GEA TDS GmbH is an established specialist in providing optimized process technology for treating food, milk, and juice products. With over 150 years of experience in engineering food and dairy plants, GEA TDS delivers expertise in designing hygienic, aseptic, and sterile processing facilities. Their product portfolio includes complete process lines, individual components, heat exchangers, ultra-high-temperature processing, filtration, mixing, and more. GEA TDS engineers provide full project support from design and engineering to commissioning and after-sales service.

1. Process Technology for the
Food Industry
Innovative Engineering –
Quality in Line.
Process Engineering
GEA TDS GmbH

2. GEA TDS …
… is established internationally 150 years of tradition and experience
as a specialist for technically in engineering of food and dairy plants
are the basis. GEA TDS delivers the
and economically optimised
necessary know-how for the design
process technology for the and manufacture of hygienic, aseptic
treatment of food, milk and and sterile plants for the production of
juice products. liquid and paste products. With short
reaction times and presence on-site we
are providing an international support
for customer service and project con-
struction – naturally speaking for
After Sales as well. Experienced and
competent teams provide a technical
service tailored to your needs.
Our product program for
the food industry:
■■ Complete process lines
■■ Valves and components
■■ Plate heat exchangers
■■ Tubular heat exchangers
■■ UHT plants
■■ Membrane filtration
■■ Homogenisation
■■ Separators
■■ Evaporation systems
■■ Deaeration technology
■■ Mixing and weighing
■■ CIP systems
■■ Process automation and integration
■■ Tank farm equipment
■■ Engineering, assembly and service

3. Process Technology for the Food Industry
Process lines from a single source
for hygiene and efficiency.
Sauce processing plant UHT plant / deaeration / homogenisation
Tubular heat exchanger VARITUBE® VARIVENT® valve matrix
2 3

4. Process Engineering
Whether your project is a From isometric drawings to pipe class
new plant or an extension, specifications, from detailed engineer-
ing to project management, we are
conversion or modernisation
taking charge of the projects on-site,
of an existing process plant, on the client‘s premises or in the
GEA TDS’ engineers, with their GEA TDS tech­ ology centre. GEA TDS
n
complex know-how, are there is part of the international process
engineering sector of the GEA Group.
to back you up with excellent
This provides access to a variety
service. of components and units made by
members of the group which can
be integrated to create high-quality
processing systems. The use of modern
CAE tools for detail engineering is
common throughout the company.
For project planning and engineering
the main focus points are:
■■ Preliminary design
■■ Support in approval planning
■■ Preliminary planning and layouts
■■ Selection/dimensioning of process
equipment
■■ Production of tender documents
for process plants
Tank farm

5. Powder dosing Liquid ingredients Mixing module Fruit crushing and defrost
Detailed engineering
Herbal & fruit
■■ Layout planning and detailed preparations
coordination/clarification of details
■■ Inventory taking on site
■■ Design of pipe layout and
instrumentation Buffer
CIP plant
■■ Arrangement of components Mixing module
■■ Calculation of material requirements
and technical specifications
■■ Definition of interfaces
■■ Configuration and dimensioning Cooler
Filling
Heating plant
of instrumen­ ation and control
t
equipment
■■ Technical description of the processes
Homogenisation
■■ Quality assurance and quality control Principle scheme
■■ Monitoring of time schedules
■■ Cost control
■■ Supervision of construction and
installation work
■■ Commissioning of plant components
■■ Supervision of commissioning
■■ Technical support for production
■■ Process optimisation
■■ Documentation
Container filling station
Pasteurising unit Degassing unit
4 5

6. Process Automation
and Integration
Quality assurance and increased GEA TDS offers a wide spectrum of
productivity drive the steadily innovative process automation solutions
that range from the provision of elec-
increasing automation of plants
tronic process control up to integrated,
and production processes. The company-wide network systems com­­ -
advantages are obvious: labour plete with the corresponding manage-
and production downtimes are ment information systems. Machine
control systems, for separators, homo­ e­
g
reduced and operator error is
nisers or filling machines for example,
safely ruled out. The plants are can be homogeneously integrated into
upgraded so that all essential the overall automation system through
parameters relevant for the the bus network.
production processes are auto-
GEA TDS uses the latest industrial
matically controlled, monitored standards for all automation projects.
and documented. In this respect batch processes
are automated in accordance with
ISA-S88a as an essential factor for a
transparent, traceable production.
To adapt existing production plants
to new generations of automation
systems (e.g. when replacing the
visuali­ ation system or upgrading
s
from S5 to S7) migration strategies
will be developed for you that allow
safe conversion while production
continues to run.
Process visualisation

