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Olive Oil Recovery

Machines and process lines from GEA Westfalia Separator

engineering for a better world GEA Mechanical Equipment


More than 6000 years ago,
the olive had already been
discovered in Asia Minor as a
versatile fruit for eating and
cosmetics. The special fatty
acid composition promotes
health and makes the
“nectar of the gods” one
of the most prized natural
products today.

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GEA Westfalia Separator
Contents
4 The Latest Chapters in a Long Success Story
6 Solutions for all Country-Specific Production Methods
8 Comparison of 2-Phase and 3-Phase Systems
10 Continuous or Batch Process
12 Repasso, Pomace and Process Water Treatment
14 Acceptance and Cleaning
15 Mills
16 Malaxers
17 Accessories
18 Decanters
20 Separators
23 Service

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GEA Westfalia Separator
The Latest Chapter in a Long
Success Story
Since the 1930s, GEA Westfalia Separator has supported industrial production
of olive oil. With innovative developments such as the environmentally
friendly 2-phase system, the company now sets global standards for efficiency
and profitability.

GEA Westfalia Separator can look back on obtained into oil and water phases in small disk
more than 115 years of tradition. Today, the separators or static sedimentation tanks – a very
company is the global leader in mechanical complex procedure with relatively low outputs.
separating technology. Its developments are
used in a wide range of areas – in the beverage While initially only separators were supplied to the
and dairy industries, in recovering and industry, later on also powerful 3-phase decanters
processing oils and fats, as well as in chemicals, were used.
pharmaceuticals, biotechnology and starch
technology. Other applications include This 3-phase technology involved diluting the
marine engineering, energy, oil fields olive pulp with water, enabling the oil to be
and industry. The ecological dimension separated from the solid matter and water – an
is particularly noticeable in the field of economical method, but one which, because of
environmental technology. Based on this its requirement for huge volumes of fresh water,
extensive experience, GEA Westfalia Separator placed a significant burden on the environment.
has developed and manufactures customized The quantities of waste water also proved to be
centrifuges especially for the olive oil industry. an ecological problem.
If required by the customer, we can also supply
entire process lines, incorporating all the Environmentally-friendly 2-phase system
processing stages from the raw olives through The crucial advance came in the form of the
to oil polishing. 2-phase system. This was a method developed
in the early 1990s by GEA Westfalia Separator,
Olive oil is one of the oldest of all cultural which uses no added water for dilution and
assets. It is thought that olive trees were produces corresponding-ly less waste water.
being cultivated as long as 6000 years ago in Besides reducing the volume of waste water,
Asia Minor. Around 1600 B.C. the Phoenicians high yield and premium product quality are
spread the use of olives through Crete and further benefits of this method.
Egypt to the rest of the Mediterranean region.
By now, nutritionists have long since discovered Decanters with Westfalia Separator  ® cetec
what makes the “nectar of the gods” so valuable. technology, introduced in 2001, brought a further
Native extra olive oil is ascribed the best increase of between 1 and 2 percent in yield.
composition of saturated and unsaturated fatty In addition, special methods are now used to
acids, making it the best of all edible oils. prepare the pomace and the process water.
The latest development from GEA Westfalia
Industrial production of olive oil has been Separator is the combined scroll (“Combi-
supported by GEA Westfalia Separator since scroll”), which enables a 3-phase process to be
back in the 1930s. Until well into the 1970s, easily converted into a 2-phase system. The most
after crushing, stirring and heating it was outstanding feature of this special design is that
standard practice to squeeze the olive using the decanter provides the same throughput
hydraulic presses and to separate the liquid required in both processes.

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GEA Westfalia Separator
Polishing separators from
GEA Westfalia Separator
ensure premium quality oils
with no residue.

Decanters are at the heart


of the recovery process.
GEA Westfalia Separator
models support both 2-phase
and 3-phase processes.

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GEA Westfalia Separator
Solutions for All Country-Specific
Production Methods
Process lines need to meet different requirements depending on national traditions
and sizes of the harvest. GEA Westfalia Separator supplies tailored solutions to
support all production methods.

