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GEA Mechanical Equipmentengineering for a better world

Systems and Processes fromGEA Westfalia Separator for theFruit-Processing and Juice-Making Industries


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3

GEA Westfalia Separator

4 1. Introduction

6 2. FruitandVegetablesasRawMaterials

6 2.1 Theanatomyandphysiologyoffruit

andvegetables

7 2.2 Definitionofrawmaterial

7 2.2.1 Fruitandvegetablejuice

8 3. ProductionofFruitandBerryJuices

8 3.1 Productionofapplejuicebycentrifugal

separationtechnologyanddynamic

filtration

9 3.1.1 Millingapplesbeforeextractingthejuice

10 3.1.2 Producingnaturalcloudyapplejuice (singlestrength)

12 3.1.3 Producingapplejuicebyapplying

enzymes

13 3.1.4 GEAWestfaliaSeparatorfrupexprocess

forproducingclearconcentrate

15 3.1.5 Performancedatafordecanterextraction

ofjuicefromapples

15 3 .1.6 Yield

15 3.2 Productionofgrapejuice

16 3.3 Plum/dateandcherryasexamplesof

stonefruits16 3.3.1 Datejuiceconcentrate/liquidsugar/

feedyeasts

18 3.3.2Cherry

19 3.4 Currantsandstrawberriesasexamples

ofberryfruits

20 3.5 Productionofpure

21 4. SpecialApplications

21 4.1 Processingresiduals

21 4.2 Treatingtrubusingdecantersorseparators

22 4.3 Concentratingretentate

24 5. TropicalFruits

24 5.1 Pineapple

24 5.1.1Processingbeveragejuice

26 5.1.2 Milljuiceproduction

26 5.2 Mango

26 5.3 Banana

26 5.3.1 Bananajuice

27 5.3.2Bananapure

27 5.4 Pomegranate

29 6. ProductionofVegetableJuices

29 6.1 Carrotjuice

31 6.2 Producingbeetrootjuice

32 6.3 Producingpulpconcentrateand

juiceswithadefinedpulpfraction

34 7. SecondaryPlantMetabolitesfrom

NaturalRawMaterials

35 . HerbExtracts/SpecialJuices/

Nutraceuticals

36 9. SystemsfortheJuice-MakingIndustry

36 9.1 Decanters

37 9.1.1 GEAWestfaliaSeparatorvaripond

reliablemasteryofsolidsconcentration

37 9.1.2 Drivesystems

38 9.2 Clarifiershighproductquality

andyield

38 9.2.1 GEAWestfaliaSeparatorhyvol

andhy drymachines

coverthefullcapacityrange

40 9.2.2 GEAWestfaliaSeparatorecoplus

separatorsforeconomicproductionof

juiceinthelowcapacityrange

40 9.3 Rotarybrushstrainerandhydrocyclone

41 9.4 Ceramicmembranefiltration

43 9.5 Lineandcontrolsystem

betterfromasinglesource

44 10. Summary

46 11. Literature

Contents


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1. Introduction

Thefruitjuiceindustryisacomparativelyyoungsector.Juicehasonlybeenproducedonalargeindustrialscalesincethe1940s,whenthefirstevaporatorforcitrusjuiceswasdevelopedintheUSA.Ashygienestandardsbecamestricter,theproductsacquiredalongerandlongershelflifeakeyconditionforthecontinuousgrowthofthemanufacturingcompanies.

WhilemarketsinChina,IndiaandEasternEuropearestillgrowingtoday,theWesternmarketsofEuropeandNorthAmericaarenowexperiencingcutthroatcompetition.

Inthesesaturatedmarkets,nicheproductssuchasthosemadefrom tropicalfruitsorso-calledsuperfruits, premium juices(NFC not fromconcentrate),pure,organicjuicesorproductsfocusingonsecondaryplantmetabolitesarenowbecomingmoreandmoreimportant.Ifyoulookaroundthebeveragesectionofasupermarketthesedays,youwilldiscoverafascinatingvarietyoffruitandvegetablejuices.Virtuallynoothersegmentinthefoodindustryischaracterizedbysuchahighdegreeofproductdiversification.Ahealthydietismoreofanissuethanever.Thisexplainsthecurrentsuccessofsuperfruitssuchasacai,gojiberries,acerola,cowberries,cranberriesandbuckthornberries.


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Juicesaremadefromthesefruitsnotjustbecauseoftaste,butprimarilybecauseoftheirnutritionalvalues.Thehighlevelofantioxidants,whichareascribedaprophylacticeffectagainstcancer,andotherdiseases, promisesadded valuewhichiscausingmoreandmoreconsumerstoreachfortheseproducts.

These innovative products have resulted in

new demands on an industry in which highyie ld has always had absolute priori ty. Thefocus is increasingly onmachines which areeasy to clean, sealed for maximum hygiene,processingwithoutoxygentoreduceoxidationandparticularlyrapid,yetgentlejuiceextraction.GEAWestfaliaSeparatorsupplies customizedprocessesandprocesslinesfortheseandmanyotherchallenges.