7. Operation and process visualisation Reporting and batch tracking
All operator interfaces are designed The process data is transferred online
with logical menu structures that to an SQL database extended with
allow intuitive operation of the plant. powerful evaluation tools:
The operator is comprehensively ■■ The report generator can be cust-
informed at a glance and guided omised so you can configure your
progressively through the system. own application-oriented reports.
■■ Batch tracking in graphical or
Manual process plant
Documentation and process tabular form helps you to keep
optimisation track of your products in accordance
The supervisory control system allows with the EU regulation 178/2002.
operators to record measured values The standardised approach allows
and switch status, thus creating the you to introduce a batch tracking
necessary transparency for process system in manageable steps at a
optimisation. Recording of measured known cost.
data is supplemented by a database-
supported event log with practice-
oriented evaluation features. This audit
Process optimisation trail allows the tracking of individual
batches or an entire production.
Central control room
Batch tracking and production data acquisition
6 7

8. Sauce processing plant
The ideal solution for the the blending table has been introduced
production of smooth sauces into the sauce tank. Homogeneity of
the sauce, which at this stage is still
and sauces containing particles
cold, is maintained by agitators. A
in the delicatessen industy. positive-displacement pump transfers
the tank contents to a VARITUBE® M
Process steps: tubular heat exchanger by GEA TDS.
1. ntake of water and pasty basic ingre-
I
dients (tomato puree, mustard, liquid The tubular heat exchanger type M
Stirring unit
seasoning) and powdery basic ingre- consists of several inner tubes sur-
dients (starch, spices, binding agents) rounded by hot water, which flows in
2. Blending and homogenization the shell. The tube bundles are mounted
3. eating the sauces and addition of
H in a “floating” manner so that the
pieces of vegetables (peppers, sweet complete bundles can be removed for
corn, mushrooms) inspection purposes. The modules
4. Buffering the prepared sauces of the tubular heat exchanger also
5. CIP cleaning contain specially designed flow devices
which keep the heat exchanger free
The plant is processing batches from from deposits when processing prod-
300–1,500 l within 20–30 min., with ucts containing fibres or particles.
temperatures between 15°–90° C. Once the specified heating tempera-
ture has been reached and cold vege-
Powder entry
tables have been added (optional), the
Plant description: prepared sauce is automatically kept
Insulated stainless steel tanks are filled warm. A push-out program conveys
with a preselected quantity of water the prepared sauce to the buffer tanks
via a recipe management sys­ em.t or the filling system.
When the specified quantity of water
has been supplied, the basic pasty and
powdery ingredients are introduced
into the circulating water stream by a
blending table, a self-priming centrifu-
gal pump and a homogenizing pump.
In the homogenising pump, the com-
ponents are finely blended in the shear
gap between rotor and stator, thus
preventing agglomeration, lump for-
mation and cross linking. The homo-
geneous blend is circulated until the
Tubular heat exchanger
entire supply of basic ingredients on

9. Mixing Plants
Mixing processes are necessary when:
■■ Dry substances or paste media
are to be added to a liquid phase.
■■ Several liquid phases or paste
media are to be blended to form
a final product.
■■ Products are made from different
components in a batch process.
■■ Basic products are varied by
adding ingredients prior to filling.
Some products require these processes
to run under ultra-clean and aseptic
conditions. Sometimes, additional
thermal process steps are required
during the mixing phase. The use
In-line dosing Powder mixing station
of volume and mass flow meters or
weighing systems allows mixing
processes to be fully automated
and recipe-controlled. By the way, Filling and dosing valves
we are supplying mixing plants as
ready-to-connect pre-assembled units.
Motor with variable speed
Jackated shell
Heater/cooler
Steam
Ice water
Scraper agitator
Condensate
Ice water
Decentral weighing
control
Load cells Product pump
Tank bottom valve
CIP booster pump
Basic layout scheme, process tank weighing system
8 9

