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Process Technology for the

Fruit Juice and Primary Industries

Innovative Engineering –
Quality in Line.

Process Engineering
… is established on an interna- GEA TDS possesses the necessary know­
tional level as a specialist for how for the design and manufacture of
hygienic, aseptic and sterile plants for
technically and economically
the production of liquid products. For
optimised process technology project engineering and customer
in the treatment of milk prod- service, GEA TDS offers international
ucts, food and juice. attendance and short reaction times
by local presence and, of course, After-
Sales-Service. Experienced and compe­
tent expert teams deliver technical
solutions tailored to the customer’s

Product programme for the fruit

juice and primary industries
■■ complete process lines
■■ short time heaters
■■ valves, pumps, components
■■ deaeration technology
■■ mixing plants
■■ tubular heat exchangers
■■ plate heat exchangers
■■ CIP plants
■■ homogenisers
■■ process automation and integration
■■ engineering, implementation and

Process technology for the fruit juice
and primary industries
■■ concentrate cooling
■■ heating of mashes
■■ tank farm equipment
■■ evaporation plants
■■ aroma extraction

Plate Heat Exchanger VARITHERM ® N40, STH Plant (RWT) for fruit juice,
capacity 24 m3 /h capacity 20 m3 /h

CIP Plant In-line dosing

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Process Engineering
Are you planning a complete From isometric drawings to pipe class
fruit juice plant or a new pro- specifications, from detailed engineer­
ing to project management, GEA TDS
cessing room or an extension?
takes charge of the projects on site, on
Whether your project is a new the client‘s premises or in our technol­
’greenfield’ plant, conversion ogy centre. GEA TDS is now part of the
or modernisation of an exist- international systems engineering
sector of the GEA Group. This provides
ing process plant, GEA TDS
access to a variety of components and
engineers, with their complex units made by members of the group
know-how, are there to back which can be integrated to create high-
you up with excellent service. quality processing systems.

The use of modern CAE tools for detail

engineering is common throughout the

Concentrate Storage


Liquid sugar Storage

Crystal sugar

Minor ingredients Storage


Concept map for continuous blending
Detailed engineering ■■ supervision of construction and
■■ layout planning and detailed installation work
coordination/clarification of details ■■ commissioning of plant components
■■ inventory taking on site ■■ supervision of commissioning
■■ design of pipe layout and ■■ technical support for production
instrumentation ■■ process optimisation
■■ arrangement of components ■■ documentation
■■ calculation of material requirements
and technical specifications For project planning and engineering
Heating plant  / deaeration /
■■ definition of interfaces the main focus points are: homogenisation
■■ configuration and dimensioning ■■ preliminary design
of instrumentation and control ■■ support in approval planning
equipment ■■ preliminary planning and layouts
■■ technical description of the ■■ selection/dimensioning of
processes process equipment
■■ quality assurance and ■■ production of tender documents
quality control for process plants
■■ monitoring of time schedules
■■ cost control

Carbonation tank



Premix Ready-to-drink Product

Deaeration of water

Pasteurisation Storage

Homogeniser Deaeration

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One of the key production Basic mixing takes place in batch The raw materials are introduced to
steps in the fruit juice and mode, i.e. a particular quantity of the valve matrix either individually or
a certain product is manufactured. from a storage tank, depending upon
primary industries is product
For exact determination of the weight the customer’s requirements. Small
mixing. In the mixing process of the individual components either quantities prepared in advance (solids,
the individual raw materials are scale balances or mass flow meters can flavourings, etc.) are similarly intro­
blended in exact proportions be used as required – in the fruit juice duced to the mixing matrix exactly in
industry today it is normally mass flow accordance with the recipe, as are the
with each other, and mixed to
meters that are used. Product mix­ container materials from the container
form a marketable product. ing using scale balances is normally station.
used in mixing processes where there
are many components and the quan­ A very high level of flexibility is
tities involved are small. GEA TDS achieved by constructing the valve
offers the ideal equipment for prod­ matrix using VARIVENT® Mixproof
uct mixing using mass flow meters in Valves that are secure against impact
the form of the GEA Varimass System. loads. By means of this design, and by
With the Varimass System the various the valves’ integrated lifting actuators,
components are integrated at a valve cleaning of the component and mix­
matrix using a varying number of mix­ ture lines can take place in parallel
ing lines, according to their mixing with the mixing process.
duty. Their quantities are registered by
means of mass flow meters. For product mixing using weighing
technology the individual component
lines, contrary to the GEA Varimass
Manual addition
Dissolving station Storage tanks
principle, are not integrated at a valve
matrix, but at one or more weighing
Scale tanks. In the weighing tanks the
Mixing valve in­dividual components are weighed
Water one after another and conveyed to the
appropriate mixing tanks. In a variant
of the mixing process, using weighing
technology, the mixing tanks are
Sugar syrup
directly fitted with load cells.
Minor ingredients



