GEA Procomac in Dairy

GEA Process Engineering / GEA Procomac

The GEA Group in Summary

The GEA Group is one of the largest providers for equipment and process
technology particularly for the food and energy industries where it ranks
among the market and technology leaders.
The GEA Group focuses on demanding production processes and supplies
its customers with efficient solutions in various end markets.

In 2012 the GEA Group employed over 24,500 people who generated
revenue of more than EUR 5.7 billion.

GEA Procomac in Dairy

GEA Process Engineering / GEA Procomac

Group Structure

GEA Food
Solutions

GEA Farm
Technologies

GEA Heat
Exchangers

GEA Mechanical
Equipment

GEA Process
Engineering

GEA Refrigeration
Technologies

Bowl Choppers

Milking & Cooling

Finned, Shell & Tube

Separators

Spray Drying

Compressors

Cooling Towers

Decanters

Aseptic Filling

Packages and Skids

Spiral Cookers

Slicers

Farm Services

Plate Heat Exchangers

Homogenizers

Brewery & Dairy

Systems

Ice Machines

Thermoformers

Farm Equipment

HVAC Systems
)

Valves

Pharma Systems

Freezers

GEA Procomac in Dairy

GEA Process Engineering / GEA Procomac

GEA Procomac vision & mission

Vision:

Mission:

A company that is identified as the

NO PRESERVATIVES

market leader for sensitive

beverages filling and generally the
best option for those markets that
require a clean filling environment

GEA Procomac in Dairy

TO PRESERVE NATURAL
LIVING

GEA Process Engineering / GEA Procomac

155 Aseptic filling lines installed worldwide

(December 2013)

GEA Procomac in Dairy

GEA Process Engineering / GEA Procomac

429 filling lines (December 2013)

GEA Procomac in Dairy

GEA Process Engineering / GEA Procomac

Complete Aseptic filling lines for

LA and HA products

Juices with pulps and fibers

Iced teas
Sport drinks
Functional drinks
Soy milk
Milk-based low acid
beverages
Aseptic CSD

GEA Procomac in Dairy

GEA Process Engineering / GEA Procomac

Complete milk filling lines

Fresh milk

ESL milk
UHT milk
Milk based products

GEA Procomac in Dairy

GEA Process Engineering / GEA Procomac

New possibilities for milk in PET

Growing trend for packaging milk

in PET containers.
PET containers offer production,
logistics and environmental
advantages.
PET containers are light,
re-closable, unbreakable, carryable
and cost effective.
PET bottles are very flexible in term
of design, shape, engravings, neck
finishes.
High product visibility and brand
identity.
New technologies allow UHT milk
filling in PET bottles.

GEA Procomac in Dairy

GEA Process Engineering / GEA Procomac

First PET bottle user in India for milk products

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GEA Procomac in Dairy

GEA Process Engineering / GEA Procomac

What means DAIRY? PRODUCTS

UHT
(Ambient)

FRESH / ESL
(4C)

Probiotics
(High Acid)
Up to 50 d

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Drinkable
Yogurt
(High Acid)
Up to 50 d

GEA Procomac in Dairy

Milk Based
(Low Acid)
Up to 30 d

Milk Based
(Low Acid)
Up to 30 d

Milk Based
(Low Acid)
Up to 12 m

White Milk
(Low Acid)
Up to 12 m

GEA Process Engineering / GEA Procomac

Shelf life and technologies

Shelf life

7 days

12

14 days

21 days

120 days

Up to 12 months

Pasteurized

ESL

UHT

Cold chain distribution

Cold chain distribution

Ambient temp.
distribution

2-4C filling

2-4C filling

15-30C filling

CLEAN

ULTRACLEAN

ASEPTIC

No container decontamination

Container decontamination
Up to 3 Log

Container decontamination
Up to 6 Log

Aspergillus niger
ATCC 16404

Bacillus atrophaeus
ATCC 9372

GEA Procomac in Dairy

GEA Process Engineering / GEA Procomac

Range of machines and speed

FRESH or ESL (cold chain)

For PET, PE, HDPE bottles with

cap and/or Foil application

Output range for pasteurized

and ESL products in cold chain:
from 6.000 bph to 36.000 bph

ASEPTIC (Ambient distribution)

For PET bottles

Output range for UHT products

from 6.000 bph
to 72.000 bph

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GEA Procomac in Dairy

GEA Process Engineering / GEA Procomac

Filling technology for pasteurized dairy products

SAFE AND HYGIENIC FILLING
No movable parts in contact with the product
except for sanitary membrane valve.

All filling valves cleaning controlled through flow

meters.

Standard automatic cleaning cycles available (CIP).

Complete automatic foaming cycle available (COP).
ENVIRONMENTAL CONTROL

HEPA filtration units to ensure air curtain over

bottle neck.
Hood version and Laminar flow (HEPA filter H14).

Clogging detection of HEPA filters.