10. CIP Systems
The diversity of products and CIP (cleaning in-place) is the commonly
processes calls for different used method for plant cleaning during
the production process where hygiene is,
methods for cleaning process
of course, paramount. Using a modern
plants. CIP system ensures the optimum quality
assurance and increases product quality.
GEA TDS is always striving to find the
optimum balance between chemicals,
mechanics, temperature and residence
time, with additional focus on environ-
mental protection and downtimes.
CIP recovery systems
These CIP systems consist of various
cleaning medium tanks for drinking
water, cleaning solution and returned
water. The system or tank size is adjust-
ed to the cleaning cycles required.
The systems are technically equipped
and configured to meet the cleaning
objectives defined.
Compact CIP system
VARIPURE® VARIPURE®
orbital cleaner rotating jet cleaner

11. VARICIP
In the VARICIP automation system,
cleaning objectives are translated into
recipes.
The recipes contain target-dependent
parameters:
■■ Start enabling and cleaning
monitoring tasks
■■ Conductivity limit values
■■ Temperature limit values
■■ Turbidity monitoring tasks
CIP cleaning unit Single-use cleaning system ECOCIP
■■ Flow rate set points
■■ Rinsing interval chains as well
as step-dependent parameters: Detergent concentrate storage Single-use cleaning system with ECO-
■■ Step function as a selection of A CIP station needs detergents. CIP
configured steps As a certified specialist company The system consists of a detergent
■■ Run and monitoring times in accordance with § 19i WHG tank for the ready-made cleaning solu-
(federal water resources law) GEA TDS tion, pre-assembled on a base frame.
These blocks can be used to configure is authorised to install concentrate The cleaning solution is circulated and
cleaning sequences freely. A water storage tanks that conform to all legal heated up to the operating temperature.
blocker considerably reduces the water and environmental requirements. Conductivity measurement and in-line
consumption during CIP. Trend curves The company has extensive experience concentrate metering ensure that the
are recorded to document the cleaning in this field for designing concentrate required amount of detergent is added.
process. An event log in table form is draw off and exhaust air cleaning The detergent flow rates are adjusted
created as a file for quality manage- and when calculating caustic, acid by the cleaning program.
ment purposes. and additive metering rates – this also
includes the generation of the necessary
balance sheets.
VARIPURE® VARIPURE®
orbital cleaner rotating spray
head
10 11

12. VARITHERM ®
Plate Heat Exchangers
Heat exchangers are at the VARITHERM® – a whole series of
heart of all process plants for multiple plate profiles and pressure
stages for a most efficient heat transfer
cooling, heating, pasteurising
and gentle treatment of different types
or UHT heating. GEA TDS uses of products in different viscosities.
plate and tubular heat exchang-
ers depending on the plant con- The advantages at a glance:
■■ Efficient heat transfer, i.e.
figuration. As a central module
small heat exchange area with
in thermal process technology, low investment costs
the plate heat exchanger has ■■ High degree of heat recovery,
always been the cornerstone this means low energy costs
■■ Low space requirements due to
in systems engineering.
large heat transfer surface in a
compact assembly
■■ Easy adaptation to changed capacity
parameters by expansion or reduction
of plates
■■ Short dwelling times in the heat
treatment section giving gentle
product treatment
Design principle of the
plate heat exchanger
FREEFLOW N
with several free-flow channels
and fewer points of support,
suitable for the processing of
products with particles up to
4 mm length.
FREEFLOW 161 and 159
with free-flow channels and no
points of support, suitable for
processing products with fibres
and particles up to 10 mm
length.
Plate heat exchanger with a capacity
of 50,000 l/h