Centrifugalseparationtechnologyisstillattheheartofcost-consciousproductionofhighquality

juice. It ensures optimum initial clarificationbefore filtration, with minimal loss of juice.GEAWestfalia Separatorhydry andhyvolcentrifugesprovidetherightconceptforeveryrequirement,dependingonwhetherhighyieldor maximum throughputs are required. TheGEA Westfalia Separator frupex methodshowshowitispossibletocombineagentlemanufacturingprocesswithmaximumeconomy.

Theperfectcomplementismembranefiltrationusingceramicelements.Ithasprovenitsworthinthemostdifficultapplicationsanditsruggedfiltermembranesandminimalcostsareconvincing.

Asthesolidsareconcentratedtothemaximum,productlossesareextremelyslight.Retentatesnolongerrequirefollow-uptreatment.Thismodernfilteringtechniquehasaverywidevarietyof

applications with colored juices, too andis successfulwherever centrifugal separationtechnologyreachesitsnaturalboundaries.Furtherpotential applications include peeling waterclarificationandprocessingofexcessproductfromthecanningindustryorfromthefreshfruitandvegetabletrade.


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1 2

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8

911

1210

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Fig. 2 Section

through the grape

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2. Fruit and Vegetables as Raw Materials

2.1 The anatomy and physiology offruit and vegetablesProcessingofthefollowingnaturalproductsis

outlinedbelow:Pomes(apples,pears,quinces,etc.)Stonefruit(cherries,plums,peaches,apricots,etc.)

Berries(currants,gooseberries,strawberries,raspberries,blackberries,bilberries,etc.)

GrapesTropicalfruits(pineapple,mango,banana,pomegranate,etc.)

Vegetables(carrots,beetroot,radish,horseradish,celery,etc.)

Plantextracts

Fig.2showsasectionthroughagrape.Threeclearlydistinctareasoftissuecanbemadeout:Exocarp(skin)Mesocarp(flesh)Andtheareaforseedsorpips

Theskinoftheberryhasaprimarilyprotectivefunction and usually contains only limitedfractionsofvaluablejuice.Inredgrapes,thisarea contains the tannins and anthocyanins.Thelatterareenclosedinsac-likedyecontainersenclosed inmembraneswithin the cells. Thecellsinturnareverysmallandhaveastablecellwall. There are almost no intercel lular spaces.Althoughthepropertiesandcompositionoftherawmaterialandoftheproductsmadefromthisvary considerably,the anatomyand physiologyof theseedible higher plants are similar. Thefundamentalrelationshipsbetweenthemwillbeillustratedusingtheexamplesofthegrapeandtheapple.

Themesocarp, which dominates in terms ofquantity,containsagreatmanylargecells(uptoathousandtimeslargerthantheskincells)whichcontainalmostallthecharacteristicanddesiredconstituents.Theliquidinthevacuolesoffruitandvegetablescontainssugar,acidsandsaltsinsolution.Thewallsofthecellsoffruitflesharevery thin, someof them evencollapsingduringtheripeningprocess.

Thiscreatesintercellularspaceswhich,inadditiontotheliquid,alsocontainrelativelylargequantitiesofair.Evenslightmechanicalmanipulationsare

usuallysufficienttodestroythesecells.

The third important area contains the seedsorpips.Theseareoftenveryhardandusuallycontainlargequantitiesoftannins,sodamagetothemshouldbeavoidedduringprocessing.

Thefinestructureofthiscellulartissuecanbeseenin Fig.3 intheexample ofanapple.Itsstructuremeansthateachcellhasadjacentcellsfromwhichitisseparatedbyacentrallamellaconsistinglargelyofpurepolygalacturonicacid

(pectin).

Theprimarywallresponsibleforstabilityandelasticityisattachedtothecentrallamella.

Seed

7Endosperm

8Coat

9Embryo

Structureofthegrape:

Pericarp

1Exocarp(skin)

2Locule

3Septum

4Mesocarp(esh)

5Cuticle6Peripheralvascularbundle

Vascularbundles

10Ovular

11Central

12Peripheralnetwork

13Startofstem

14Brush


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Microfibrilsmadeofcelluloseforwallstabilityareembeddedinpectins,proteinsandhemicellulosesofverydifferentstructures.Thesehydrocolloidsform the basic amorphous structure whichfacilitatesthemetabolicprocessesofthecell.If fruitcontains a lot ofpectin (currants,forexample,butalsocertaintypesofgrape),thishasagreatdealofwaterboundinitandthismakesitmoredifficulttoobtainliquidfromthevacuoles.Toobtainjuiceeconomically,itisnormallybeneficialtobreakthepectindownusingenzymes.