At present, around 2.5 million tons of olive oil Despite similar conditions in terms of the
are produced every year. More than 80 percent of quantities to be processed and the level of
this figure comes from countries in the European soiling, there are differences in how the olives
Union. The most important growing countries are processed in the individual growing countries
are Spain, Italy and Greece. However, the trend outside Spain. Depending on local traditions,
towards olive oil has led to rising production requirements and the opportunities for further
figures in other Mediterranean countries, the treatment of the pomace, both 2-phase and
Middle East, Africa and elsewhere in the world. 3-phase decanters can be used.
Turkey, Syria, Morocco, South Africa, Australia,
Argentina and Chile are particularly important. There are much greater differences between
individual growing regions when it comes to the
Spain is the largest international producer of extent to which production of the oil is grower-
olive oil. Growing and harvesting are mainly based. There are countries, such as Greece and
carried out on an industrial scale on the Iberian Turkey, where a batch production method is
Peninsula. Olives from farmers, many of whom predominantly used. The reason for this is that
are grouped into production collectives, are in these countries individual farmers produce
brought to the mill and collected in huge silos their own oil from olives they have grown and
by type. Depending on the weather, sell the oil themselves. They bring their olives to
the level of soiling of the olives can be the mill and wait until they have been processed.
relatively high. Because of this, facilities
with a much higher cleaning, washing and In other countries, such as Australia, Argentina
buffer capacity than production capacity and the USA, the oil is produced continuously.
are required. The olive oil is produced using a This means that the olives are only separated by
continuous process with 2-phase decanters. By types before processing.
comparison, other production countries have
small to medium harvests. The olives are also
relatively clean. The result is that the cleaning,
washing and buffer capacity matches the plant
output. Thus, if the output of a decanter is 100
tons per day, the washing capacity is also
designed for 100 tons. By contrast, in Spain the
washing capacity is normally around twice the
decanter output.

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GEA Westfalia Separator
D e p e n d i n g o n r e q u i r e m e n t s, G E A
Westfalia Separator supplies both
2-phase and 3-phase decanters to support
all country-specific production methods
– whether they are continuous or batch
methods. The ratio of washing and
cleaning capacity to processing capacity
can be individually adjusted according to
specific requirements. The company’s services
cover planning, engineering and process
monitoring for plants for between 20 and 240
tons of olives per day.

Continuous method
Batch method
2-phase and 3-phase systems
Configurations for capacities of between
20 and 240 tons of olives per day

Harvesting and processing


methods for the olives differ
according to the growing region.

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GEA Westfalia Separator
Comparison of 2-Phase and
3-Phase Systems
GEA Westfalia Separator supplies appropriate 2-phase or 3-phase decanters to
support both methods. In every case, the result is maximum yield of premium
quality product. However, the considerably lower consumption of fresh water
makes the 2-phase system significantly more environmentally friendly.

What both processes have in common is that the All the advantages at a glance:
olives are initially reduced to a pulp. With 3-phase Maximum oil yield
technology, this olive pulp must be diluted with Premium product quality
warm water so a layer forms between the oil and Minimum waste water volumes
solids in the decanter. This is the only way to (in 2-phase system)
achieve the subsequent separation into oil phase, 1 – 2 percent additional yield thanks
pomace and waste water. Depending on the type to innovative Westfalia Separator ®
of olive, the required volume of water is 15 to cetec technology
20 percent, in rare cases as much as 50 percent. Robust technology
The amount of loaded waste water produced by Individually adjustable machine parameters
this process is correspondingly high. Cleaning Easy handling
the waste water is also very demanding and High efficiency –
cost-intensive. rapid amortization

In the environmentally-friendly 2-phase Advantages of the 2-phase process:


system, the preliminary treatment of the No addition of dilution water necessary
olives is essentially the same as in a 3-phase in most cases
system. However, the fruits are milled smaller The olive oil obtained in the 2-phase
and malaxed for longer. After defoliation, the process contains all natural constituents of
olives are milled in hammer mills with mesh oil (polyphenols), giving the oil a more
sizes of 5 to 6 mm and the pulp is malaxed intense taste
(at a maximum of 27° C for cold pressed olives) Solid / water mixture can be processed
to allow the oil to be separated from the fruit relatively easily (e. g., for pit separation,
particles. For the subsequent 2-phase separation, water separation and olive oil recovery)
GEA Westfalia Separator developed a decanter No separate waste water phase in decanter
with a special scroll, which separates the pulp
into (1) oil, and (2) pomace and water. In addition Advantages of the 3-phase process:
to the ecological issues, the 2-phase system is also Dry solids are easy to transport
impressive from an economic perspective. It Solid quantity is only 50 percent
ensures the best possible oil quality by retaining of the feed quantity
the highest possible polyphenol content. The Established infrastructure for processing
taste is intense, because fewer flavors and of solids in traditional industry
ingredients are washed out. At the same time,
these oils have an exceptionally long shelf life.

