diabetes is not only serious. Global market Until very recently. The cells then need to be ruptured. It is also ruinously expensive. which supplies specialist GEA Diessel process systems for the pharmaceutical and biotechnology industries. In the UK. Synthetic insulin has been available since 1921 as a result of Nobel Prize-winning work by a group of Canadian scientists. But with ever-increasing demand. GENERATE MAGAZINE ISSUE 16 3 . In Africa. Over the next five years the company was responsible for the planning. this involves actual human DNA being inserted into host cells – often E. A global insulin market worth almost USD 12. this 20. In Type 2. Type 2 diabetes is largely the result of lifestyle factors – and it accounts for 90 per cent of all cases. World Health Organization figures suggest that. was first approached by Julphar to work on the project in 2006. Undiagnosed Diabetes has traditionally been viewed as a disease of affluence.5 mILLION PEOPLE. Companies in India and China are already manufacturing insulin for domestic markets and export. Today’s top three – China. the body either does not produce insulin at all. The GEA Diessel package also included managing the process integration of all the main manufacturing elements such as fermentation. to reach more than USD 32 billion by 2018. a world leader in the manufacture of insulin.000 square-meter plant is one of the largest insulin production facilities in the world and will manufacture 1. Four of the top ten are Pacific island states: the other six are all in the Middle East. insufficient insulin is produced. So where next? Diabetes isn’t going away and can’t be cured. and the only change over the next 20 years is predicted to be the order in which they appear. THIS IS A SERIOUS ILLNESS. the number of prescriptions for treating the disease rose by 50 per cent between 2006 and 2012. or the body’s cells fail to use it properly. coli bacteria or bakers’ yeast cells. 2 WHAt IS INSULIN? Insulin is a hormone that is an important part of the process by which living organisms convert food into glucose – the sugar which cells and bodies use as energy for movement. But it can be treated – which presents both a human need and a market opportunity.5 billion in 2011 has been forecast. in the pancreas. HIGH PRESSURE HOMOGENIZAtION Manufacturing biosynthetic human insulin involves fermenting cells and then separating them in a high speed centrifuge. The cost of treating diabetes worldwide in 2011 was an astonishing USD 465 billion according to the IDF – or 11 per cent of total global healthcare spending. chromatography.W orldwide in 2011. In most rich countries it is the fourth or fifth leading cause of death. The Julphar plant. can be seen as part of a new wave. The hosts are then allowed to grow and reproduce normally. with the Danish firm Novo Nordisk at one time accounting for around half of global supply. there were almost 370 million diabetics. commissioned in 2012. There are two main types of human diabetes. Representing an investment of more than USD 135 million. until the 1970s. more than 90 per cent of the world’s insulin was produced by just three European and American pharmaceutical companies. due to the inserted human DNA. All animals need it – except for certain insects – and its action is almost identical in creatures as different as nematode worms and humans. engineering. chief executive of Diabetes UK. The pressure can be varied to achieve the right degree of cell rupture and the equipment can be sterilized without being disassembled. by then.

it is clear that glass is the material that will make them a reality in the not too distant future. Glass is also playing a key role in the treatment of malignant tumors. glass is playing a pivotal role in ubiquitous computing – in which information processing is thoroughly integrated into everyday objects and activities. Its startling adaptability is what makes it so popular. crucially. functionality and. for example. When the late Steve Jobs was developing the iPhone. alumina-silicate glass microspheres containing radioactive yttrium can be injected into the bloodstream to attack the tumor in a more localized way. As an alternative to external beam radiotherapy. At BESt. weather-resistant. swimming goggles and cameras. Another new project is evaluating bioactive borate glass for healing large wounds such as skin ulcers. a headmounted display that resembles the frame of a pair of glasses. Meanwhile at the pioneering Massachusetts Institute of Technology (MIT). are ideal for cooker hobs. Enter Corning. GPS and a camera that takes pictures at the nod of a head. Glass ceramics. A newly toughened glass has recently been manufactured to make stronger glass cartridges for EpiPen injectors – used to treat life-threatening allergic reactions. Each is made of strong but thin glass that can carry complex electronic circuits and nano functionality. Its applications extend to pharmacy. will be self-cleaning and will also repel water. wItH wINDOwS OR wItH CRYStAL VASES. BUt IN COmBINAtION wItH NEw tECHNOLOGIES It wILL PLAY A KEY ROLE IN INNOVAtION OVER tHE NEXt FEw YEARS. he wanted a touch screen that wouldn’t scratch like plastic but feared glass was still too breakable. the device uses glass and mirrors to project a computer display onto one eye. In particular. in 2012. Corning has released a series of visionary videos entitled ‘A Day Made of Glass’ which show interactive touch displays on kitchen work surfaces. in changeable traffic warning signs. and provides internet access using voice commands. 4 GENERATE MAGAZINE ISSUE 16 5 . the glass revolution GLASS IS SO FUNDAmENtAL tO mODERN LIFE tHAt mOSt OF US SCARCELY GIVE It A tHOUGHt. The material has antimicrobial and fibrous qualities and releases bio-active ions. very resistant to thermal shock. Vision of tomorrow Among others. optics. Microsoft has been looking at the possibilities for transparent computer displays. Multifunctional glass Still in the world of technology. Through subtle alterations in its chemical and physical composition. Glass optical fibers that can guide light and transmit images round corners are used in endoscopy. Medical breakthroughs The applications of glass in the field of medicine are many and varied. Its quality. car dashboards and wardrobe doors. An obvious example is the increasing need for thin but highly durable glass for mobile communications devices such as mobile phones and tablets.G lass has come a long way since 4000 BC when man first discovered obsidian – a naturally occurring substance produced when the intense heat of a volcano melts sand at the edge of its crater – and used it to coat the tips of spears. wE mIGHt ASSOCIAtE It wItH DRINKING BEER. it will be ideal for car windscreens. the US-based glass manufacturing leader that produced what came to be known as Gorilla Glass and. electronics. resulting in glass which is very clear but has no reflection. And since water will bounce off the surface. its affordability are progressing fast. Its pristine and non-porous qualities make it ideal for sterile environments. hi-tech global industry. construction and lighting. a team has been developing a new glass that eliminates some of the drawbacks we have hitherto accepted as inevitable. Alkalibarium silicate glass is used to absorb harmful x-rays from televisions. Google has been working on ‘Project Glass’. In place of lenses. What is indisputable is that its role in our daily lives is growing in importance. how glass can be used to project a 3D image that a user can control from behind the image. the 20 per cent thinner Gorilla Glass 2: the resilient but sensitive-totouch material now used in more than a billion mobile devices worldwide. The technology adds a digital layer to what the wearer sees. The manufacturing process uses a surface pattern of nano-scale cones of glass that are approximately five times as tall as they are wide. Fashion guru Diane von Fürstenberg’s models wore the devices at New York Fashion Week in spring 2012 and they are expected to be on the consumer market later this year or early in 2014. Transparent or otherwise. Biocompatible glass is used extensively to repair and replace diseased or damaged bone. and are key to telephone and internet technology. Today glass is a very competitive. So the glass of tomorrow can be nonreflective. we can process it into many different shapes and textures. self-cleaning and smart. Their not yet patented ‘multifunctional glass’ will not produce glare. gas or coal fire windows and even missile nosecones. among many others. Glass and communications But it is perhaps the fusion of new communications technologies with exciting developments from glass-manufacturing companies that will capture the imagination of everyday consumers. Antimicrobial glass also has the potential to kill bacteria and viruses including MRSA. This will benefit mobile phone and tablet users trying to read their screen in bright light. Though these applications may not all yet be affordable or scalable. Its self-cleaning qualities mean it can be used as surface glass to protect photovoltaic cells which otherwise can lose up to 40 per cent of their efficiency in six months because of accumulated dirt.