Toextractthejuicefromfruitandvegetables,thecellwallshavetobebrokenopenataminimumofonepoint.Inpractice,thisisusuallyachievedbyacombinationofmechanicalandenzymaticmeasures,supportedbyhightemperatureswithcertain products. Heating mashes makes thecellmembranespermeabletojuice.Someofthepectinsarehydrolyzedbyheatinthisprocess.In process technologyterms, the actual juiceextractionwhichfollowsdestructionofthecellsisaseparationofsolidandliquidintoserum

andpulporjuiceandpomace.Ifthephasesareseparatedinpresses,theactiveprincipleisthedifferenceinpressure.Thejuicefindsawayoutthroughtheinsolubleconstituentsofthemash.Withdecanters,theactiveprincipleofseparationiscentrifugalforce,whichseparatestheliquidandsolidsonthebasisoftheirdifferingdensities.Dependingonhowthefruithasbeenpretreatedandthephaseseparationtechnique,thejuiceobtainedcontainsacertainquantityoftrubsubstances.Theparticlesizeofthesetrubsubstancesrangesfromthecolloidaltothecoarsely-dispersed,inotherwordsfromlessthanamicrontoseveralmillimeters.Theparticlesareessentiallymadeupoffragmentsofcellwall,mainlyskin,andaccordinglycontainhighquantitiesofpectin,cellulose,minerals,proteins,lipidsandtannins.Asinnaturalcloudyapplejuice,theycanalsoincludereactionproductsthatoriginatefromthecellcompartmentalizationbeingbrokenupinthemillingstage.Someoralloftheseparticlesareremovedasprocessingcontinues.

2.2 Denition of raw material2.2.1 Fruit and vegetable juiceOnly healthy, unfermented fruit/vegetablessuitableforconsumptionandsufficientlyripemaybeusedtomakefruitandvegetablejuicesandproducts(semi-finishedproducts)derivedfromthem.Inadditiontorawfreshproduce,itisalsopossibletouseproductswhichhavebeenchilledtoextendtheirlives.However,noconstituentsessentialfortheproductionofjuicesmayberemoved.

Certaincodes(AIJNCodeofPractice)areusedtocharacterizetheindividualproductsinEurope.Thesecodesareavailableforthefollowing,forexample:Appleandpearjuice(pomefruit)Apricotandsourcherryjuice(stonefruit)Blackcurrantandraspberryjuice(berryfruit)Orange,grapefruitandlemonjuice(citrusfruit)

Pineappleandmangojuice(tropicalfruit)

Vegetablejuicescanbemadefrom:

Rootvegetables(carrots,beetroot,radish,horseradish,celery,etc.)

Perennialvegetables(rhubarb,asparagus)Tuberousvegetables(potatoes)Leafandfloweringvegetables(spinach,cauliflower)

Fruits(tomatoes,bellpeppers,cucumbers,pumpkins)

Leguminousvegetables(peas)

In termsof quantity, carrot and tomato juicedominate. In the production of juices frommedicinal plants, comparable productionprocessesarefrequentlyemployed,whichiswhyvalerianandnettle shouldbeincludedhere.Forthesakeofcompleteness,itshouldbementionedthat beveragescan also bemade from cerealmashestreatedindifferentways.

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Fig 3 Anatomy of apple tissue

a: Cross-section; b: Electron microscope image,

freeze-dried material; c: Peel; p: Flesh

100 m100 m aa

pp

b10 m10 m

cc


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3.1 Production of apple juice bycentrifugal separation technologyand dynamic ltration

Fig. 4 shows applications for centrifugalseparationtechnologyinthedifferentprocessingstagesfromtheappletotheendproduct.Clearconcentratedominatesintermsofquantity,buttheproductionof naturalcloudyjuiceswithand without concentration (single strength)has become more and more established inrecentyears.

Decantershavebeenusedforsomeyearsnowtoextractthejuicefromthefruitandtoconcentratethetruborretentate.Polishingfollowingjuice

extraction/fining is the responsibility of self-cleaningseparators.Ultrafiltrationusingceramicmembranesgivesthejuicetherequiredclarity.

3. Production of Fruit and Berry Juices


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Fig. 5 Eccentric screw pump with force-feed

and connected macerator

3.1.1 Milling apples before extractingthe juiceThe first important process technology step

intheproductionofapplejuiceistomilltheapples.Particlesizesfrom58mmdiameteraretheobjectiveforpresses,35mmfordecanteruse.Themechanicaldestructionofthecelltissueeliminatesitscompartmentalizationandcombinestheenzymesinherentinthefruitwiththeliquidinthevacuoles.Uncontrolledoxidationprocessesandpectindegradationoccurimmediately,asdotrub-formingreactions.

Thefollowingpropertiesarerequiredofasystemtomillwholeapples:

Sealedsystemwhichdoesnotincreasethequantityofairnaturallypresentintheintercellularspaces.Thissignificantlyreducesfoamingandconsumptionofascorbicacid.

Narrowrangeofparticlesizesasafunctionofripeness.Ifthepiecesofapplearetoobig,thiswillresultinaloweryield;iftheyaretoosmall,theywillincreasethecolloidcontentofthejuiceandmakephaseseparationmoredifficult.

Thefast-runninggrindingorhammermillswhich

areusuallyusedonlysatisfytheserequirementstoacertainextent.Fig.5showsasystemdesignedspecifically for the requirements outlinedabove. An eccentric screw pump which isforce-fed by a fil led raw material hopperupstreamensuresthattheapplesareinitially

mil led and then feeds a macerator in theimmediatevicinitywithinthesealedsystem;themaceratorhasaninterchangeableholeplateand

cuttinghead.