Mixer Pasteuriser Filler

Blending concept map

A further variant of the prod-
uct mixing process is provided
by continuous in-line mixing

In this procedure we blend the indi­

vidual components or a prepared
premix direct prior to the following
processing. Using this technology the
available capacity of the ingredients
or final product can be increased.
Tank farm Small volume mixing system

A mixing plant that is optimised and

matched to customer requirements
increases the efficiency and reliability
of the product mixing process. This
enables customers to react with a high
degree of flexibility to the rapidly devel-
­oping requirements of the market and
to achieve considerable cost reductions.
Our aim is to create and offer optimised
plant designs to meet individual cus­
tom­er requirements.

Valve matrix for mixing

In-line dosing

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Pasteurisation plant
Fruit juices as well as beverage This task is achieved by thermal The heat treatment system to be used
bases require a long shelf life. treatment of the product using a depends first of all on the properties of
pasteuriser. In a short time heating the product to be treated. The correct
Conservation of the product
plant (STHT plant) the product is design of the pasteuriser as well as the
shall be achieved by efficient heated for a short time to the required selection of appropriate components
processing without affecting temperature and rapidly cooled down. allow the treatment of the following
the product quality. Plate or tubular heat exchangers at products:
choice are used to heat the product ■■ Smoothies
to the required pasteurisation temper­ ■■ fruit juices and drinks with and
ature. without cells, pulp and CO2
■■ vegetable juices
■■ primary products
■■ mashes

Vacuum Deaeration
For not affecting the quality
through oxidation, the product
undergoes a vacuum-deaera-
tion which partly takes place
during the pasteurisation

Via an especially designed cascade valve,

the product is conveyed at a temperature
between 55° and 60° C into the deaerator
vessel where the major part of the total
gas amount is removed from the product.
The aroma substances entrained by the
degassing procedure are recovered in a
tubular heat exchanger and returned to
the product.

Heating plant 30m³/h capacity

When producing beverages GEA TDS offers carbonation of bev­
containing CO2, carbonation erages. Gaseous CO2 is added to the
product. This continuous process can
is integrated into the overall
be integrated into the overall process
line concept. either upstream or downstream of the
thermal treatment.

Carbonisation system

Sterile tank
In aseptic process technology, Aseptic storage prevents recontamina­
product safety takes top tion of the product and helps to ensure
a long shelf life and stability.
priority. Food processors use
sterile tanks as storage or After pasteurisation, hygienic treatment
buffer tanks. of the product is required. Sterile tanks
can perform a buffer function in the
process upstream of the filling line.

Sterile tank

The GEA Niro Soavi high- The capacity ranges from 10 l/h to
pressure homogenisers and 50,000 l/h at an operating pressure
of 1,500 bar max. For special appli­
microsizers reflect the latest
cations, a homogenising pressure of
innovative developments 2,000 bar max. can be achieved. The
and show excellent results Ariete series are capable of process­
in respect to capacity and ing products at temperatures up to
180° C. Special operating conditions,
reliability. Homogeniser
e.g. adherence to hygienic and aseptic
requirements or treatment of abrasive,
viscous or corrosive liquids, can be
fulfilled with the standard treatment