aluminum oxide as well as recycled glass. MIXINg Most types of commercial glass are made from fine grains of silica (sand). Top rollers draw out the glass to the required width and thickness.000 Bischoff installations worldwide. also supplied by GEA Heat Exchangers.4 millimeters to 25 millimeters and up to three meters wide. FlOAT BATH From the furnace the glass is poured onto a surface of molten tin in the float bath where it forms into a smooth ribbon.330 kilowatts of electrical energy out of the heat from the exhaust gases into electrical energy without affecting the quality of the glass or the gas cleaning process. There are three main modules. To avoid this happening the glass is conveyed into an annealing furnace. The data is fed to the cutters so that they can avoid any flaws. As it flows through the furnace the molten glass is held at a high temperature for up to 50 hours to allow the trapped air bubbles to escape before being cooled down to 1. One of these is at the AGC Flat Glass Europe plant in Cuneo Italy. supplying more than 15.Making flat glass In 1952 Sir Alastair Pilkington invented the float process for making clear.000 tonnes of glass. Fume extractors draw off the reactive gases created during this process into scrubbing units. Finally. INSPEcTION At every stage of the process the glass is inspected by a laser scanner capable of taking more than 100 million measurements a second across the ribbon. known as a lehr. First the Waste Heat Recovery Unit uses GEA Heat Exchangers to cool down the exhaust gases from the process and transfer the heat to a carrier fluid (thermal oil). the ingredients for each batch must be carefully weighed and mixed. It is designed to produce 1.100 degrees Celsius. The first installation of its kind. 7 CuTTINg The glass ribbon is fed through computerized cutters which cut the glass to the size required by customers. MElTINg The batch is melted in a furnace at 1. “I am very pleased with the overall result and the way we achieved it. For the GEA team there were the twin challenges of limited space and a tight timescale – the work had to be completed during a planned shutdown. The proportions vary depending on the end product.” says Andrea Angelucci. tinted and coated flat glass for glazing.” The system was commissioned in 2012 and could become the standard for all glass production plants. The technology can detect flaws not visible to the naked eye. GEA Process Engineering is the market leader in industrial gas cleaning for the iron and steel. As it flows along the bath. Next the ORC module transfers the heat of the carrier fluid to an organic fluid that vaporizes and drives a turbine coupled to a generator to create electricity. Engineering Manager at the AGC Cuneo plant. the temperature of the glass gradually reduces from 1. These will change the optical properties of the finished glass. GEA AND GLASS MANUFACtURE In common with most industrial processes. cool down the water which condenses the organic fluid vapor back to a liquid.540 tonnes a year.500 degrees Celsius. calcium oxide. COATINg Next. ANNEAlINg As the glass ribbon cools it develops stresses that could cause it to break when it goes through the cutter. This is how the process works. for example to reflect visible and infrared wavelengths. magnesium oxide. it also reduces CO2 emissions by up to 5. “But the team from GEA was very skilled and experienced. coatings made from metal oxides are applied to the cooling glass ribbon. The GEA team worked closely with AGC to engineer and customize the unique system for the flat glass industry. air coolers.100 degrees Celsius to 600 degrees Celsius. chemistry and fluid catalytic cracking (FCC). where it is reheated and cooled to remove any stress points. cement and glass industries. The company was so satisfied with the supplied gas cleaning technology that it appointed GEA Process Engineering to install an energy recovery system based on an ORC (Organic Rankine Cycle) turbine. There are now around 260 float plants around the world with a combined weekly output of 800. sodium oxide. 6 GENERATE MAGAZINE ISSUE 16 7 . understood our business and our needs and worked with us the whole way to create the optimum design. manufacturing glass creates gaseous pollutants and also waste heat. As consistency of composition is essential to successful glass manufacture. nonferrous-metallurgy. A typical float plant makes around 6.000 kilometers of glass a year in thicknesses from 0. such as a bubble or grain of sand that hasn’t melted.

GCMMF’s Amul business became the first dairy company to order GEA Mechanical Equipment’s bacteria removing centrifuge. In addition the co-operative provided support to farmers in areas such as veterinary care and feed. GENERATE MAGAZINE ISSUE 16 8 9 . When India’s Government set up the National Dairy Development Board in 1965 to facilitate growth in the dairy sector. Growth of co-operatives GEA Process Engineering India was involved right at the start of India’s milk revolution as a supplier to liquid milk processing and milk powder co-operative plants in Gujarat. the Indian dairy market is also seeing an increased demand for milk-related products like curd. Growing demand India’s milk production is growing by four per cent per year but estimates suggest that customer demand is growing at twice that rate. and increasing the amount of milk processed by the co-operatives and dairies by growing membership of the co-operatives and the network of milk collection facilities. The National Dairy Plan aims to teach farmers better livestock management skills and give them access to better feeds. As the co-operatives grew in number and expanded their operations across India over the years. market i ndia is often described as a country of contrasts – the haves and the have-nots. including the country’s biggest milk powder plant in operation at Mother Dairy.1 billion for milk and milk-related products. this needs to change. milk animals. processed and marketed dairy products at village. Its Amul brand is one of India’s top milk products. All GEA’s businesses are represented and the Group is increasingly marketing itself as a total solutions provider across the country. BUt AS tHE COUNtRY’S BURGEONING mIDDLE CLASS BECOmES mORE AFFLUENt. As a result. These areas also represent opportunities for all the GEA companies operating in India. India’s milk industry is the country’s most important sector and equipment and technologies from GEA have been in use in the sector for 60 years. Farmers in largely rural areas kept small numbers of cattle and had low production costs but also low milk yields. Not surprisingly.Milk on the rise in india INDIA IS ALREADY tHE wORLD’S LEADING mILK PRODUCER. GEA Heat Exchangers and GEA Mechanical Equipment are all active players in a sector that is becoming more industrialized. The second strand in the National Dairy Plan is increasing the amount of milk processed by the co-operatives – and the plan aims to increase the amount of milk handled by the organized sector from 30 per cent to 65 per cent over the next 15 years. This unorganized sector accounts for approximately 70 per cent of the milk produced in India. butter milk. which effectively means millions of smallholder farmers in rural areas with small herds of cows or buffalo. one of its very first actions was to try to replicate the Gujarat model throughout the country. the vast potential of the milk industry and associated milk products means overseas companies are vying to either partner up with the country’s key dairy players or build new milk processing centers. Traditionally. India may currently account for 17 per cent of global milk production but of that only a third passes through the organized sector – co-operatives and government and private sector dairies. India’s drinking yoghurt lassi and cheese. INDIA NEEDS tO FIND wAYS OF ImPROVING DAIRY PRODUCtIVItY tO KEEP PACE wItH ANtICIPAtED DEmAND. India’s largest food product marketing company. White revolution Milk co-operatives are nothing new in India: they were central to the country’s so-called White Revolution which started in the 1960s and helped India become the world’s leading milk producer. As the Indian milk industry focuses on improving both the quality and quantity of milk produced by the organized sector. the Indian dairy system has been based on a low cost – low output model. The Government is also involved in a program to improve various Indian indigenous breeds. which improves product safety and shelf life. There are two key strands to this plan: improving the productivity of the milk animals. For India to satisfy the demands of its population of 1. AND REQUIREmENtS FOR mILK AND mILK-RELAtED PRODUCtS INCREASE. The Gujarat model operated a structure that collected. GEA Farm Technologies. district and state levels. One of the keys to making this happen is to provide rural milk producers with greater access to the organized milk processing sector. GEA Processing Engineering India’s milk processing equipment is used in many of the country’s liquid milk dairies and milk powder plants. The Gujarat co-operatives subsequently grew to become the Gujarat Co-operative Milk Marketing Federation (GCMMF). the new and the old. which can produce one hundred tonnes of milk powder a day. In 2010 India’s Dairy Development Board drew up a National Dairy Plan aimed at doubling the country’s milk production by 2020. Gandhinagar. The hope is that the farmers will increase the size of their herds and the end result will be higher-yielding For the GEA Group. GEA Process Engineering successfully won repeat business from its customers. The co-operatives set up in Gujarat after India’s independence in 1947 were among the pioneers in the dairy industry. As well as a demand for more milk. This dichotomy is equally applicable to the country’s milk industry. The remainder comes from the unorganized sector.

HALF tHE wORLD’S SEVEN BILLION PEOPLE ARE CItY DwELLERS wHO ACCOUNt FOR mORE tHAN 70 PER CENt OF GLOBAL GREENHOUSE GAS EmISSIONS. NOw. 10 GENERATE MAGAZINE ISSUE 16 11 . tHE CHALLENGE IS HOw tO ACHIEVE It mORE SUStAINABLY. AS URBANIZAtION CONtINUES tO GROw RAPIDLY.

