Energy-Saving Processing
Gerstenberg
Schröder A/S (GS) develop, manufacture and install modern, highefficient and
reliable processing lines for the food industry, especially for the production of crystallised
fat products like margarine, butter, spreads and shortenings. GS also deliver
process lines for emulsified foodproducts such as mayonnaise, sauces and dressings. We
have been in business for more than 100 years and have installations in more
than 110 countries around the world.
The main focus of
GS is to be the preferred partner when the food industry demands scraped
surface heat exchangers (SSHEs) for the manufacturing of food products, e.g.
for the crystallisation process of margarine or for starch cooking of
mayonnaise. The SSHEs manufactured by GS are known on the market under the
names Consistator®, Kombinator and Perfector.
Process knowledge
and process expertise exist in all departments of GS, even in the top
management. By spreading expertise concerning the business of GS customers
throughout the organisation, every enquiry will be met with an understanding of
the customer’s business, needs and challenges. The process knowledge, the
understanding of the needs of the food industry and the technical expertise are
the major drives of the development work in GS.
Energy Saving by using SSHE Technology:
Increasing energy and raw material prices,
increasing demand to the efficiency of the machinery and processing as well as
intense competition among the food companies are challenges which the industry
is experiencing today. Various processes continue to use designs which in
energy terms are inefficient as the heating or cooling process occurs e.g. in
relatively open systems and thus high amounts of energy are lost to the
environment. Optimisation of energy consumption per kg produced product is
possible by exchanging the open systems with the SSHE technology. Especially
for products exhibiting high viscosities, the energy consumption per kg
produced product can be significantly reduced when SSHE technology is
used.
Product Development – Focus on Energy Consumption:
In 2008, two new
machines were launched: A new high pressure SSHE and a low temperature SSHE ice
extruder marketed under the names Nexus and Kombinator X250, respectively.
During the development of these machines, apart from functionality and hygienic
design, environmental aspects have been in focus. It has resulted in energy efficient
processing lines to the fat crystallisation industry and ice cream industry.
Nexus is designed
to use CO2 as refrigerant compared to the traditional SSHE which uses Ammonia
or Freon. CO2 as cooling medium has in pilot scale proved up to 20 percent more
efficient, which results in less consumption of energy per kg product produced.
The low temperature
extrusion of ice-cream down to -15°C gives energy saving because it is possible
to produce directly to cold storage avoiding the hardening tunnel. Using SSHE
for cooling the ice cream from -6°C to -15°C is a much faster cooling process
compared to the hardening tunnel. Furthermore, the quality is improved as the
process enhances the creaminess of the final ice cream due to the mechanical
treatment of the ice cream during this further cooling process. With the
Kombinator X250 technology ice cream with lower fat and protein content can be
developed with the same mouth feel as premium traditional high fat ice cream.
Development and Optimisation of the Process:
GS offer expert
assistance in product development and process optimisation. The service can
take place in our pilot plant in Copenhagen, Denmark, or at the customer’s
site. The pilot plant is well equipped with not only SSHE or related equipment
but also a laboratory where raw materials or final products can be analysed and
evaluated. Often trials initially take place in the pilot plant and the best
process and parameters are being assessed before the final optimization trial
takes place at the customer’s site.
During
the past years, numerous trials have been conducted in the pilot plant where
the main focus has been to save energy per kg product produced. One trial
involved meat and was especially interesting as the calculation of the energy
consumption showed more that 25 percent energy saving if the current process
was replaced by SSHE technology. Another interesting investigation showed a
significant waste reduction only by changing the start-up procedure for
production of mayonnaise.
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