EASY TO MANAGE
Fully automated machine with integrated and online
HMI interface.

Full control of Filling and Cleaning automatic

cycles.

Glass protection for easy accessibility to the bloc.

No base frame for ideal cleanibility and absence of
stagnation points.

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GEA Procomac in Dairy

GEA Process Engineering / GEA Procomac

HDPE / PET bottle for pasteurized product

in cold chain
GEA
Procomac
Ecoflux

Alu foil application

Filling
Alu Foil Welding
(or Capper)

Bottle sterilization
H202 + Steam

No
waste
product
change

Bottle outlet

Bottle intlet
Alu foil
sterilization

Alu foil press

Specific integration with

GEA Process Engineering
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GEA Procomac in Dairy

GEA Process Engineering / GEA Procomac

Filling technology for ESL dairy products

ULTRACLEAN AND HYGIENIC FILLING
FOR COLD CHAIN DISTRIBUTION
Up to 3 Log reduction efficiency to meet most
demanding quality specifications.

Automatic cleaning and sterilization cycles

(CIP/COP/SIP/SOP).

Ultraclean sterilizing, filling and capping bloc

with either DRY or WET bottle/cap sterilization
technology (HDPE and PET).

Complete isolation of sterile area from

mechanical components and lubrication points.

Suitable for the more demanding ultraclean

products: no compromise in terms of
cleanliness, hygiene and product safety.

A microbiological isolator housed around the

filling area to maintain a controlled overpressure
of redundant HEPA filtered air (class 100).

Slanted base frame for ideal cleanibility and

absence of stagnation points.

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GEA Procomac in Dairy

GEA Process Engineering / GEA Procomac

ABF 4C for ESL product in PET

Blower
Stretching
Blowing P1 / P2

Air-recovery (Option)
Exhaust

Ecoxide

Chiller

CLEAN
Ecoflux

ZONE

Preform sterilizer
Internal and external
preform surface
sterilized at the same
time

Filler
Capper
Oven

First Reheating
Stabilization time
Second reheating
Inversion time

Preform dedusting

Preform infeed system

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GEA Procomac in Dairy

GEA Process Engineering / GEA Procomac

Filling technology for UHT dairy products

SAFE AND HYGIENIC FILLING FOR
AMBIENT TEMP. DISTRIBUTION: Aseptic

Up to 6 Log reduction efficiency to meet

most demanding quality specifications.

Up to 3 h for automatic cleaning and

sterilization cycles (CIP/COP/SIP/SOP).

Up to 120 h of continuous production

without any intermediate SOP cycles.

FDA approved technology (ECOSpin).

Residuals below 0,5 ppm as per FDA
regulation.

Full control of Filling and Cleaning automatic

cycles and CCP (critical control points).

A microbiological isolator housed around the

filling area to maintain a controlled
overpressure of redundant HEPA filtered air
(class 100).

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GEA Procomac in Dairy

GEA Process Engineering / GEA Procomac

Aseptic: GEA Procomac solutions

WET technology on bottles

DRY technology on preforms

ECOSpin 2

ABF

Aseptic Filling
Bottle sterilization
Spray Liquid Peracetic Acid

Aseptic Blow-Filling
Preform sterilization
Spray H2O2 Vapor

Why and When?

FDA Approved
Easy Neck Change (28 - 38 mm)
Layout Constraints

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GEA Procomac in Dairy

No water waste
Reduced Footprint
Reduced Chemical use
Lightweight and Special bottle design

GEA Process Engineering / GEA Procomac

Aseptic: GEA Procomac solutions

PAA technology on caps

VHP technology on caps

Sterilcap IM

Sterilcap VHP

Suitable for both sport and flat caps

Compact layout: decontamination and buffer
phases integrated in one unit positioned above
the capper
Possible retrofit on PAA wet aseptic line for dry
solution and sport caps handling

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Can treat 1-piece caps

Sterilisation in bath of PAA solution
Rinsing with sterile water
Positioned above the capper: sterilised caps are
transferred to the capper by gravity only

GEA Procomac in Dairy

GEA Process Engineering / GEA Procomac

ECOSpin 2 - Flow chart: production

Sterilising Solut.
Production
and Recovery

Caps Supply

Caps
Sterilization
and Rinsing

Sterile Water
Production

Bottle Handling

Internal and
External
Bottle Steriliz.