But this won’t solve the problem of how to accommodate dairy herds and other large livestock.” Schuring explains. the credit for inventing urban planning lies with the Greek architect Hippodamus. such as those in Egypt. His solution was to demolish parts of the old city and build wide boulevards. experts have recognized the need to change current farming practices. we will need the equivalent of two planet Earths by 2030. social and economic problems. “Unfortunately. milk production. In its ‘Living Planet Report 2012’ the WWF warns that the one-way traffic approach of taking what we need and when to satisfy demand for food. economic and environmental policy globally.” said Dr.” GEA Farm Technologies can provide the expertise and technology that will enable farms to adapt to meet the increasing demand for dairy products in a sustainable and future-oriented way. the report says that if. Once considered science fiction. Farm of the Future was launched at EuroTier 2012. A potential solution is the vertical farm where food is grown in and on top of buildings in cities. sometimes even beyond the city walls. “But we need to provide more open access to knowledge. To put this in perspective. The company has developed a holistic vision of the ‘Farm of the Future’ that encompasses all the key operations of a dairy farm from animal feeding. There heads of state and high-level representatives renewed their commitment to sustainable development and to promoting “an economically. What’s remarkable about this figure is that it’s roughly equal to the total world population for 2002. An early example of modern urban planning is Baron Georges-Eugène Haussmann’s remodeling of Paris in the 1850s.” Dr. attracted by the promise of jobs and a better quality of life. including where they live. Gradually. And. and we need a new way of working internationally that is fit for the 21st century. compared with around half today. GEA Farm Technologies. are thought to have been built to a plan. Energy production. with most of the population living in cities.” The proposals were incorporated into a ‘State of the Planet Declaration’. services and resources they use plus the waste they generate. the report states: “In 2008. Urban centers drew people from a wide area and from all walks of life. together with the invention of the wheel. automation and waste collection to training. lasting only as long as the soil produced good crops. Encouragingly. we need to move away from GDP as the only measure of progress. By the 19th century many of these new industrial workers found themselves living in crowded slums. Meanwhile. The first towns were the direct result of improvements in agriculture and transport. Because early cities and towns were often under threat of attack they were usually surrounded by walls and towers. could have the answer to making dairy farming more sustainable. And. As urbanization continued to increase rapidly during the 20th century. energy. The community would then up sticks and move to a new site. held in Rio de Janeiro in June 2012. energy and land costs. while the inexorable rise in urbanization is a given. of course. a leading provider of solutions and systems for milk production and livestock farming. However. technical experts and business leaders to tackle the most pressing environmental. These included: a set of sustainability goals for all nations. the global agricultural show. “In the last decade we have become a highly interconnected society and are beginning to realize this new state of humanity can be harnessed for rapid innovation. Yet. The style was copied for other Greek and also Roman cities. IF EVERYONE ADOPtED tHE LIFEStYLE OF tHE AVERAGE AmERICAN. in what is now Turkey. Fragkias was among 3. this demographic was reversed in the US in the 1950s and 60s as the moneyed classes sought bigger and better properties outside the city. He also set regulations for all building facades. in Barcelona. Then. This trend has since been repeated in other countries. breathing air polluted by the smoke from their employment activities. for example. socially and environmentally sustainable future for our planet and for present and future generations”. public parks. such as the one in a converted meat packing plant in Chicago. B y 2050 the number of people living in urban areas is forecast to reach 6.3 billion.000 scientists and environmental experts who took part in the ‘Planet Under Pressure’ conference. four Earths would be required to regenerate our annual demand on nature’s bounty. unless the urbanization process changes the environmental wound will get wider. He says the big challenge for farmers is producing enough highquality milk profitably against a background of rising animal feed. while the poor lived further away. Permanent settlements New technology has always been an essential part of the urbanization story. But the biggest upswing in urbanization was sparked by the Industrial Revolution as people migrated from the countryside on an unprecedented scale to work in the new factories. creating a diverse population. This means that. Early in the 20th century the UK tried to improve urban life by building so called garden cities. if we continue to consume resources at the current rate. Many of the ancient cities. In around 407 BC he designed the city of Miletus. 12 GENERATE MAGAZINE ISSUE 16 13 . “Farmers are looking for system solutions that will improve their profitability and sustainability. As farming methods became more sophisticated. UN Secretary General Ban Ki-Moon said the publication of the document was timely. it gave rise to a new phenomenon – suburbia. They set up ten global expert groups to support problemsolving in numerous critical areas. housing.” It describes how each person’s Ecological Footprint depends on a number of factors. farmers were able to produce surplus food. in September. Michail Fragkias of Arizona State University. is putting a severe strain on the ecosystem. Previous settlements tended to be temporary. including economic growth. creating a UN Sustainable Development Council to integrate social. So far it has five tenants whose products are sold to local markets and restaurants. an international research program and providing regular global sustainability analyses. engineer Ildefons Cerdà devised an extension to the city consisting of a series of 550 uniform blocks built around central gardens. the UN launched the Sustainable Development Solutions Network which brings together scientists. “Reducing the use of fossil fuels and greenhouse gas emissions and achieving higher yields though better animal nutrition and milk handling practices is only possible with sophisticated systems. using a grid layout. coming just two months before the UN Conference on Sustainable Development: Rio+20. employment opportunities were not necessarily matched by better living standards. the most recent year for which data are available. maintenance and consumption of energy and water. FOUR EARtHS wOULD BE REQUIRED tO REGENERAtE OUR ANNUAL DEmAND ON NAtURE’S BOUNtY. fertilizer value from waste and manure. governments and city authorities recognized that urban growth and development needed to be better controlled and healthier environments provided for the workers. Mesopotamia and the Indus Valley. transport and other goods and services. As cities developed and grew into mercantile hubs people flocked to them. The rich and powerful lived in the center. while the new and expanding cities may be good news for future economic prosperity and offer millions of people a better quality of life. Alarmingly. Held over four days in London during March 2012. adding revenues to the operation. Norm Schuring at GEA Farm Technologies in the US is VP for the Farm of the Future concept. GEA Farm Technologies’ focus is to research and develop new and creative multi-functional processes. they could afford the travel. sewerage systems and water works. FARM Of THE fUTURE Feeding the world when it reaches the expected nine billion in 2050 will require extra land the size of Brazil to grow enough crops. the amount of goods.” said conference co-chair Dr. Unfortunately. However. the conference reviewed the latest research findings on the state of the planet and recommended a series of practical solutions. Mark Stafford Smith. access to healthcare and transferring to low carbon energy. water recycling and reuse are processes that can add revenues while reducing costs. our Ecological Footprint exceeded the Earth’s bio-capacity – the area of land and productive oceans available to produce renewable resources and absorb CO2 emissions – by more than 50 per cent. vertical farms are becoming a reality. This. According to the WWF. reducing poverty. The new suburbs tended to provide homes for the poorest while the wealthy enjoyed all the advantages of living in the vibrant city centers. the way it will develop now and in the future is under serious debate.But if everyone adopted the lifestyle of the average American. we all lived like the average Indonesian we would use up just two-thirds of the Earth’s bio-capacity. “The question isn’t whether to urbanize but how. which set out how current international arrangements were failing to deal with long-term challenges such as climate change and loss of biodiversity in an interconnected way. if the planet’s human inhabitants reach the predicted nine billion mark. made it practical to transport the surplus from the countryside to the towns. These were specially designed towns that incorporated green spaces. today’s ongoing pattern of urban sprawl puts humanity at severe risk due to environmental problems. monuments. urban dwellers will make up two-thirds of the population.