Thenumberofcuttingplatesinthemaceratorvaries.Thisallowsindividual adjustments tobemadetosuitthestateofthefruit.Ripeapplesneedtobecoarselycut;underripeapplesneedamoreintensivemillingprocess.

The hopper above the eccentric screw pumpmaintains throughput at a constant level. Ifnecessary,itisfedviaametaldetectoranditcontrolsitsfillinglevelbymeansofmin./max.

sensors.Amashbuffertankisconsequentlynotrequiredontheshortroutetophaseseparation.Followingmilling,furthertreatmentofthemashdependsonoperationalobjectives.Thevariantsbelowarefoundinthefield:

Directjuiceextractionwithoutmashstackingorstorage,usuallytoproducesingle-strengthjuices

Additionofenzymestothemashinthecoldstate

Additionofenzymestothemashat

heightenedtemperature(approx.45C)Totalliquefaction

Inpractice,theseoptionsarecombinedwiththeadditionofascorbicacidtopreventbrowning.


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3.1.2 Producing natural cloudy applejuice (single strength)Naturalcloudyapplejuiceisbecomingmoreandmorepopularduetoitsimageasanatural,healthyproduct.20to25percentofallapplejuiceinGermanyisconsumedinthenaturalcloudystate.

Theconsumerexpectsthetrubinnaturalcloudyjuices to remain evenly distributed, in otherwords, not to settle. Several physical variablesareresponsibleforthesuspensionstabilityofthesubstanceswhichcreateturbidity:ParticlesizeParticledensitySerumviscosityParticleshapeParticlecharge

Fig.6comparestheparticlesizedistributionsofjuicesextracted bydecanter and bypress. Indecanterjuice,60percentoftheparticlesaresmallerthan1m,whereasinpressjuice,thisfigureisonly20percent.

The key factor in the production of naturalcloudyjuicesisrapidprocessing.Pasteurizationmustfollowimmediatelyafterextractionofjuicetoinactivatethenaturalenzymesinapple.

Fig.7showsthechangeinparticlesizesduetotheeffectofanaddedpectolyticenzyme.Damage

tothehydrocolloidsheathoftheparticlescausesthe particles to agglomerate. This results inclarificationofthejuice.Asimilarreactioniscausedbythefruitsownenzymescontainedinthejuicewhenitislefttostand.

Toproduceajuicehighintrubcontent,aregularmilling step can be followed by an ultrafinemillingstep.Avarietyofsystemsisinuse,thefollowingresultswereobtainedinthefieldwithaGCE535withWestfaliaSeparatorvaripondincombinationwithatoothedcolloidmill.

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0.1 1 10 100

Particle size [ m ]

Percentproportionbyvolumerelatedto

thetotalvolumeofallparticles


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0.35

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.23

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0.53

1.86

6.52

22.84

0.23

0.81

2.8

3

9.91

34.69

52.68 2

0 50

120

0Particlesize[m]

Time[min

.]

Percentoftotalvolumeof

allparticles

Fig. 7 Trub breakdown with pectolytic enzyme preparation

Thewholeofthesealedprocess,frommillingtheapplestothetrub-intensiveapplejuice,ideally

takes only a few minutes. Investigations atWdenswilCollegeinSwitzerlandshowedthattheappleflavorstartsdevelopingimmediatelyaftermilling.Theflavorinitiallybecomesmoreintenseuntilthedesiredfreshapplenoteislostafterawhile.

Itwasnotpossibletomatchthisreaction/subjectiveperceptiontoaspecificchemicalcompound.The

resultrecordedwasthatthemostintensiveandbestflavorisachievedabouttenminutesaftertheapplehasbeenmilled.Theseprocessesshouldthenbeinhibitedbythermalpasteurization.


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Theproportionofstableturbidityishigherthanwithconventionalpressingtechnology.Viscosity,ontheotherhand,isintheusualrangebetween1.5and2cStokes.

Ifaparticularlyhigh-viscosityjuicewithvaluesofover3cStokesistobeproduced,itisnecessaryto

heatthemashto4550C.Light-coloredjuiceswith stable and not overly intensive turbidityrequireascorbicacidbeaddedtothemashbeforecentrifugation.Atnotimecanthemashstandand come in contact with air. Under certaincircumstances,aprotectivegasblanketcanbeusedovertheprocessline.

Prognosisforstablejuiceturbidityinthebottle

Itispossibletopredictthesubsequentturbidityof the juice using a simple prognosis test.Changesincomparisontothelevelofturbidity

directlyafterjuicingareduetosedimentationofcoarseparticlesandchangesinstructureduringsubsequentdevelopment.

Turbiditystabilityismeasuredbyacentrifugationtest.Turbiditystability(percentT)isgivenintheformoftheturbidityofthesupernatantfollowingcentrifugation(Tz)asapercentagerelatedtotheturbidityofthejuicebeforecentrifugation(To).This test is based onthe match between theturbidityinthesupernatantofthecentrifuged

juiceandtheturbidityinajuicewhichhasbeenstoredinabottleforayear.