Line
Control
Software
Safety
devices

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GEA Procomac in Dairy

Internal
Bottle Rinsing

Bottle Filling

Microbiological
Isolator

Product
Pasteurisation

Aseptic
Air Conditioning
System

Product
preparation

Bottle Capping

Finished
product

GEA Process Engineering / GEA Procomac

6th generation: ECOSpin 2

(in bloc with blower)

Blower

Ecodox
with caustic COP

Sterilizer

Ecoflux with H2O filtration

and CIP on board

Rinser

Filler

Oven

Exit tunnel

Preform inlet

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GEA Procomac in Dairy

Caps sterilization unit

Capper

GEA Process Engineering / GEA Procomac

6th generation: ECOSpin 2

(bloc with air conveyor and blower)
Ecodox
with caustic COP

Ecoflux with H2O filtration

and CIP on board

Blower

Pitching starwheel
Sterilizer

Filler

Oven

Preform inlet

Sterile Zone
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GEA Procomac in Dairy

Rinser

Exit tunnel

Caps sterilization unit

Capper

GEA Process Engineering / GEA Procomac

ABF - Flow chart: production

H2O2 Sterilising
Solution
preparation

Caps Supply

Caps
Sterilization

Preforms
Supply

Internal and
External
Preform Steriliz.

Line
Control
Software
Safety
devices

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Bottle blowing

Microbiological
Isolator

Aseptic Air
Conditioning
System

GEA Procomac in Dairy

Bottle Filling

Bottle Capping

Product
Pasteurisation

Product
preparation

Finished
product

GEA Process Engineering / GEA Procomac

ABF - Aseptic Blow Fill

Blower
Ecoflux with H2O filtration,
CIP on board and caustic COP

Ecoxide

Chiller

Preform sterilizer
Filler
Capper
Oven

Preform dedusting

Preform infeed system

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GEA Procomac in Dairy

Sterile Zone

GEA Process Engineering / GEA Procomac

Effects of light on milk: new bottle solutions

Extended exposure to visible light
will initiate photo oxidation of
vitamins B6/B12 and B2 (riboflavin)

Secondary degradation due to auto

oxidation of lipids results on offflavours and nutrient losses,
especially of vitamins, the so called
light taste

New development of PET (dairy

resin) offers a very high light barrier
(> 99,5%) that may guarantee over
4 months shelf life for UHT milk
(depending of the local laws)

Virtually total light barrier for very

low wall thickness

Potential for reducing bottle weight

Reduced cost
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GEA Procomac in Dairy

GEA Process Engineering / GEA Procomac

UHT Milk bottle solutions: Light Barrier

TiO2 dispersion during Polimerization Step

Coloured PET

Multilayer TiO2 PET

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GEA Procomac in Dairy

GEA Process Engineering / GEA Procomac

Filling flexibility

Fillstar FX

STANDARD ASEPTIC FILLERS

For clear products

For still products containing pulps/fibres

Fillstar FX P

- Max size: 3 mm () x 20 mm (L)

For beverages containing pulps/fibres or pieces

- Max pulp/fibre size: 3 mm () x 20 mm (L)
- Max pieces size: 5x5x5 mm

For beverages containing pulps, fibres and

pieces with dimensions bigger than 5x5x5 mm

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GEA Procomac in Dairy

Fillstar FX C

DUAL filling

GEA Process Engineering / GEA Procomac S.p.A.

Production availability

PRODUCT
CHANGE

FORMAT
CHANGE
ECOSpin2

FORMAT
CHANGE
ABF

Rinsing with
sterile water
(0-20min)

Change Parts

Last bottle
T = 0 min

Last bottle
T = 0 min

Last bottle
T = 0 min

Filler drainage
(5 min)

Blower

2 min/mould

Blower
Change Parts
2 min/mould

Filler priming
with product
(5 min)

First bottle
T = 10- 30 min

Filler Change
Parts
30 min

Bloc setup (*)

30 min

First bottle
T = 90-120 min

Filler Change
Parts
30 min

Bloc setup*
30 min

First bottle
T = 90-120 min

Blower SOP 60min

(overlapped with Filler activities)

(*) Filler priming with new product, cap sterilizer start up, preform / bottles sterilizer startup
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GEA Procomac in Dairy

GEA Process Engineering / GEA Procomac

GEMS - GEA Embedded Maintenance System

Computerized Maintenance
Management System

Automatic list of all devices that

exceed the Lifetime threshold and
automatic communication to
headquarter

Personalized maintenance on the

base of the real life and usage of the
plant

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GEA Procomac in Dairy

GEA Process Engineering / GEA Procomac

PLUS: plant management software and database

PLUS HD is an integrated
Hardware-Software system designed to
perform production plant analysis and
optimization.
It is the GEA Procomacs answer to the most
advanced market demands for
interconnecting machine on a production line
and recording production data in order to
controlling systems performance.

Real-time monitoring: a global control

over line efficiency from a single location.

A tool for statistical analysis of alarms

and machine states to spot critical
points (line bottlenecks).

Enabling technology for quick, focused,

and therefore more effective
interventions.

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GEA Procomac in Dairy

GEA Process Engineering / GEA Procomac

Thank you for your attention

GEA Process Engineering

GEA Procomac S.p.A.

Via Fedolfi 29 - 43038 Sala Baganza (PR) ITALY
Tel +39 0521 839411 - Fax +39 0521 833879
sales.procomac.it@gea.com www.gea.com

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GEA Procomac in Dairy

GEA Process Engineering / GEA Procomac