GEA Heat Exchangers equipment. The urban landscape can be a problem when it rains. sauces and other fluid products. heating. That’s bigger than Uganda. They work by drying deep-frozen food in a vacuum to vaporize the ice. This conserves groundwater. which normally absorbs the rainwater. All offer high heat transfer capability. generated by the sun. Latin America four and two each in Africa. estimate that. The system reduces the bacteria count by 90 per cent before pasteurization. the largest being in Singapore. The SDA process also doesn’t generate any waste water. it will be half by 2035. All GEA Heat Exchangers’ technology takes into account ecological and geographical conditions. One of the most significant landmarks in the urban landscape is the megacity. Overall. is mostly covered by buildings and roads. GEA Heat Exchangers plays an important role in producing and storing food and beverages. A unique feature of the GEA Niro technology is the Niro spray drying absorption (SDA) process. ice cream and bakery items.2 million. hospitals. Because the ground. prevents the warming of surface water and is ideal in areas where water is scarce. 20. Public transport is another aspect of urbanization involving GEA Heat Exchangers. schools.4 million. In fact. Küba and Searle coolers and condensers are necessary for storing and transporting fresh produce. International water conservation policy underlines the importance of treating waste water. followed by Delhi at 22. GEA heat exchange equipment is found in power stations. fish. airports. cement and glass with more than 15. This reduces the quantity of water channeled into the sewers and on to the sewage treatment works. the developing economies are rapidly catching up. ketchup. ESSENtIAL tO URBAN LIFE Technology from GEA is at the heart of many industrial and processing activities – from power generation to food supply – that are the lifeblood of urban living. half the population of Asia will live in urban areas while. High pressure homogenization is an important part of processing beverages. if Tokyo was a country it would be the 35th largest in population terms. nonferrous-metallurgy. defined as having a population of ten million and above. condensing and evaporating. transport and storage of food. products keep their shape. vegetables. Niro Soavi homogenizers from GEA Mechanical Equipment are used in processing many foods and drinks that are part of consumers’ daily lives including fruit juices. Since the 1970s it has been removing acidic pollutants. However. GEA Mechanical Equipment has supplied decanters to water treatment plants worldwide. the Population Division of the UN Department of Economic and Social Affairs has issued urban and rural population projections for all countries. during heavy rainfall the water can exceed the sewage treatment works’ capacity. The GEA Westfalia Separator® prolong system. maintains the correct climate in offices. gas installations and biomass facilities. including Air Treatment systems and Delbag filters. the light weight of the pump helps lower the train’s energy consumption. OF wHICH DEVELOPING REGIONS wILL ACCOUNt FOR 64 PER CENt. Freeze drying can be applied to fruit. GEA Heat Exchangers provides the 2H TUBEdek® clarifier that improves the capacity of the stormwater treatment tanks handling the overflow. chemistry and fluid catalytic cracking (FCC). marinating. heavy metal particles and dust from flue gases at fossil-fuelled power stations.BY 2050 tHE wORLD wILL BE 67 PER CENt URBAN. GEA Heat Exchangers also plays a key role in helping chemical plants to comply with emissions regulations. poultry. Finally. GEA Food Solutions is a major supplier of machinery for preparing. while Goedhart. By 2025 the number of megacities is expected to grow to 37 – accounting for 13. iron and steel. taste and nutritional content. For example. processing. mainly from power plants. with 37. The Bischoff range also includes energy recovery systems to produce energy from the available hot gases. including soups. From a single machine to a complete production line. For example. ready meals and beverages. slicing and packaging meat. Latin America and the Caribbean will also see their urban populations increase. Rise of the megacities Today. 2H GEOdek® infiltration boxes store the rainwater and release it slowly into the ground. GEA Process Engineering helps prolong the shelf life of food with its GEA Niro freeze dryers. by 2020. It’s actively involved in the renewable energy sector. and are light and easy to transport. Canada or Algeria. homogenization makes for a more stable product and improves both texture and taste. The pump’s special design. GEA Process Engineering also supplies TDS process lines used to make many well-known products. Now there are 23: Asia has 13. waste incinerators and steel plants worldwide. has a low energy consumption and provides a product with the same vitamin content as traditional fresh milk and a shelf life of at least 21 days. GEA Heat Exchangers has one of the most comprehensive portfolios of heat exchange equipment in the world. CLEAN AIR Urbanization is often linked to air pollution. commissioning and maintenance. GEA Process Engineering is the market leader in the key industries. Many of these processes involve transferring heat from one medium to another during cooling. it supplied two mini desublimators to a chemical plant in Belgium to reduce emissions from naphthalene tanks. with condensers at more than 40 solar power installations in Spain. The most populous megacity is Tokyo. museums. salad dressings.7 million and Mexico City. The company’s test center at Bakel in the Netherlands gives customers the opportunity to try out new processes – for example. seafood. GEA Renzmann & Grünewald transformer oil pumps are used to circulate oil in railway traction transformers. for African countries. The latest figures. Europe and North America. while the well-established cities get bigger. factories and vehicle exhausts.000 m3 of waste water per day. FASt FOOD Today’s urban lifestyles demand a range of processed foods that are easy and quick to prepare yet still nutritious. In addition. GEA Refrigeration Technologies provides innovative freezing and chilling technology throughout the production.6 per cent of the world urban population. The condensers cool the exhaust steam. by 2050 the world will be 67 per cent urban. petrochemical plants. energy-saving potential and enhanced operating conditions. GEA Process Engineering is a major player in environmental protection with its Bischoff and Niro technology.000 Bischoff installations worldwide. In 1970 just two cities met the criteria – New York and Tokyo. cheese and other foods. As a full system supplier for the industrial gas cleaning including planning. which avoids any additional sealing and assures a safe and reliable operation. In which case the overflow bypasses the sewage works and is discharged into the rivers. helps the transformers to operate with minimal noise and vibration. With this method. For example. shopping malls and many other public buildings. 14 GENERATE MAGAZINE ISSUE 16 15 . for instance Ecoflex plate heat exchangers are used in manufacturing cheese and beer. Every two years since 1988. baby foods and tomato paste. With the aid of 30 decanters from GEA the plant handles around 800. URBAN GROwtH This is the first time in human history that the majority of the world’s population lives in urban areas. adapted from a method used to manufacture cheese. of which developing regions will account for 64 per cent. a cooker with a high-velocity air flow which ‘fries’ foods without oil so that they are healthier. meat. By reducing and standardizing the particles. published in 2011. has been successfully applied to the production of ESL (extended shelf life) milk. GEA companies specialize in equipment and processes to enable manufacturers to improve the quality and prolong the shelf life of their products. oil refineries. data centers. the company has pioneered the use of air rather than water for industrial coolers. which drives the turbines.

for example. However. ‘carbon footprint’. street lights can be switched off in deserted streets to save energy or brightened in busy ones.5 million square kilometers – an area the size of France. So. severe traffic congestion. For example. the Green City Index report points out that the cities highlighted are examples of good practice rather than standard practice. the series is intended to provide a benchmark for urban environmental sustainability. But that was indeed one of the highlights at Floriade 2012. more importantly. with 215 millimeters of rain falling in 16 hours. Some of the most radical sustainable solutions are to be found in the so-called eco cities where urban planning is closely linked with environmental management. It recommends that cities need to take a holistic approach to sustainable urbanization rather than solving environmental problems individually. such as ultralow flush toilets and low-flow shower heads. where it is pumped up to the building for heating. healthcare and a whole host of other services. violence. Construction materials are sustainably sourced. And it’s estimated that city residents are responsible for over 70 per cent of fossil fuel-related CO2 emissions. Brazil. education. Embedded sensors in the streets and buildings monitor everything that helps the city to run smoothly. the water flows approximately 100 meters to the second well system. Cities are the engines of economic growth that drive global trade and provide the service centers for the information technology industries. by 2030 humanity’s urban footprint will occupy an additional 1. in turn. The Thai Government’s policy of refunding tax for first-time car buyers has brought five million vehicles to the streets of Bangkok – over three million more than the city can comfortably handle and in the Indonesian capital. North America and Africa. The above-mentioned index is one of a series drawn up by the Economist Intelligence Unit. Elsewhere in Europe. Songdo is also equipped with charging stations for electric cars and has 26 kilometers of cycle lanes. renewable and recyclable. scoring highly in seven out of eight categories. pressure on resources. one of the delegates at the Planet Under Pressure conference explained: “People everywhere have increasingly embraced Western styles of architecture and urbanization. Called Villa Flora and designed by Volantis BV (Venlo) on the basis of a concept from the Dutch architect Jón Kristinsson.” The conference revealed that. Latent heat accumulators (PCM – Phase Change Materials) balance the internal temperature in the air handling systems. Latin America. Developments such as this could hold the key not only for new cities but. Even more remarkable is the pneumatic waste collection system that transports rubbish through a network of pipes. transport. Its green credentials include a strict urban planning policy. traffic congestion costs economies an estimated one to three per cent of GDP – a problem that not only wastes fuel and causes pollution. in combination with HVAC systems from GEA Heat Exchangers and a heat pump from GEA Refrigeration Technologies. Copenhagen has won recognition for its environmental policies. Green space makes up 40 per cent of the city and there are measures for trapping rainwater and recycling ‘grey water’ from sinks and dishwashers. Chinese meteorologists suggested that the effects were made worse because the city acted as an urban heat island. the 30 meter-high glass building is the greenest office in the Netherlands. in Freiburg all houses are built to a low energy consumption standard – some homes actually generate more energy than they consume – and one district is completely car free. vulnerability to natural disasters and pollution. held every two years.No to the status quo There’s little doubt that urbanization has brought enormous benefits in terms of greater access to employment. Jakarta. As well as being built from recyclable construction materials – known as the cradle-to-cradle principle – Villa Flora is CO2 neutral and uses solar panels to generate electricity. GEA Heat Exchangers’ air handling systems also provide a hygienic change of air within Villa Flora. produces heat. The Danish capital tops the European Green City Index. such as solar and wind power. cities bring together resources to generate ideas and productive uses of new technology. which are resource-intense and often not adapted to local climates. Exploiting renewable and cleaner alternatives to fossil fuels. Heat from the city pushed up the clouds. the star performer in Asia is Singapore. Worldwide. For example. This water absorbs heat from the building with GEA Heat Exchangers´ Fan Coil Units and then flows into the second well system. the GEA heat pump driven by a GEA Grasso compressor raises the water temperature to the required level. Beijing experienced its worst storm in more than 60 years. Through regular reports on the state of the world’s cities and the World Urban Forum. overcrowding. it involves creating structures designed to reduce their environmental impact throughout their lifecycle from design to demolition. In July 2012. However. In the offices. So too are initiatives for recycling waste materials and the development of manufacturing methods that use less water and energy and give off fewer emissions. Singapore has also embraced solar power and is helping to develop solar technology to meet the specific requirements of the tropics. New York City’s congestion costs an estimated USD 4 billion a year in lost productivity. controlling the number of cars in the city. On a really bad day the jams can be as long as 295 kilometers. Also known as green construction or sustainable building. To heat and cool the building. an underground long-term heat and cold-storage system with two dual-well systems goes into action. UN-HABITAT. These councils’ efforts are supported by the World Green Building Council which offers advice and reviews green construction activities globally. Asia. crime. Copenhagen has set itself the target of becoming carbon-neutral by 2025 and aims to be the best city in the world for cycling. water recycling plants and waste-to-energy facilities. 16 Sustainable solutions But it’s not all doom and gloom. The words ‘climate change’. It’s a combination of offices and giant greenhouse that brings together people and plants in a sustainable setting. local organizations and the private sector to promote better urban planning and help cities to improve living conditions and the livelihoods of people living on the poverty line. Meanwhile in Sao Paulo. The UN agency for human settlements. For example. provide a blueprint for improving the existing urban landscape to meet future needs without causing further damage to the planet. unless development patterns change. Many urban problems are partly due to taking a one-size-fits-all approach. is on the increase. Cold water pumped upward from one of the wells cools the building in summer. Germany and Spain combined. since its initial temperature is not sufficient for building heating. VILLA FLORA SEtS GREEN StANDARDS Among the things you wouldn’t expect to see at an international garden show is an office building. works with governments. the World Horticultural Expo. Green building is another concept that has come to prominence in recent years. ‘environmentally-friendly’ and ‘energysaving’ have crept into common parlance as people heed the experts’ warnings against maintaining business as usual. transport and environmental governance. Built on reclaimed land 56 kilometers west of Seoul and due for completion in 2016. UN-HABITAT galvanizes governments and experts behind the need to create safer. Songdo is the ultimate in green living. citizens plan their lives around traffic jams. including energy efficiency. As they attract new jobs and investment. However. The North American suburb has gone global. GENERATE MAGAZINE ISSUE 16 17 . but also time. Germany is one of the countries taking the lead in this direction. Until the following winter. Professor Karen Seto of Yale University. In other words it was higher in temperature than the surrounding areas. held in the Dutch city of Venlo. Covering 120 cities in Europe. there are several downsides to urbanization: the loss of arable land. Radio frequency identification tags on cars transmit data to a central hub so that heavy traffic can be identified and signals altered to ease the congestion. The buildings usually run on solar power or other renewable energies and include water-saving features. More than 80 countries now have green building councils that promote the sustainable urban development agenda among their respective governments and industry experts. cleaner cities that provide equal opportunities for all. and car-dependent urban developments are more and more the norm. which produced more rain as they gained altitude so that the downpour was more locally concentrated. tailbacks in and out of the city extend on average 180 kilometers at peak times. Even organic waste is collected and transformed into biogas which. Perhaps new cities like Songdo International Business District in South Korea hold the answer. air supply flows through outlets in double floors which serve to heat the floor and cool the ceiling.