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Plate Heat Exchanger

The core piece in process Type VARITHERM®
plants are heat exchangers VARITHERM® plates are used for the
thermal treatment of:
– they are used for cooling,
■ clear or turbid products with and

heating, pasteurising or UHT without CO2

heating. GEA TDS use plate ■ Products containing fibres with a max.
Type H and tubular heat exchangers edge length of 0.5 mm to 1 mm.

depending on the plant

You can choose between various types
configuration. of heat exchanger plates with different
embossed profiles:
As a central module in thermal process ■ Plate type H with horizontal

technology, the plate heat exchanger has chevron pattern for high thermal
always been the cornerstone in systems efficiency
Type V engineering: design and development are ■ Plate type V with vertical chevron
continuously adapted to the needs of the pattern for lower pressure drops
changing market and trends in product ■ Plate type M and P with V­shaped
specifications. chevron pattern for highest differen­
tial pressure resistance

The advantages at a glance:

■ thermal treatment of products Type Freeflow N
Type M/P
containing cells and fruit pulp The Freeflow N plate is the right
■ efficient heat transfer, i.e. small heat choice for:
exchange area and thus low ■ clear or turbid products and products

investment costs containing fibres

■ high degree of heat recovery (up to ■ up to a length of approx. 5 mm and
96 %), this means low energy costs 1 mm in diameter
■ low space requirements due to large
heat transfer surface in a compact
Type Freeflow N assembly
■ easy adaptation to changed capacity
parameters by expansion or reduction
of plates, i.e. high­flexibility
■ short dwelling times in the heat
treatment section, thus gentle product

Tubular Heat Exchanger

The VARITUBE® Tubular Heat VARITUBE® S – the single-tube heat
Exchanger is specifically exchanger for indirect heat exchange
for the treatment of products contain­
designed for the thermal
ing pieces. Product recovery is possible
treatment of low- to high- using pigging technology.
vis­cosity products and for
VARITUBE® S and M, corrogated
products containing particles, VARITUBE® M –the multi-tube heat and plain inner tubes
exchanger for indirect heat exchange
pulp and fibres. The VARITUBE®
is also suitable for products containing
system is mainly used in particles of approx. 18 mm length.
heating, cooling and aseptic
systems. VARITUBE® P – for the direct prod­
uct/product heat exchange in all appli­

VARITUBE® SK – for the direct prod­

uct/product heat exchange of fibre-
containing products up to a length of
30 mm.

Functional principle: Patented flow

devices installed on the bottom plate
provide additional acceleration and
generate a transverse flow, ensuring
that no fibres collect on the tube
bottom. Longer production cycles VARITUBE® SK

are thus achieved.

Profile of VARITUBE® SK VARITUBE® HS – the multi-tube heat

exchanger for indirect heat exchange,
suitable mainly for hot water genera­
tion and heating of CIP media.

VARITUBE® E – Multitube with indi­

rect heat exchange, suitable mainly for VARITUBE® HS

hot water generation and heating of

CIP media for medium thermal out­
puts and volume flow rates of up to
165 m3/h.


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Process Automation
and Integration
Quality assurance and GEA TDS offers a wide spectrum of
increased productivity drive innovative process automation systems
and services that range from the provi­
the steadily increasing auto-
sion of electronic process control up to
mation of plants and produc- integrated, company-wide network
tion processes. The advan- systems complete with the correspond­
tages are obvious: labour and ing management information systems.
Machine control systems, for separators,
production downtimes are
homogenisers or filling machines for
reduced and operator error example, can be homogeneously
is safely ruled out. The plants integrated into the overall automation
are upgraded so that all essen- system through the bus network.

tial parameters relevant for the

GEA TDS uses the latest industrial stan­
production processes are auto- dards for all automation projects. In this
matically controlled, monitored respect batch processes are automated
and documented. in accordance with ISA-S88a as an
essential factor for a transparent, trace­
able production.

To adapt existing production plants to

new generations of automation systems
(e.g. when replacing the visualisation
system or upgrading from S5 to S7)
migration strategies will be developed
for you that allow safe conversion while
production continues to run.

