This document discusses key considerations for choosing dairy processing technology. It addresses factors like desired products, capacity, flexibility, and shelf life. It compares plate and tubular heat exchangers, describing their performance characteristics. Aseptic filling machines are presented as necessary for extended shelf life products due to lower recontamination risk. Maintaining a cold chain below 8°C is also highlighted as important for maximizing shelf life. The document outlines mixing, drying, filtration, and other technologies that may be required and notes the importance of understanding different options and tradeoffs.

1. ESADA, September 2015
Hendri Downing
CHOOSING TECHNOLOGY

2. Process Engineering / GEA TDS GmbH
General Considerations
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• What Product/s do you want to produce?
• What will your capacity be?
• Milk Quality/Juice with preservatives?
• How Flexible do you want to be?
• Will you contract pack?
• Product Shelf Life/cold chain
Aseptic CSD Isotonics Juices LA drinks Water CSD
HOT
FILL
ESLASEPTIC FILLING TRADITIONAL FILLING

3. Process Engineering / GEA TDS GmbH
Plate VS Tubelar HX
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Performance
• Viscosity
• Particles
• Fibers
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1
3
5
Price
SSHE
THE
FF
PHE
• Price / Performance - Relationship
Basic Process Equipment

4. Process Engineering / GEA TDS GmbH
Overview
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Technological Aspects - PHE
Plate Heat Exchangers • small gap
• forced turbulence flow
• good mixing effect
• high k-Values at low  p
• for smooth products (VT)
• for products with small
particles and fibres ( FF )

5. Process Engineering / GEA TDS GmbH
Overview
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• wide gap
• small mixing effect
• high k-Values only at high  p
• high operation times
• for middle viscous products with
fibres and particles
Tubular
Heat Exchangers
Technological Aspects - THE

6. Process Engineering / GEA TDS GmbH
Overview
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Technological Aspects - SSHE
Scraped Surface
Heat Exchangers
• wide gap
• good, mechanically forced
mixing effect
• high k-Values via
surface scraping effect
• avoidance of fouling
• for high viscous products
with and without particles

7. Process Engineering / GEA TDS GmbH
Packaging technology
• It was found out in a study, that the highest recontamination in a
process line of pasteurised fresh milk is caused in a filling machine
(Process line: From raw milk to the packed final product)
That implies:
• Sterile air blanketing of filling elements or an aseptic filling machine
have generally been accepted in the market as basic requirements
for the production of ESL/UHT milk.
• Another important aspect is the integrity and proper decontamination
of package material.
Shelf life
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8. Process Engineering / GEA TDS GmbH
Continuous cooling chain:
• For each 2°C increase of the storage temperature,
the shelf life of milk will decrease by approx. 50 percent.
That implies:
• A temperature below 8° C until the date of consumption must be
maintained during storage and transportation.
General shelf life extending factors
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9. Process Engineering / GEA TDS GmbH
• Cost of Packaging (cartons/HDPE/PET)
• OPEX vs CAPEX of the equipment
• Product Change-over times
• Format change-over times (30min – 3 days)
• Label vs printed Cartons (contract packing)
General Considerations for Packaging
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10. Process Engineering / GEA TDS GmbH
• Line Flexibility
• Line Speeds
• Format Sizes (150ml – 2000ml)
• Water/Electricity Usage
• Chemical Usage
General Considerations for Packaging
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11. Process Engineering / GEA TDS GmbH
Depending on the product recipe different technologies cane be
used:
• High Shear mixers
• Inline mixers
Mixing Technology
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12. Process Engineering / GEA TDS GmbH
High Shear Mixer in Operation
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13. Process Engineering / GEA TDS GmbH
Choosing the Right Technology
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• There are many more technologies involved:
• Seperators/Decanters
Spray Drier for WMP

14. Process Engineering / GEA TDS GmbH
Choosing the Right Technology
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• Deaeration
UHT Plants
Filtration Plants

15. Process Engineering / GEA TDS GmbH
Choosing The Right Technology
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In Conclusion - To understand what you are getting/paying for:
• Understand the Technologies
• Understand WHY some cost more/less
• Understand what you are gaining/giving up
• Be clear of what you want to Achieve.
• Thanks for your attention!