purifying. science fiction writers. market-leading charge air coolers for predicts that. promises to “boldly go” where no other the Internet has made booking transport theme park has gone before. bilgewater. earth-bound tourists need not range of public buildings. any place. GEA AND tHE tRAvEL INDUStRY attracting visitor dollars. attracts millions of visitors the automotive and marine industries and for every year. She will be the eighth fare-paying visitor to the station since US Over the past 60 years. a tropical holiday without the long-haul travel. space will truly be. Soyuz rocket in 2015. cruise ships. which first professional singer to try out her vocal measures travel movements in terms of chords in space. Sarah Brightman is set to blast off to the US. “the final frontier”. the Meanwhile. Italy. limitless: walking the Inca trail in Peru. Founder and room temperature any time. of the world’s largest and fastest growing economic sectors. stakes. When asked Air-conditioning technology with GEA Bock compressors in resort in Brandenburg. is reaching to vacation. As well as space program. arranges the trips with the Russian For many developing countries tourism is Government and the fees – around EUR one of the main sources of foreign exchange 35 million a head – help to support Russia’s income and the premier export. has already gas recirculation coolers that set new the rate of that for more mature economies. is a big fan. Also. B GENERATE MAGAZINE ISSUE 16 19 . His sub-orbital trip will has the type of vacation. snowboarding and Germany and nearby countries to experience reality. pleasant example of this. buses or on ships ensures a consistent. according to the billionaire Dennis Tito took one giant leap for UNWTO. such as artificial climates. tourism has developed into one space tourism in 2001. beach holiday is still high in the popularity art systems for heating. the trains. King Abdullah and hotels. The coolers can be found in London. The UN for the stars – literally.” Should off-world travel become a create an indoor winter wonderland for skiing. experiences and flag up the best – and worst and hydraulic oil and for sea water desalination. as they say in ‘Star tobogganing anywhere in the world. Built in an old airship tourism. 18 ritish classical singer Sarah Brightman. As an export category it The American company Space Adventures ranks fourth after fuels. the Technology from GEA helps creates jobs and businesses and encourages ultimate wild ride. it’s just compressors and GEA Geneglace snow cannons it’s possible to degrees Celsius. hotels. as marine vessels. water rafting. Germany. Among them will be Alan Watts from Since the 1950s when package holidays made emissions. who gave the green light for the easier. the tourist industry for those with a hefty bank balance. yachts and other miles he’d planned to use travelling the world number of destinations has increased. said: Thanks to the company’s range of GEA Grasso screw rainforest with a constant temperature of 26 “It’s not the money or the regulations. when he retired.Ready for take-off TOUrIst trIps tO spaCe are nearIng the LaUnCh pad. The top ten destinations are France. Spain. climbing and cycling holidays. arrivals Virgin Galactic. While developing spacecraft has grown faster than that in the more a variety of leisure facilities. Also in the marine sector. sludges. Heat Exchangers are used to cool machinery in were launched. lube extra on the show. China. having once appeared as an blogs travelers have been able to share their treating fuel oil. The company ‘Star Trek’ attraction being built in Jordan more often – and further – for less. Germany is a perfect what was the biggest obstacle to space railways. Turkey. GEA Mechanical Equipment himself. international tourist arrivals. Indeed. museums and leisure centers. to keep the world moving development of infrastructure. tourism in emerging economies right environmental conditions at tourism race. the focus is on sub-orbital flights. The Tropical Islands incomes remains to be seen. wherever in the world people choose Heart to a Starship Trooper’. through social websites and has a portfolio of high-performance separators for park. ballast water. He is cashing in the two million air foreign travel affordable for more people. white Kennedy Space Center at Cape Canaveral. The UNWTO term. The resort enables people in doing it. Trek’. that How soon lifting off from earth into space handling units for climate control on board cruise ships were once restricted to the imaginations of becomes affordable for those with modest as well as refrigeration for storing food and beverages. the Budget airlines have enabled people to travel generating fresh water on cruise liners. The terminals. as well as finding the best deals. one of four companies diesel and gas engines and exhaustto emerging economies will increase at double offering the sub-orbital route. including airport choices for the intrepid traveler are almost miss out on space-related activities. Rise in tourism who had a hit in the 1970s with ‘I Lost My But. taken reservations from more than 500 standards in reducing nitrogen oxide people. said numbers were up from 990 million in 2011 to one billion An impossible dream? Far from it. cooling. hangar. International Space Station aboard a Russian Malaysia and Mexico. while also supplies Air Treatment Systems to ships. SOOn the sky wILL nO LOnger be the LImIt FOr traveLers. – places to visit. in 2012. it boasts the world’s largest indoor President of the Space Tourism Society. between 2010 and 2030. Gasketed plate heat exhangers from GEA where the Apollo missions and space shuttles to name but a few. comfortably and provides the Other companies have now joined the space Historically. tourism is big business. While the traditional GEA is also renowned for its state-of-themake him the first frequent flyer in space. as are the trips to theme parks Space attractions humidifying and dehumidifying air in a wide like Disneyland for those with children. in the short GEA Heat Exchangers supplies trend shows no sign of slowing. Taking off into space is. UK. John Spencer. modern technology has brought to life GEA Refrigeration Technologies supplies chillers and air many ideas. capable of taking passengers to the moon economically advanced countries and the and beyond is the ultimate aim. chemicals and food. For fans of the TV series. She wants to be the World Tourism Organization (UNWTO).