13. VARITUBE ®
Tubular Heat Exchanger
The VARITUBE® tubular heat VARITUBE® M – the multi-tube heat
exchanger is specifically exchanger for indirect heat exchange
is also suitable for products containing
designed for the thermal treat-
particles of approx. 18 mm length.
ment of low- to high-viscosity
products and for products
containing particles, pulp and VARITUBE® S – the single-tube heat
VARITUBE® M and S, plain
exchanger for indirect heat exchange
fibres. The VARITUBE® system and corrogated inner tubes
for the treatment of products containing
is mainly used in heating, cool- pieces. Product recovery is possible
ing and aseptic systems. using pigging technology.
VARITUBE® P – for the direct
product/product heat exchange
of smooth, fibre-containing and
viscous products.
VARITUBE® P
VARITUBE® HS – the multi-tube heat
exchanger for indirect heat exchange,
suitable mainly for hot water generation
and heating of CIP media.
VARITUBE® SK – for the direct
product/product heat exchange of VARITUBE® HS
fibre-containing products up to a
length of 30 mm.
VARITUBE® E – the multi-tube
heat exchanger for indirect heat
exchange, suitable mainly for hot
water generation and heating of
CIP media (fully welded, removable VARITUBE® SK
bundle), volumes up to 150 m3/h.
VARITUBE® E
12 13

14. UHT Plants for Aseptic
Product Treatment
Depending on the product to UHT plant, type P
be treated, its quality and the Similar to the indirect UHT plant
type I, the UHT plant type P is widly
process efficiency, three differ-
based on identical process technology.
ent types of UHT processes are The difference is the tubular heat ex­­
at your disposal. changer type P used here, it dispenses
with the indirect heat transfer circuit
between the product to be heated
UHT plant, type I and that to be cooled. The advantage
These product treatment plants work is that this plant type P achieves an
according to the indirect heating prin- even higher efficiency and improves
ciple. Their great benefit: providing product quality without the need of
a very high production safety. This expanding the heat exchange surface.
process technology has proved success-
ful for many years. The UHT plants UHT plant, type D
have optimised flow conditions which The direct heating method used in
UHT plant, type P
produce good product quality and these UHT plants gives a very high
high efficiency with a heat recovery product quality. The integral steam
up to 90%. injector and a flash cooler provide very
short dwelling times in the temperature
intensive zones.
Membrane Filtration for Liquid Separation
Reverse osmosis, nanofiltration, Membrane filtration is specifically
ultra-filtration and microfiltration used for mass transfer at low tempe­
ratures and/or ambient temperatures
in special applications. This method
is used to separate liquid components
or concentration of solids without
thermal or mechanical treatment. The
filtration plants are equipped with
spiral membranes made of organic
Membrane filtration plant
polymer or ceramics.

15. Homogenisation
Homogenisation under high pressure
plays a key role in many production
processes. GEA TDS has extensive
experience in this sector and is able
to supply homogenisers, complete
with valves, which fit perfectly into
the production process of the specific
product. Homogenisers work at pres-
Homogenisers with a capacity of 50,000 l/h, 180 bar
sures up to 1,500 bar.
Assembly and After Sales
GEA TDS as a matter of course
undertakes the task of assem-
bling entire plants. A compre-
hensive range of services is
available throughout the entire
service life of your plants, all
designed to achieve maximum
productivity and economic
efficiency.
Assembly
Our extensive After Sales program
includes a permanent support service:
taking care of service and maintenance
directly after hand-over of the plant.
Customer support also includes
defined maintenance and individual
inspection agreements to ensure fault-
free and reliable operation and to keep
your plant running efficiently for years.
Maintenance and inspection
14 15

16. Innovative Engineering –
Quality in Line.
To find out more about GEA TDS process
technology, see www.gea-tds.com.
Process Engineering
GEA TDS GmbH
Voss-Straße 11/13 · 31157 Sarstedt · Germany
Phone +49 5066 990-0 · Fax +49 5066 990-163
434e-02/09 inform-werbeagentur.de
Am Industriepark 2–10 · 21514 Büchen · Germany
Phone +49 4155 49-2200 · Fax +49 4155 49-2724
Kruppstraße 3 · 48683 Ahaus · Germany
Phone +49 2561 8602-0 · Fax +49 2561 8602-130
www.gea-tds.com
geatds@geagroup.com 16 16