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GEA Westfalia Separator
3-phase decanter Polishing separator
Pulp
Oil

3-phase process

2-phase decanter Polishing separator


Pulp
Oil

Pomace

2-phase process

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GEA Westfalia Separator
Continuous or Batch Process
Depending on the company and the sales structure, olive oil can be produced
using a continuous method or a batch process. GEA Westfalia Separator has
developed individual process lines to provide optimum support for both methods.

Continuous method
With this method, the olives are delivered by GEA Westfalia Separator 2-phase or 3-phase
tractor or truck and are washed immediately systems can be used for both methods
before they are stored in huge silos for a of production. The crucial difference in
maximum of 48 hours. Alternatively, olives of the process lines lies in the number and
one particular type are delivered continuously dimensions of the malaxers. While a relatively
and spend just a short time in the silo. From large series of malaxers are used in the
the silos, the olives are continuously fed into continuous method, for the batch process several
the process. The oil produced is fed into small, independent malaxers are used in parallel.
storage tanks and sold by the oil mill. The olive This enables each olive farmer to have his olives
farmers are paid according to the quantity processed separately from the other farmers
of olives and the oil content. The continuous and there is no chance of the olive batches
method is suitable for collective operations in being mixed.
centralized markets and for uniform olive types.
The major advantage of the GEA Westfalia
Batch process Separator solution lies in the fact that the
In a batch process, the famers deliver their malaxers for a batch system can be individually
olives in large sacks or plastic boxes. The heated rather than in groups. This means that the
olives are processed in batches directly, with desired product quality can be reliably ensured
no intermediate storage. The farmer thus in every single batch. In addition, there are no
receives the oil from the olives he has grown energy losses, for example if only one malaxer
himself. A batch process is used in areas is in operation. Because a batch system involves
where growing and processing are very setup times when changing to a new batch, the
decentralized and the system is based on the line output is around 10 to 20 percent less than
olive oil producers. that of a continuous method.

Use of 2-phase or 3-phase systems possible


for both methods
Individual heating of malaxers in batch
method for optimum product quality and
precise use of energy for the process

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GEA Westfalia Separator
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GEA Westfalia Separator
Repasso, Pomace and
Process Water Treatment
Further treatment of pomace and process water with process lines
from GEA Westfalia Separator provides additional profitability from
the overall olive oil production process.

Pomace treatment in a second Process water treatment using


decanter stage the Borrass method
In traditional 3-phase systems, the de-oiled GEA Westfalia Separator has developed
pomace is dried and any residual oil is extracted a special decanter process, which can be
using hexane. The remaining pomace is used to specifically treat the process water.
primarily used as a fuel. However, as the oil Although the 2-phase technol-ogy does not
extracted with hexane can only be used as a require any dilution water, other stages of the
foodstuff after refining, olive oil producers have process – as with any process – do consume
a considerable interest in installing a second water. Around 200 liters are required per ton of
decanter stage for treatment of the pomace. This olives processed. This water then becomes waste
additional stage is able to recover 40 to 50 percent water. If it is concentrated by sedimentation
of the olive oil remaining in the pomace, thus or flotation, it is referred to as residual sludge
increasing profitability. Separating the pomace (Spanish “borras” = sediment). A 3-phase
into olive pits and pulp also provides valuable decanter with a high level of separation then
by-products. While the pits can be used as a separates out the residual oil and extremely
high quality fuel, for example in the oil mills fine particles from this residual sludge. Overall,
themselves, the pit-free pulp can be dried and the Borras process has three key advantages.
then sold as fertilizer or as a high-fiber feed First, it reduces the volume of waste water by
additive. This pomace treatment is possible in 15 percent. Second, all of the parameters relevant
both 2-phase and 3-phase systems. for assessment of the waste water fall, resulting
in lower waste water charges. Third, the oil
Prompt treatment of the pomace is known as mill gains up to an additional 0.5 percent of oil
the repasso process. The quality of the pomace relative to the quantity of olives processed.
oil obtain-ed is usually not much lower than
that of the native olive oil. Alternatively, Gain of additional oil with identical quality
the pomace can be collected, stored for Saleable by-products
several months and continuously processed Reduction in waste water volume
through the year. The oil obtained in this case is of
lower quality and therefore more expensive and
complicated to refine than repasso oil.