THOMAS SCHRÄdER eXpLaIns. NOw. 20 GENERATE MAGAZINE ISSUE 16 21 . It COULd hOLd the key tO a sUstaInabLe FUtUre.German meChanICaL engIneerIng knOwhOw has LOng been reCOgnIZed and sOUght aFter the wOrLd Over. as DR.

For example. reducing the use of fossil fuels and cutting CO2 emissions. fairs and exhibitions and on our website. they are allowed to use the Blue Competence logo internationally. We believe that the mechanical engineering sector is an ‘enabler’ for meeting these global challenges by providing the pioneering technology that will support a sustainable future. And these costs are highly dependent on the efficiency of the building technology installed. The statement underlines the industry’s continuing role in providing groundbreaking equipment and technology. Thomas Schräder is Managing Director for Air Handling Technology at VDMA and was involved in setting up the initiative. GEA AND BLUE COMPEtENCE GEA Group is an alliance member of Blue Competence in order to support sustainable technology. Launched in 2011. Responsible for the day-to-day running and all promotional activities is Judith Herzog-Kuballa from Technical and Environmental Affairs who contributed to the answers below. There is a lot of mechanical engineering technology in a building – heating. the different trade associations and individual companies or alliance members. It aims to provide a ‘green’ platform for developing and implementing environmentally-friendly. These requirements help support our arguments about optimizing – lowering – life-cycle costs. social media. Why was Blue Competence established? A. it would need one campaign and one color. The case studies provided by alliance members represent success stories. will be paid by the building’s user. mail shots. The site. How is Blue Competence promoted? A. However. Membership is available to companies at European level and. The EU policy on environmental protection has recognized that the building sector accounts for 40 per cent of total energy use in Europe. Nowhere is this more apparent than in the VDMA’s sustainability initiative. customers buy according to price and don’t take into account the costs of using the products over their life-cycle. The VDMA is the sponsor and governing body and is also responsible for advertising and promotion. What are the main challenges for achieving sustainability in the mechanical engineering sector? A. Through a comprehensive series of communications involving all three levels. metals and other essential resources is due to peak and then decline so there is no way we can continue business as usual. Q. We achieved that figure by October 2012 – it’s drawn the biggest response of any initiative we’ve had so far. On joining Blue Competence. This is a particular dilemma in the building industry where you have an investor and an end user. Etched into the glass by the entrance to its offices in Frankfurt are the words ‘Wissen für morgen heute nutzbar machen’ which mean ‘Knowledge for tomorrow to be used today’. They show how the companies act sustainably through their products or manufacture of their products. cooling. in order for the industry to be recognized as an enabler by policy makers and the public. Blue Competence. Q. Yes. air conditioning. It is particularly useful in the production of food and beverages. if those companies are operating globally. valves. We chose blue because it is generally associated with technology and efficiency. Today there are seven billion people on earth and their quality of life depends on which part of the world they live in. Does that mean that Blue Competence applies outside Germany? A. For example. any new legal requirements should be balanced by what is technically possible. The VDMA decided that. Q. We speak to politicians in Germany and at EU level and the fact that the export rate for German mechanical engineering is about 75-80 per cent helps to support the message that we are enablers. This technology enables waste heat from refrigeration systems to be used in production processes. Through Blue Competence we are accepted by policy makers at European and national level as competent partners in defining the technology best practice to be included in legal requirements. pumps. GEA Refrigeration Technologies has developed a heat pump that converts heat emitted by refrigeration equipment into usable energy and reduces CO2 emissions. maintaining the required temperatures throughout the year. GEA Refrigeration Technologies has a proven track record in providing energy-efficient and sustainable technology. How many companies have signed up to Blue Competence and how do you ensure that they meet its aims? A. but the bulk of the life-cycle costs. One half of the greenhouse needs to be heated to 28 degrees Celsius for young plants and the second zone requires a temperature of 19 degrees Celsius for mature plants. includes all the success stories from our members. ventilation. Blue Competence has a three-level structure comprising the VDMA. Q. The VDMA established a building sector group that brings together all the different trade branches. The branch organizations and alliance members can promote their successes in their own marketing activities. What’s being done to change the situation? A. We can seek proof that members are meeting the requirements through on-site inspections. One of the case studies submitted to Blue Competence describes how GEA Refrigeration Technologies rose to the challenge of providing the two climate zones in one greenhouse at Van der Hoorn Orchids in the Netherlands. is less noisy than standard cleaners and is more than 90 per cent recyclable. How are the achievements of Blue Competence being measured and can you give some examples of successes? A. We are able to offer very efficient products with a long-term payback but they require a higher investment. Its ‘green’ credentials have won many awards. Generally. For example. Estimates from the United Nations and other institutions have shown that we would need the equivalent of two and a half planet Earths to provide resources for a lifestyle comparable with 2000 levels in the western world. energy-efficient or resource-efficient products and processes. elevators and building automation systems – and the investor will try to save money on the purchase. from waste and recycling technology to cutting tools. Kreisel has invented a cellular wheel sluice that reduces the environmental impact of cement production and Kärcher has developed a vacuum cleaner that runs on just 750 watts.The VDMA. the cost during use. Blue Competence links all mechanical engineering sectors. Dr. Q. the industry is not very homogenous and has 38 different specialized branches. The company’s Energy Enhancer – a combination of an ammonia refrigeration unit and a heat pump – won the 2012 Dutch Refrigeration Prize. As the sponsor. represents more than 3. We launched in 2011 and planned to have 300 alliance members by the end of 2012. Q. Our aim is to improve communication with architects and all industries involved in constructing a building. they must provide at least one case study that demonstrates the environmental effectiveness of their products and maintain a management system where sustainability goals are monitored in the same way as quality targets. brochures. Q. Production of oil.000 companies and is one of Europe’s largest industrial networks. the German Mechanical Engineering Industry Association. An electrically-powered ammonia heat pump uses ground water to heat and cool the greenhouse. alliance members are asked to sign a contract committing them to a set of sustainability goals and standards. GENERATE MAGAZINE ISSUE 16 22 23 . Accordingly. By 2050 the number is predicted to increase to nine billion and most of the additional people will expect a high standard of living which will require more resources. The EU Ecodesign Directive includes requirements on future energy use which covers most of the engineering products supplied to the building sector. the VDMA promotes Blue Competence via advertising campaigns. In 2011 GEA Refrigeration Technologies received the German Refrigeration Prize for the GEA Grasso BluAstrum ammonia chiller in the category ‘Climate-Friendly Application of Refrigeration Systems in Food and Beverage Production’. The trade associations are also supporting these activities and can define additional technology requirements that are specific to their sector and the alliance members must provide evidence that their components and machines are sustainable. available in English and German. Q. But we have found that members are generally very serious about fulfilling their commitments and success is based on mutual trust. How is it organized? A. offering numerous solutions.