Thefollowingholdstrue:

T=turbiditymeasuredinturbidityunits(TE/F)intheshakensampleofjuice.

T = turbidity in the supernatant followingcentrifugation(15min.at4200ginTE/F).

%T=turbiditystability=proportionofturbidityinthesupernatantrelatedtotheoriginalturbidityintheshakensampleofjuice.

Fig.10showstheturbidityandturbiditystabilityoftwoapplejuices,comparingproductionbypressanddecanter.

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Fig. 9 Toothed colloid mill

Fig. 10 Turbidity and turbidity stability of two apple juices,

comparing production by press and decanter

Thesedatashowthatwithbothtechniques,aroundhalftheoriginalturbiditywillremainstableinsuspension,butthedecanterjuicehasthreetimesgreaterturbidityintensitycomparedtopressjuice.

3.1.3 Producing apple juice by adding

enzymes to the mashTechnical enzyme preparationshavebeen animportantconstituentoffruitjuicemanufacturesince the 1930s. They were initially used toclarify and depectinize juices and then inthe early1970s,for adding enzymes toapplemash. The pectolytic enzymes usually usedhave polygalacturonase as their primaryactivityandpectinesteraseastheirsecondaryactivity.


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Inaddition,theymaycontainamylase,cellulaseandproteaseactivities.Pectolyticmashenzymesprimarilyhydrolyzethesomewhatlessesterifiedpectinsofthecentrallamella.

Addition of enzymes to themash speeds upjuiceextractionandincreasesyields.Ripeand

usuallyverysoftapples,inparticular,arevirtuallyimpossible to press and juice economicallywithouttheadditionofenzymes.

Applemashtowhichenzymeshavebeenaddedisparticularlyeasytojuiceusingadecanter.Thereductioninviscosityachievedbytheactionoftheenzymestogetherwiththeelevatedtemperaturelead to higher outputs and better degrees ofclarification in the production of juices. The1-stageprocesscombineshighyieldswithgoodjuicequality,thoughitisvirtuallyimpossibleto

producecloudyjuiceswhenenzymesareaddedtothemash.

The technicalequipmentrequiredto producejuicebyaddingenzymestothemashconsistsofanapplemill,mashtemperaturecontroldevice,enzyme-dispensingstationandadwelltankfortheenzymaticreactions.Subsequentphaseseparationwiththedecanterenablesyieldsof90percentandovertobeachieved.Afinisherseparatesoffbitsof

peel,pipsandcore,allowingthethroughputoftheprocessinglinetobeincreased.Theparameterswhichaffectyieldandqualityaretheactivitiesoftheenzymesused,dwelltimeandtemperature.Thecombineduseofpectinasesandcellulasesfinal ly leads to l iquefaction of the mash.Complete hydrolysis of sugar-containingmacromolecules causes the sugar contentof the juice to rise considerably, along withtheyield.Themashliquefactionprocessislegallypermittedonlyincertaincountries.

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Fig. 11 Decanter output in apple juice production (total liquefaction)

3.1.4 GEA Westfalia Separator frupexprocess for making clear concentrateClearapplejuiceisusuallyproducedbyredilutingconcentrate.Tothisend,applejuiceisproduced

andthenevaporatedtothedesiredBrixcontentof70to72Brixfollowingfiningandfiltration.IntheGEAWestfaliaSeparatorfrupexprocess(see page 14) , the apple mash is juiced in2-stagesusingdecanters.Thefirstdecanterstagecorrespondstotheproductionofnaturalcloudyjuices.Rapidprocessing(withorwithouttheuseofenzymes)createsapremiumjuiceofuniformlyhighquality.

Thepomacewithmuchofitsmoistureremovedis diluted with vapor condensate from the

evaporator immediately. It is discharged fromdecanter I and is heated to a temperature ofabout4550C.Followingareactionperiod,phaseseparationiscarriedoutagainindecanterII.Addingenzymesduringthereactionperiodincreasesyieldandthroughput.Thesecondjuicedoesnothavethequalityoftheprimaryjuiceandisnotusuallysuitablefortheproductionof cloudy juices. Ideally, it is processed intoclearconcentrate.

Fig.12showsaGEAWestfaliaSeparatorfrupexlinewithreactiontanksfordegradationofpectinbyenzymes.Thedownstreamseparatorisforfollow-upclarification.Intheinitialevaporation

stages, the flavor is removed from the juiceobtainedinthisway,andevaporationiscontinuedtocreateasemiconcentrateofapprox20Brix.Thesemiconcentratefromwhichtheflavorhasbeenremovedhastobestabilizedtopreventsubsequentturbidityduetoreactionsbetweenphenoliccompoundsandproteins.Finingagents(suchasbentonite,gelatineandKieselsol)and/orenzymesareusuallyusedforthis.Precisetrialsneedtobeconductedbeforehandtoachievethebestpossibleeffect.Decanterjuiceshavetobetreateddifferentlythanpressedjuicesbecauseof

thedifferenttypeofstructureandconcentrationof col lo idal and coarsely d ispersed trubsubstances.Overthepastfewyears,ultrafiltrationhas become established as the method forpolishing the stable supernatant producedduringfining.Useoftheceramicmembranehasarangeofbenefitshere,particularlytheoptionofconcentratingtheretentatetoasolidscontentofupto90percentbyvolume.