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GEA Westfalia Separator
Olives

Pulp Polishing 2-phase decanter


separator Oil

2-stage malaxer
Oil
Water Alpeorujo

Polishing 3-phase decanter


separator Oil
Alpechin
Malaxer for
pomace Oil

Solids
(Orujo)

2-phase oil production combined with 3-phase repasso process

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GEA Westfalia Separator
Acceptance and Cleaning
As a system partner, GEA Westfalia Separator supplies complete process lines.
These include components for accepting and cleaning of the olives.

Before the olives can be milled, they need to be GEA Westfalia Separator supplies all of these
weighed, washed and cleared of stems, leaves components. Because everything comes from
and other vegetable and non-vegetable matter. the same supplier, the systems are perfectly
GEA Westfalia Separator supports the olive oil compatible. Production runs smoothly, reliably
business with proven components for every step and quickly, from start to finish.
in the process.
GEA Westfalia Separator supports
For acceptance of the olives, special scales are you with:
available, allowing the olives to be Acceptance hoppers
weighed quickly and accurately. Cleaning Conveyor belts
machines reliably remove all stems and Cleaning machines
leaves that are still attached to the fruits. Washing machines
Appropriate washing systems are also of vital Scales
importance for cleaning the olives of any dirt or Stick removers
soil, ensuring that the oil is of optimum quality.

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GEA Westfalia Separator
Mills
Various mill models are available, which can be optimally adapted
to local conditions.

The pre-treated olives are reduced in hammer GEA Westfalia Separator customizes mill design
mills and milled to form olive pulp. Hammer to fit requirements and physical constraints.
mills are used because they are best suited for the For continuous operation, the mills are often
heterogeneous mixture of soft fruit flesh and installed directly underneath the silos, and
hard pits. A rotor with moving steel hammers the olive pulp is normally transported to the
rotates at high speeds in a metal housing. The malaxers by pumps. For a batch process, the
olives are fed into the impact zone of the rotor, mills can be attached directly to the malaxers,
where they are crushed by the steel hammers. which eliminates the need for transportation.
The mixture of fruit flesh and pits remains in the
reduction zone until it fits through a perforated Single mills
strainer at the mill outlet. The perforation size Double mills
can be varied by using different strainers. Stand alone installation
In combination with malaxers
Centralized or decentralized
Screw conveyors
Rotating or stationary strainers

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GEA Westfalia Separator
Malaxers
Malaxers from GEA Westfalia Separator are individually adjusted for a continuous
or batch process. This ensures the required product quality and optimizes the use
of energy.

Before the pulp can be fed from the hammer mill individual heating cuts energy losses, which
to a decanter, it must pass through a malaxing are possible with complete heating if the full
process. This process, in which the pulp is stirred capacity of the malaxers are not being used.
at a particular temperature for a specified
period of time, leads to an additional breakdown GEA Westfalia Separator supports
of the cells. The proportion of free oil is increased you with:
and the oil droplets can flow together to form Malaxers for continuous processing
larger droplets. GEA Westfalia Separator supplies Malaxers for batch processing –
malaxers for this stage. While the continuous individually heatable
production process uses a small number of large Horizontal and vertical agitating
malaxers, the batch process uses several small Malaxers for manual and automatic
malaxers, as the batches belonging to the operation
different growers need to be kept separate.
Benefits of malaxers from GEA Westfalia
Batch malaxers from GEA Westfalia Separator can Separator:
be individually heated. The advantage of this is High energy efficiency, due to
that the heating can be adjusted to the specific individual heating
volume of the relevant batch, ruling out the Level monitoring
possibility of overheating with the resulting Optimized usage, particularly
detrimental impact on quality. In addition, for production of cold pressed olive oil

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GEA Westfalia Separator
Accessories
GEA Westfalia Separator also supplies supplementary accessories,
from vibrating strainers and centrifuge platforms through to buffer and
pure oil tanks for appropriate storage of olive oil products.