carbon-neutral 500-seater stadium that reduced the pitchside temperature to 23 degrees Celsius.TECHNOLOGICAL INNOVAtION IN SPORt IS tAKING PERFORmANCE LEVELS tO NEw HEIGHtS. heated player benches in American Football grounds certainly aid players’ performance through the simple virtue of keeping them warm. swimming pools and velodromes built for big events they can all benefit from performance-boosting technology. Advances in technology have also made it possible to build an indoor ski slope in Dubai. GEA Heat Exchangers also has a presence in the swimming pools sector. Aerodynamic resistance The design team that built the world’s fastest cycle track for the 2012 Olympics included Olympic Champion Sir Chris Hoy. which turns stadia into multifunctional venues that can host concerts and exhibitions. And GEA Refrigeration Technologies even supplies the snow to indoor and outdoor ski slopes through its range of GEA Geneglace snow cannons. also conducive to fast times because it decreases the aerodynamic resistance faced by the riders and keeps the athletes’ muscles loose and flexible. Many elite athletes across a host of sports have their clothes and accessories such as helmets individually designed after a full body scan shows which contour gives them the most aerodynamic shape. London’s stunning Olympic Stadium featured a £1 million state-of-theart running track with a cushion backing for shock absorption and a solid upper layer that optimized slip resistance. Runners’ footwear is custom-moulded to their feet and there have been advances in the grip. GEA Refrigeration Technologies is at work on the team buses by supplying GEA Bock vehicle compressors for air conditioning systems to keep the players from German clubs. Of course it’s not just elite athletes who benefit from advances in technology. traction and durability. if it is deep enough to dissipate the downward waves created by swimmers’ kicks before the waves hit the pool’s bottom. Swimmers’ outfits are lighter. reducing moisture and condensation. Engineers ran extensive wind tunnel tests to assess the impact of wind in the stadium and decided on a partial roof to minimize wind at track level. Some people believe the technological ‘arms race’ leaves athletes from poorer countries with no chance of getting near their technologically enhanced competitors. GEA aND THe SPORTS INDUSTRY Different GEA companies play a role in supplying products and services that can improve athletes’ performances. GEA Heat Exchangers’ engine cooling technology helped ensure that there was a secure power supply for the F1 teams’ workshops and kitchens. T echnological advances mean that sports professionals are looking for – and increasingly finding – the extra edge that helps improve their levels of performance. For example GEA Process Engineering supplies the Procomac cold aseptic filling lines for sports drinks which are filled in easy-grip PET bottles (with both flat and sports caps) that can be held while running. a quality surface generally produces a better performance.famous Ski Dome at a temperature of just below freezing – quite an achievement when the temperature outside can be 40 degrees Celsius. Qatar’s organizers subsequently announced plans to build nine fully air-conditioned open-air stadia that will convert solar energy into electricity to cool down both players and spectators. And before football players even get to the stadia. the organizers of the Qatar World Cup in 2022 face an entirely different challenge. The sustainability of these plans has since been questioned and there are suggestions Qatar will use ‘wind towers’. once athletes step onto the track in the new stadia. through both its Plate Heat Exchanger and Air Treatment technologies. GEA Refrigeration Technologies is a long-time supplier to ice skating rinks through its GEA Grasso refrigeration technology. The jury may still be out on exactly how Qatar is going to achieve its goal of cooling down the stadia. but there’s no doubting the importance that technology is playing in designing the stadia of the future. With temperatures hitting 50 degrees Celsius in the summer months. Swimming pools can also aid performance by being what swimmers call ‘fast pools’. The track’s layout was specifically designed to increase the chance of world record times. where GEA Refrigeration Technologies maintains the world. is a retractable pitch that can be mechanically rolled out of the stadium when required for nonmatch usage. including Borussia Dortmund. For example in the Netherlands. The temperature inside the velodrome was maintained at 28 degrees Celsius. GEA refrigeration technology is also used at a bobsled track in Russia. Pop-up ice rinks have become increasingly popular in Europe in recent years – and advances in cooling technology mean we can enjoy iceskating all year round. Elsewhere. lane markers and proportions can all be engineered to minimize water turbulence. which can slow down competitors. However. y g o l s o n h ort c e T p ew s es o n v i dr rs t sta g i e H s t h Skiing in Dubai 24 GENERATE MAGAZINE ISSUE 16 25 . Put simply. comfort and strength of their shoes. GEA Heat Exchangers’ cooling technology helps football fans enjoy food and drink at stadia including Bayern München’s famous Allianz Arena. The stadium’s roof was also designed to maximize track speeds. The depth of a pool is also significant for performance. a traditional Arabic cooling method used before the advent of air conditioning. on-track hospital and the timekeeping and loudspeaker systems. it built six of the 17 major skating rinks and is now responsible for maintenance at nine of them. In the colder parts of the US during the winter months. where it gained special approval to use ammonia as a refrigerant for the first time in a Russian sports facility. FIFA delegates were suitably impressed and for the first time awarded the World Cup to a country in the Middle East. they built a full-scale air-conditioned. FC Schalke 04 built the first moveable pitch in the German League in 2010. INNOVAtIONS ARE IN EVERYtHING FROm PSYCHOLOGY AND NUtRItION tO FOOtwEAR AND CLOtHING AS wELL AS tHE SPORtS VENUES tHEmSELVES. As part of their bid. Quality surface For sports like football and American Football. which supply plate heat exchangers and dehumidifiers respectively for pools at leisure centres and for domestic pools across Europe. cool and ready to play. A pool’s gutters. The range of products helps ventilate the swimming pool area. When India hosted its first ever Grand Prix in October 2011 at the Buddh International circuit in Uttar. The sliding pitches sit in a tray containing irrigation and drainage systems that work both inside and outside the stadium. One option currently in vogue in the US. stronger and reduce the drag caused by clothing in the water. there is a lot of focus on the hallowed grass turf.

a Russian immigrant to the US.175 kilograms and standing 1. Around the world people have dreamed up an almost limitless choice of flavors. Its Aquarius portfolio sets the standard for forming. invented a machine for inserting the sticks automatically. two stage dryers and coolers and fluidized bed coolers used in the sugar industry.8 meters high. The GEA Aquarius PopCooler models cool the lollipops while ensuring that they retain their shape and quality. GEA Food Solutions knows more than most about creating eye-catching packaging and exciting candy shapes. the lollipops need to be cooled. As beet sugar was cheaper than cane sugar and honey. Lollipops are generally fruitflavored and round in shape. For example. GEA Process Engineering has a portfolio of rotary dryers. Later. or a complete production line. and in different sizes to suit capacity. like a ball or wheel. Confectionery started to develop in Europe with the coming of sugar during the Middle Ages. Finally the GEA Aquarius packaging machines offer different wrapping options to ensure optimized product protection and shelf life. corn syrup and flavorings. including novelty three-dimensional (3D) versions. of course. The lollipop really came to prominence during the 20th century as a result of new manufacturing technology. like the wheel. the lollipop has the same mysterious provenance in that no-one really knows who invented it. As these events demonstrate. the Racine Confectionery Machine Company in Wisconsin marketed the first automated machine capable of making 40 lollipops a minute. cooling. And. evaporation and drying technology for processing sugar. GENERATE MAGAZINE ISSUE 16 27 . based on its popular chocolate-covered Gourmet Lollipop. when it comes to wrappings. it was displayed in San Francisco’s Justin Herman Plaza. The main ingredients for candy lollipops are hardened sugar. used in China. n 2012 a US confectionery company enjoyed the sweet taste of success by breaking the Guinness World Record for the largest ever lollipop.100 lollipops per minute. for example. However the term lollipop actually dates back to the 18th century English term meaning ‘tongue slap’. the name has stuck and is often shortened to lolly. make a lollipop from ground-up pearls – they are believed to act as an aphrodisiac. the logo was positioned on top of the wrapping rather than the side so that it would always be seen intact. Connecticut. It also provides systems for dissolving sugar into syrup. Sugar rush Historians have suggested that Stone Age people used sticks to collect honey from beehives. And. Sucker and sticky pop are also popular terms for lollipop. at his suggestion. CONTAINS SUGAR GEA supplies cooling. Lolly Pop. water. available only to the wealthy. combined rotary dryers/coolers. Mechanization made it possible to extract sugar from beets on a large scale. The sugar was boiled and formed into blocks and elaborately carved sticks were made to spear them. more people could enjoy a sweet fix. Surreal wrapping And. The GEA team used advanced CAD/CAM software to produce the 3D die set for shaping the lollipops. while Samuel Born. GEA Food Solutions engineers worked with Turkish confectionery company Sugabee to produce a 3D football lollipop in four flavor/color combinations to match the top Turkish soccer teams. After forming. shapes and sizes for this treat on a stick. is black ants which apparently taste like chili peppers. The Japanese. Plate heat exchangers from GEA Heat Exchangers are used to heat or cool. See’s Candies made the huge confection. GEA Process Engineering’s Courtoy compression technology is also widely used by candy manufacturers to produce single and multi-layer lollipops and other confections. Sticks for the candy versions are usually made from tightly rolled paper coated with wax. For example. the ancient Egyptians.Treats on a stick NO ONE KNOwS wHO FIRSt CAmE UP wItH tHE IDEA OF A SwEEt ON A StICK BUt tHE LOLLIPOP IS A FAVORItE AROUND tHE wORLD. Weighing in at 3. to coincide with National Lollipop Day on July 20. The distinctive daisy logo was designed by the famous surrealist artist Salvador Dali. there is something about the lollipop that captures the imagination. Meanwhile George Smith from New Haven. they don’t come much better than the one for the Spanish brand Chupa Chups. Arabs and Chinese are believed to have inserted sticks into their sweetmeats – usually fruits and nuts covered in honey – to make them easier to eat. He reportedly got the name from a popular race horse of the time. The Dum Dum Lollipops brand is so called because it was thought the name would be easy for children to say. They enable customers to manufacture different lollipop formats in one machine. With more than 50 years’ experience of providing lollipop manufacturing equipment. sometimes with ice cream fillings. Food manufacturer Del Monte created a frozen smoothie on a stick modeled on James Bond actor Daniel Craig and there’s even a candy lollipop version of the Mexican drink Mezcal – complete with edible worm. The GEA Aquarius FlexFormer forming machines can produce between 300 and 2. wrapping and packaging lollipops. It EVEN INSPIRED SALVADOR DALI tO DESIGN A BRAND LOGO. Another unusual lollipop flavoring. while ice lollies have flat wooden ones. laid claim to inventing the modern lollipop and trademarked the name in 1931. especially candy. heat exchange. Ice lollipops are frozen water- based. The equipment is available as individual machines. Finally the whole thing is wrapped in cellophane or printed wax paper. 26 I These are. the extreme end of the scale. mixed juice or molasses from sugar cane mills and are extremely energy-efficient. Until the Industrial Revolution sugar was a luxury item. membrane filtration for clarifying the raw sugar juice and evaporation plants to concentrate the sugar solution ready for crystallization. the main ingredient of lollipops. for example. Developments like the 3D lollipop continue to add excitement to the market for this everpopular sweet treat. Whatever the origins.