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Fig. 12 GEA Westfalia Separator frupex line

Raw material in2-stagemilling station Initial addition of

enzymes

Addition of enzymes

Hotwater /enzymes

1st stagedecanter

2nd stagedecanter

Initial evaporation /

flavor recovery

Clarifier

Reaction tanks

Cross-Flow Filtration

Evaporator

Concentrate tank

Otheradvantagesincludemechanicalstabilitytopressuresofupto100barandtemperaturesofover100C.Themanyadvantagesofthissystem,

inadditiontoitstechnologyandengineering,aredescribedseparatelyinSection9.4.

FinallythesemiconcentrateisadjustedtothedesiredBrixcontent intheevaporator.Fig.13shows concepts for GEAWestfalia Separatorfrupexlineswiththedifferentmachinetypesfordifferentprocessingoutputs.Differentoutputsarepossiblewithdifferentmachineconfigurations.

Theoutputsquotedarebasedonyieldsof90percentormoreformashestowhichenzymeshavebeenadded.

Fig. 13 Example concepts for GEA Westfalia

Separator frupex lines

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3.1.5 Performance data for decanterextraction of juice from applesFig. 14 summarizes the performancedata fordecanter extraction of juice from apples. Inadditiontothemechanicalparameters,thedegreeofripenessandtemperatureoftheapplesandtheadditionofenzymesplaykeyroles.ThevaluesrelatetouseinthefirststageoftheGEAWestfaliaSeparator frupexprocess.Outputisabout25percentlowerinthesecondstage.

3.1.6 YieldSincerawmaterialisoftenexpensive,thejuicemustbeobtainedeconomicallyandatahighquality.

The easiest way to represent the yield fromextractionofjuicefromapplesistofigurehowmanykgofjuicehavebeenobtainedfrom100kgofmash.

Yieldsof90percentormorecanbeachievedinthe

2-stageGEAWestfaliaSeparatorfrupexprocess.However,inordertogetarapidoverviewofyield,itispossibletodeterminethedrysubstanceinthe pomace discharged. These values can bedeterminedbyusinganinfrareddryinglampwithin2030minutes.

3.2 Production of grape juiceInprinciple,allvarietieswhichhavearelativelyhighacidcontentandproducearomaticjuicesareidealforgrapejuicepreparation.Grapesshouldbe healthy and ripe and have anappropriate

mustweight.

Forproduction,thegrapesshouldinitiallyhavetheir stalks removed by a stalking machine.Beyond this, no further pretreatment of thegrapes,suchasadditionalpressingwithrollers,forexample,isrequiredforjuiceextractionbymeansofdecanters.

Addingenzymestothemashofwhitegrapesbeforephaseseparationcanincreasetheyieldandimprovethedegreeofclarityofthejuiceproduced.Thejuicethenhastheflavorremoved,issubjectedtoaninitialconcentrationprocessand thesemiconcentrateis fined andclarifiedbyultrafiltration.

To prevent subsequent precipi ta ti on o fc re am o f t ar tr at e, t he con ta ct method

is used in conjunction with the GEAWestfal ia Separator separation process.Followingthistartratestabilizationprocess,thepreconcentratedgrapejuicecanbeevaporatedtothedesiredBrixcontent.

The process for the production of red grapejuiceismodifiedtoextractthevaluablephenoliccompounds, namely colors and tannins, fromthe cells of the skins. For this purpose,withredgrapes,forexample,themashisheatedto8085Cfor26minutesandisthenfeddirectly

tothedecanterwithoutanytimetostand.Thehotjuiceisthenvigorouslyexchangedwithcoldmashonthecountercurrentprincipleandcooleddownbyafurthercoolingunit.

Inthecaseofparticularlypectin-richvarietiessuchastheConcordgrape,forexample(HotConcordprocess),it is recommended that enzymes beaddedtothemashfollowingheatingandcoolingbutbeforeitispassedtothedecanter.

Thefollowingapplicationsmayariseforseparators

anddecantersinconjunctionwithultrafiltrationduringtheproductionofgrapejuice:ExtractingjuicefromthegrapemashClarifyingthefreshlyobtainedjuicePolishingthejuiceclarifiedandstabilizedbymeansofenzymesorbyfiningagents

ClarifyingtheretentateinconjunctionwithultrafiltrationUltrafiltrationCreamoftartrateseparation

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Theproductionofgrapejuicebydecanterhasbothqualitativeandeconomicbenefitscomparedtotheconventionalprocess:GentlemethodBettersensoryqualityNofiltrationauxiliariesrequired

Forredgrapes,thereareadditionalbenefits:HighercoloryieldContinuousprocessSimplecleaningFlexibleandreliableSimpleandspace-saving

3.3 Plum / date and cherry as examplesof stone fruits

3.3.1 Date juice concentrate /liquid sugar / feed yeastsThe growing requirement for foods meansthat raw agricultural materials which were

onceusedonlylittleoronlylocallyarebeingprocessed into usable, high-quality products.The speci al decomposi ti on method andcentrifugalseparationmeanthatitisnotonlypossibletoobtainjuice,butalsoby-productsforfoodandanimalfeedorprimarymaterialsforbiotechnologyandchemistry.