Our product range includes all of the required Also available as accessories are pure oil tanks for
accessory components, for 2-phase or 3-phase intermediate storage of the olive oil following
separation using a continuous or batch process. 2-phase or 3-phase separation. The pure oil tanks
feature high quality materials and optimum
Vibrating strainers are used to filter out slight impuri- hygiene conditions.
ties such as very fine lees. GEA Westfalia Separator
vibrating strainers are designed for 2-phase or Vibrating strainer for 2-phase
3-phase operation as required. and 3-phase operation
Centrifuge platform –
with and without pipelines
Buffer tank –
for decanters and / or separators in a batch
process
Pure oil tank with one or two chambers,
following 2-phase or 3-phase separation
Cleaning-in-place (CIP) stations

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GEA Westfalia Separator
Decanters
2- and 3-phase decanters from GEA Westfalia Separator set standards
for reliability and profitability.

Decanters are at the heart of every modern All the advantages at a glance:
process line. The 2-phase and 3-phase decanters 2-phase and 3-phase decanters
from GEA Westfalia Separator are the result Standard or combined scroll
of more than 115 years of experience in the 2-gear drive
development of centrifuges. Innovations Low vibration operation, leading to
such as the 2-phase separation process, excellent reliability
Westfalia Separator ® cetec technology and the Robust quality
combined scroll are constantly reinforcing our Long service life and maximum availability
technological leadership in the market. Besides Easy operation and monitoring
increased product yield, olive oil manufacturers High efficiency – rapid amortization
particularly value the durability of our decanters. Maximum product yield
This is of vital importance in load intensive Westfalia Separator ® cetec technology
manufacture. Long service life and for 1 – 2 percent additional oil yield
constant availability make GEA Westfalia Conversion from 3-phase to 2-phase process
Separator’s developments the first choice with identical throughput
worldwide. Depending on the required
capacity, models for processing between Advantages of the 2-phase process:
20 and 240 tons of olives per day are available. No addition of dilution water necessary
in most cases
Our developments feature impressive The olive oil obtained in the 2-phase
technological features such as the patented process contains all natural constituents of
2-gear drive. This drive type allows automatic oil (polyphenols), giving the oil a more
torque measurement and differential speed intense taste
regulation. 2-gear drive is highly recommended Solid / water mixture can be processed
because it achieves the lowest possible relatively easily (e. g., for pit separation,
residual moisture in the solid output. Even water separation and olive oil recovery)
with fluctuations in production, a uniform No separate waste water phase in decanter
dry substance content can be maintained.
In addition, the throughput is higher than using Advantages of the 3-phase process:
decanters with a standard drive. You can choose Solids are easy to transport
from decanters with Westfalia Separator  cetec
®
The solid quantity is only 50% of the
technology, standard or combined scroll. The feed quantity
outstanding benefit of the GEA Westfalia Established infrastructure for processing of
Separator combined scroll is that the change to solids in traditional industry
a 2-phase process does not result in any drop
in output.

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GEA Westfalia Separator
Product

GEA Westfalia Separator


supports the environmentally-
friendly 2-phase process
with its 2-phase decanters.

Olive oil

Water / solid mixture

Product

The 3-phase decanter –


robust technology
for the 3-phase system

Olive oil
Water

Solids

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GEA Westfalia Separator
Separators
Polishing separators from GEA Westfalia Separator ensure the required premium
quality by removing all residue while handling the product with extreme care.

The separated olive oil from the decanter still


contains residual water and extremely fine lees
material. Therefore, the oil phase is polished
by a separator after the decanter. Once again,
GEA Westfalia Separator equipment is state of
the art here. The self-cleaning models reduce
maintenance costs to a minimum, while
handling the oil with the utmost care and using
the Westfalia Separator ® hydrostop system to
ensure optimum product yield and solids almost
totally free of oil.