studied and worked in the US. As GEA’s Head of Corporate Organizational Development. N After working for another mechanical engineering company she joined GEA in 2006. It’s her job to systematically manage this part in order to serve the company’s goals. grew up in Italy. She also enjoys travelling with her family. based at the headquarters in Düsseldorf. literature and “having fun with my almost four-year old son”. which. “Even though there is a strong business case for diversity. She admits that it won’t all happen overnight. “I see this as an early success because it’s a sign that the topic is slowly taking hold within GEA. She is the first to admit that introducing what may be considered “abstract” areas in the technology-driven world of mechanical engineering is not straightforward. dIversIty Is beCOmIng InCreasIngLy sIgnIFICant.” A few months after assuming the position as Head of Corporate Diversity Management in 2011 her remit was expanded to include promoting the newly-established GEA Group values of excellence. she says is “the most difficult and trying part of the exercise: it means to manage the values message across all segments and to get it into the heads and hearts of staff. even controversially. I rediscovered my interest in the sector!” The move to her current role began in 2010 with an invitation to join a working group of colleagues from around the GEA Group to look into the issue of diversity and recommend appropriate strategies. Walking the talk obue Beate von Wurzbach loves hearing colleagues talking about diversity and the company’s values. GEA GrOUp appOInted NOBUE BEATE VOn WURZBACH tO prOmOte dIversIty and vaLUes thrOUghOUt the OrganIZatIOn and. And speaking to her leaves you in no doubt about her commitment to that. passion. integrity. This is a long-term project and I find the topics relevant and the challenges positive. “I’d been working in business development and marketing and wanted to make a career switch. But there is still a way to go”. as well as in Spain I fulfill a lot of diversity criteria. Organizational Development. “But when I was offered the position of Head of Strategic Marketing within GEA Mechanical Equipment. half Japanese. responsibility and GEA-versity.In a gLObaLIZed bUsIness wOrLd. there is still a lot of promotion that needs to be done and you can always try to do things better”. she says with the smile of someone who relishes a challenge. peOpLe are begInnIng tO respOnd.” Having lived in different countries von Wurzbach has developed an international circle of friends who she keeps in contact with in her spare time. as she dIsCOvered. “As I am half German. mountain hiking. Besides managing each topic separately her long-term aim is to make them more interconnected. involving representatives from all segments of the GEA Group meets regularly to agree strategies and actions. Our management is committed to values and diversity and is driving them from the top. “Some people are acting as champions and some managers are saying that diversity is a good thing for them and their staff. because it means that people are starting to deal with the issue.” A steering committee. With the addition of the ideas and improvement management function ‘i2m’ in May 2012. Diversity can definitely be a success factor. she is responsible for driving the diversity and values agenda throughout the business.” she explains. “Corporate cultures and organizational structures are man-made and man-driven and changing them requires commitment. she says. developing a diversity concept for GEA and is now specifying measures and concrete objectives to be achieved at the various levels within the Group. “We live in an interconnected world and diversity is a global issue. For diversity she initially began by examining the status quo. the department was renamed Corporate 28 GENERATE MAGAZINE ISSUE 16 29 . The values were launched to staff at a series of cascading workshops. One of the proposals was to set up a diversity management function and von Wurzbach was offered the job. These are signs that we are heading in the right direction. although the focal points vary.” she says with a smile. A key part of von Wurzbach’s role now is “making the values come to life”.

30 GENERATE MAGAZINE ISSUE 16 31 .At first glance this looks like a close-up of the inner workings of a locking mechanism. Its primary application is for bending flat steel of varying thicknesses through a 90 degree angle. But it can also be used to shape plates and wires into a number of semi-finished products. But it is actually a bending tool of a bending machine used in manufacturing various types of milking equipment.

DairyProView is the first software to allow comprehensive monitoring of a dairy farm’s entire operations. is exploiting the Qinghai provinces’ extensive magnesiumbased mineral and energy resources. are used as condensers. MEDAL wINS FOR GEA DAIRY INNOvAtIONS The EuroTier exhibition in Hannover – the global showcase for domestic livestock management – was a major success for GEA Farm Technologies.lang-communications. DairyProQ is the world’s first milking cluster module. formed in 1987. COpYRIgHT © 2013 by GEA Group Aktiengesellschaft. New Zealand.gea. stalling and automation equipment. GENERATE is the magazine of the GEA Group. Exhibition host Deutsche Landwirtschafts-Gesellschaft (DLG) awarded the company’s DairyProQ a gold medal and the Deutsche Landwirtschaftsverlag (dlv) named it ‘innovation of the year 2013’. cooling. feature: Gareth Sambidge Page 20-23: James Bell Page 28-29: Orde Eliason PROdUCEd BY MerchantCantos www. CHILLERS COOL MORE COSt-EFFECtIvELY GEA Heat Exchangers has launched new air-cooled chillers that enable customers to save on energy costs. COnTACT For any questions or suggestions contact: generate@gea. Published twice per year. These heat exchangers transfer heat more effectively. The GEA Niro SWIRL FLUIDIZER™ is a vortex type dryer for production of fine powders from viscous slurries. The contents do not necessarily reflect the opinion of the publisher.com 32 . GEA SUPPLIES wORLD’S LARGESt vORtEX DRYERS tO CHINA GEA Process Engineering has been awarded the contract to supply two GEA Niro SWIRL FLUIDIZER™ dryers to Qinghai Salt Lake Haina Chemical in Xining. Reprinting only with the permission of the publisher. a subsidiary of the state-owned Qinghai Salt Lake Industry Group. China.com FORMER ISSUES All former issues of GENERATE will be found on www.com dESIgn JohnstonWorks www. are more energy-efficient and are more resistant to corrosion. It will be integrated into GEA Farm Technologies. Germany.co. which replaces the GLAC 01521204-BD models. It provides a continuous and efficient process and can be fitted to various types of milking parlors. The dryers for Qinghai Salt Lake Haina Chemical will each have a capacity to produce more than nine tons per hour. it is distributed across the world. along with service programs focused on grazing farm applications. which offer a superior performance to classical Cu-Al heat exchangers. Another GEA Farm Technologies innovation – the DairyProView – was awarded a silver medal. is available in various sizes and is ideally suited to small and medium-sized HVAC systems. 12. Milfos. pastes and other products that are difficult to disintegrate in a single step. The GLAC-CD range.johnstonworks. facilities with low-volume water systems and refrigeration ratings of 40-350 kilowatts. Peter-Müller-Str.com COpY dESK Lang Communications www. Due to be in operation in July 2013. It provides a complete range of milking. The company’s integrated industrial complex includes several other GEA Niro plants.uk GEA exclusively uses paper from certified sustainable forests. 12 40468 Düsseldorf Germany RESpOnSIBLE FOR EdITORIAL COnTEnT Isabel Blank PHOTOgRApHY Cover.GEA ACQUIRES NEw ZEALAND-BASED MILFOS INtERNAtIONAL GEA has increased its expertise in pastoral-based dairy farming with the acquisition of the Milfos International Group. has more than 100 employees and exports to more than 20 countries. the company is a leading designer and manufacturer of innovative dairy technologies. Qinghai Salt Lake Haina Chemical. 40468 Düsseldorf. IMPRINT PUBLISHER GEA Group Aktiengesellschaft Peter-Müller-Str. they will not only be the largest GEA Niro SWIRL FLUIDIZER™ dryers supplied but also the world’s largest of this type of dryer.merchantcantos. Based in Hamilton. Microchannel heat exchangers.