Fig. 15 Processing dates / plums into juice

Heating

Steam

Heating tanks

Feed belt

ClarifierEvaporator


2nd stagedecanter

1st stagedecanter

Stone removal


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Making date syrupDuringtheproductionofdatejuice,thecookedmashisjuicedbydecantersintwostages,thefirst separation stage being to obtain directjuice.Inthesecondextractionstage,thesugarisrecoveredoncetheseparateddatepomacefromthefirststagehasbeenremashed.Thisrecovered

juice,withareducedBrixcontent,isreturnedtothediffusionstageascookedjuice.Thedatepomacewiththesugarremovedcanbebrokendownfurtherifrequiredorusedasanimalfeed.Thedescriptionoftheprocessforprocessingdriedplumsissimilartotheapplicationjustdescribed.

Description of lineDatesarecleanedintensivelyinawashingdeviceandfedviaaninspectionbelttoeitheratankheaterwithstirrerortoacontinuoussteamingscrew.Thestonesareremovedfromtheheated

dateswhicharethenroutedtothecontinuousdiffusionprocess.Tothisend,apartial-flowofcookeddatejuice(secondextractionstageforsugarrecovery)andfreshwater(canbewatervapor) is added to the diffusion volume in aparticularratio.Aftertherequiredreactiontime,thehotdatemashispassedtothefirstdecanterprocessstageforjuicingandphaseseparation.

Afterbeingreturnedtothemashviaagitatortanksandheatedforfollow-upextraction(cookedjuice),thejuicedsolidphasepassesthroughthe

seconddecanterstage.

Theextractedrawjuiceofthefirststage(approx.1820Brix)isroutedviaabuffertankstraighttothedownstreamclarifierforthejuice-polishingstage.ThesubsequentlyclarifiedrawjuiceistakentotheevaporatorforconcentrationviaaCross-FlowFiltrationsystem.Theconcentrate(approx.70Brix)isprocessedfurtherbythemixingunitandthetubeheaterdownstreamforsterilefillingortankstorage.

Otherapplicationsfordateprocessinginclude:Additionofyeasttorawjuicestocreatebakingandfeedyeasts

ProductionofliquidsugarProductionofvitaminsbyfermentingsugarPharmaceuticalproducts

Productionofalcoholorvinegar

Process for making dried plums into juiceThe fruit is heated, the stones are removed,pectolytic enzymes are added, the mixtureis cooked for therequired reaction time andseparatedintojuiceandpomaceinthedecanterwhen sti ll hot. To increase yield, the pomacecan be rediluted and extracted again in theseconddecanter.

The cooked juice with a reduced Brixcontent obtained in this way is returned

to the first diffusion stage. The decanterto be used for these extraction processesis equipped with GEA Westfalia Separatorvaripondasstandard.

Process for making fresh plums into juiceThedecantercanlikewisebeusedtoproducejuicesfromfreshplums.Followingmillingandremovalofstones,thefruitisjuiceddirectly.Ahigh-performanceseparatorthen polishes thejuicetofillingquality.Thedecanterusedintheextractionprocessshouldlikewisebeequipped

with GEA Westfal ia Separator varipondasstandard.


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3.3.2 CherryTomakecherryjuice,thewashedfruitscanbeprocessed indifferentways. Stoneremovers/

finisherscanbeusedfirsttopreventablockageinthetubularheatexchangerdownstream.Heatingisperformedeitherbytubularheatexchangersorbysteamscrew(blancher).

Whenjuiceisextractedbyadecanter,itisnotabsolutelyessentialtoremovestones,butthesupplytankwhichfeedsthedecantershouldbeequippedwithastirrertopreventsedimentationofthestonesandtoensureahomogeneousfeed.Notanninsorcyanogensareextractedinthedecanteritself.

Theflavoristhenremovedfromthejuiceobtained,itisinitiallyconcentratedandenzymesareadded.

The fining process which follows additiono f the enzymes i s re sponsible fo r colorstability and intensity and trub quantity. An

ultrafiltrationunitwithceramicfilterelementsisnowusedforpolishing.Thejuicesfilteredwith these membranes show that color losscan be virtually ruled out in contrast topolymermembranes.

Following pol ishing, the next step is theevaporationprocesstothedesiredBrixcontent.Inadditiontothetwotypesofstonefruitalreadymentioned,peaches,apricots,sloesorCorneliancherries canalsobejuicedwith equalsuccess.The necessary process technology should be

modifiedaccordingly.

Fig. 16 Process

for making

cherries into

juice

Raw material in

Finisher Heat exchanger


Evaporator

Initial evaporation /flavor recovery

Tank for concentrate

Decanter

Milling

Addition of enzymes / fining

Tanks for addition of enzymes


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19


3.4 Currants and strawberries as

examples of berry fruitsThemainberryfruitsarecurrants,gooseberries,strawberries,raspberries,blackberries,blueberries,cranberries,bogcranberries,buckthornberries,elderberriesandbarberries.Allthesetypesoffruitcanbejuicedwithadecanterandclarifiedbyultrafiltration.