The oil is purged of the lees and water in the


disk stack. The separated heavy liquid phase
(water) drains freely out of the bowl through the
separating disk. The cleaned light liquid phase
T h e p a t e n t e d We s t f a l i a S e p a r a t o r ®
(oil) is discharged under pressure via centripetal
hydrostop system ensures that during the
pump. The centrifuged solids collect in the solid
partial ejection – when the bowl is open
chamber and are discharged at periodic intervals.
for a sufficiently short time – no product
losses can occur. Only the collected solids
are discharged, the oil remains inside the bowl
where polishing occurs. The bowl can be cleaned
manually or automatically using the PLC system,
which involves complete emptying of the bowl.

Westfalia Separator® hydrostop system


for minimum oil losses
Self-cleaning effect after total ejections
Improved clutch design
for a longer wear lifespan
All parts coming into contact with the
product are made of stainless steel
Flat-belt drive design
Higher g-force
Automated operation
Continuous processing mode
Simple maintenance
Low noise design

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GEA Westfalia Separator
Oil phase
from the decanter

Polished
olive oil

Water

Solids

Thanks to its excellent separation effect,


the polishing separator makes for maximum
product yield.

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GEA Westfalia Separator
Ensuring Maximum Process Efficiency,
Availability and Budget Security with
Westfalia Separator® capitalcare
The demands of olive oil processing can be A variety of service contract options are available
tough. Equipment must perform reliably, safely to our customers. Contracts can include safety and
and at maximum efficiency all day, every day. performance audits, training of plant personnel,
As a DIN EN ISO 9001 company, we stand behind vibration and process monitoring and a spare
our products, our service and the quality of parts inventory.
our work. Our commitment is to provide
customers with the highest level of support Guaranteed parts from
available to maximize the productivity and GEA Westfalia Separator
longevity of their equipment. Because centrifuges are subject to extreme
operating conditions, safety is a critical issue. The
With Westfalia Separator capitalcare, use of anything other than genuine OEM parts
customers enjoy peace of mind and introduces an uncontrolled source of weakness in
benefit from: an otherwise perfectly balanced machine.
Uninterrupted equipment performance
Maximized plant productivity and profitability The quality and functionality of our parts
Maximized equipment utilization is the result of extensive chemical analyses
as well as tests of corrosion resistance,
Minimized downtime
temperature extremes, hardness and surface
Optimal equipment performance tests, stress trials and goodness of fit – all to
Enhanced plant and operator safety. within miniscule tolerances. This ensures hours
of trouble-free operation.

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GEA Westfalia Separator
Maximum availability
Services performed by specialists
When normal equipment use results in wear
and tear, we stand behind the quality of Absolute budget reliability
our repair services. GEA Westfalia Separator
has trained mechanics on staff that have the
proprietary knowledge to make the necessary Permanent efficiency
repairs. In true emergencies, a response team
can be quickly deployed to your facility. Spare
bowl and scroll assemblies are readily available In addition to traditional
for your use, so process/production lines are not services such as
idle while repairs are underway. And when maintenance or repair,
equipment needs to be repaired off-site, we Westfalia Separator
capitalcare also provides
offer two full service locations. Our brand new
solutions which avoid
facility in Patterson, California was specifically risk and assure the
developed to service customers based in installation’s availability.
western North America. Here, decanters and
separators of all sizes can be repaired. There
is also a large parts inventory and a specially
designed training facility.

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GEA Westfalia Separator
Excellence Passion Integrity Responsibility GEA-versity

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

GEA Mechanical Equipment US, Inc.

Westfalia and Westfalia Separator are registered trademarks of GEA Westfalia Separator GmbH.
GEA Westfalia Separator Division
Headquarters: West Coast:
100 Fairway Court Western Region Customer Support Center
Northvale, NJ 07647 555 Baldwin Road
201-767-3900 Patterson, CA 95363
209-895-6300
Midwest:
725 Tollgate Road, Suite B
Elgin, IL 60123 GEA Mechanical Equipment Canada, Inc.
630-503-4700
GEA Westfalia Separator Canada Division
South:
4725 Lakeland Commerce Parkway, Suite 4 835 Harrington Court
Lakeland, FL 33805 Burlington, ON L7N 3P3
863-603-8900 289-288-5500

Southwest:
2408 Timberloch Place, Suite C-4 Toll-Free: 800-722-6622
The Woodlands, TX 77380 24-Hour Technical Help: 800-509-9299
2372

281-465-7900 www.wsus.com

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