Operation and Process Visualisation

All operator interfaces are designed with
logical menu structures that allow intui­
tive operation of the plant. The operator
is comprehensively informed at a glance
and guided progressively through the
Documentation and Process Reporting and Batch Tracking
Optimisation The process data is transferred online
The supervisory control system allows to an SQL database extended with
operators to record measured values and powerful evaluation tools:
switch status, thus creating the neces­ ■■ the report generator can be cust­
sary transparency for process optimi­ omised so you can configure your
sation. own application-oriented reports.
■■ batch tracking in graphical or
CIP curve Recording of measured data is supple­ tabular form helps you to keep
mented by a database-supported event track of your products in accordance
log with practice-oriented evaluation with the EU regulation 178/2002.
features. This audit trail allows the
tracking of individual batches or an The standardised approach allows you
entire production. to introduce a batch tracking system in
manageable steps at a known cost.

Fruit juice blending

Reception Track & Trace

Signals STH Login

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CIP Plants
CIP (cleaning in-place) is the Using a modern CIP system ensures the
commonly used method for optimum quality assurance and increas­
es product quality.
plant cleaning during the pro-
duction process where hygiene CIP Recovery Systems
is, of course, paramount. These CIP systems consist of various
cleaning medium tanks for drinking
water, cleaning solution and returned
Variable CIP systems are available for water. The system or tank size is adjust­
different cleaning procedures. The diver­ ed to the cleaning cycles required. The
sity of products and processes calls for number of cleaning systems installed
different methods for cleaning process determines the cleaning frequency, the
plants. Variable CIP systems are avail­ simultaneous execution of operations
able for different cleaning procedures and the number of objects. The systems
within the production process where are technically equipped and config­
hygiene is paramount. ured to meet the cleaning objectives
GEA TDS is always striving to find the
optimum balance between chemicals, Single Use Cleaning System with
mechanics, temperature and residence ECOCIP
CIP Plant time, with additional focus on environ­ The system consists of a detergent tank
mental protection and down-times. for the ready-made cleaning solution,
pre-assembled on a base frame. The
cleaning solution is circulated and heat­
ed up to the operating temperature.
Conductivity measurement and in-line
concentrate metering ensure that the
required amount of detergent is added.
The detergent flow rates are adjusted
by the cleaning program. CIP modules
are easy to integrate into the process
and offer the most appropriate clean­
ing even for demanding products.

CIP batch cleaning assembly

Packing technology
With GEA Procomac we Their core business is the engineering,
respond to the need of the manufacturing and installation of com­
plete filling lines for the beverage indus­
beverage market for an overall
try both for conventional and aseptic
solution and can provide com- applications. The proportion of aseptic
petent on-the-spot services. filling lines is about 70 % of all the lines
GEA Procomac based near
Parma in Italy is one of the GEA Procomac supplies complete filling
lines for juices, teas, still/carbonated
world’s leading suppliers of
beverages, dairy products and water,
cold aseptic filling technology. in a constantly high quality from the Aseptic filling system

process technology to the packaging


Assembly and After Sales

GEA TDS services also include The GEA TDS After-Sales programme
the assembly of entire plants. includes a permanent support service:
taking care of service and maintenance
A comprehensive range of
directly after hand-over of the plant.
services is available throughout Customer support also includes defined
the entire service life of your maintenance and individual inspec­
plants, all designed to achieve tion agreements to ensure fault-free
and reliable operation and to keep your
maximum productivity and
plant running efficiently for years.
economic efficiency.

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Innovative Engineering –
Quality in Line.

To find out more about your particular process

technology application, contact GEA TDS at

The juice industry produces many different products and this

brochure could not possibly describe all the potential process lines

Process Engineering
Voss-Straße 11/13 · 31157 Sarstedt · Germany
Phone +49 5066 990-0 · Fax +49 5066 990-163

Am Industriepark 2–10 · 21514 Büchen · Germany

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

Kruppstraße 3 · 48683 Ahaus · Germany

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

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