Asarepresentativeforthegeneralprincipleofprocessingberries,wewillexplaintheprocesstechnology and achievable outputs using theexampleofblackcurrants.

Fig.17showstheprocessingofblackcurrantsintojuice.Thefreshorthawedberriesaretakenoffthestalks,milled,heatedandhaveenzymesadded.Thisproductthenpassesthroughacontrollable,gentleMohnopumptothedecanter,wherethemixture is separated into juice and pomace.Furtherprocessingof thejuicetoobtainflavor,followedbyfining,filtrationandevaporationisinlinewiththeGEAWestfaliaSeparatorfrupexprocess.

However, themachine parameters and fining

sequenceneedtobeadaptedtotheparticulartypeofberry.

UltrafiltrationisincreasinglybeingperformedwiththeaidofaCross-Flowunit,displacingthetraditionalDE filtration.Itisimportantheretoselectthecorrectporesize.Theceramicmembranewithaveryfineporesizehasbecomeestablishedinpractice.

Thekeybenefitoftheceramicmembraneisitsabilitytoconcentratethesolidsintheretentate

toupto90percent.Thisminimizesjuicelossesandrendersawkwarddiafiltrationunnecessary.Comparedtoplasticmembranes,discolorationisreducedaswell.Thissavestimeandmoneyforthesubsequentevaporationstep.Furthercommentsabout filtration with ceramic membranes aresummarizedinSection9.4.

Fig. 17

Process for

making

blackcurrant

juice

Raw material in 2-stage milling Heat exchanger

Initial addition of enzymes

Decanter


Evaporator

Tank for concentrate

Initial evaporation / flavorrecovery

Addition of enzymes / fining


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20


DecantertypeGCE535isfittedwithGEAWestfaliaSeparatorvaripond.OutputsinlinewithFig.18canbeachievedwiththissetup.

3.5 Production of pureInmanycases,fruitistobemadenotonlyintojuice,butalsointopureorconcentratedpure.This semifinishedproductservesas astartingmaterialfortheproductionofproductscontaining

realfruit,suchassmoothiesandbabyfood.Thejobofseparationtechnologyistoseparateoffundesired particles such as pips, skins, stalkresiduesandcoarsetissuefromthecorearea.Themilledfleshisintendedtobeevenlydistributedinthejuice.

Thistaskcanlikewisebeperformedwiththedecanter. The focushereis not onmaximumclarification,butonclassification.Byselectingsuitable machine parameters, the undesiredconstituents of the fruit can be selectivelydischargedatahighlevelofdrysubstance.

Alternatively,apurecanbemadewithafinisher,thoughthereisalmostnopossibilityinthiscase

ofadjustingtheconsistencyofthepure.Ifyoucombineafinisherandadecanter,puresofanyspecification can be produced. Concentratedpureswithasolidconsistencyarejustaspossibleasamorejuice-like,liquidpure.Theprocessinglinecanthenalsobeusedtomakejuice.

Abb. 19 Production diagram for making juice and pures from apricots

FruitFinisher

Initial milling pump

KZE

Decanter

Sterile filling


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4.1 Processing residualsInadditiontotheproductionofjuices,awholeseriesofotherproductssuchasfruitcocktailsare

alsoobtainedfromfruit.Thecanningindustry-factoriesprocessing pineapple orcarrots,forexample-producespeelingwasteandtopsandtails.Likesecond-qualityproduce(non-standardgrowth),theseconstituentscannotbeprocessedbythefactoriesdirectly.Yetthesepartsofthefruitcontainconsiderablerecoverablequantitiesof

sugarandextractandarethereforejuicedlikethefruititself.Preparationofthemashisgenerallymodifiedandadaptedtosuittherequirements

inquestion.

Fig. 20 shows the processing output of pearresidues.Theuseofdecantertechnologyallowspartswhichusedtobediscardedtobeprocessedforfurtherextraction.

4. Special Applications

4.2 Treating trub using decantersor separatorsTrub forms in a number of process steps infruit or vegetable processing and this has tobe separated off and concentrated as far aspossibleinsubsequentsteps.Examplesofthisarecoarsetrub(whichsettlesveryquicklyinfresh,conventionallypressedjuice),finingtrubandretentatefromthecross-flowfacility.Yeast

sediment also forms during the productionofcider.

The following strategies can be employed toreducetheburdenonfruitjuicemanufacturersofhavingtoprocessthetrub:MinimizethetrubfractionOptimizetrubprocessing

Minimizingthetrubfraction

Afundamentalapproachtosolvingthisissueistoreducethequantityoftrubproducedduring

juicing.Differentprocesstechnologymethodsforextractingjuiceareavailable,withthelowesttrublevelcomingfromtheuseofcentrifugalseparationtechnologyinadecanter.Thesolidscontentcanbereducedtoaminimumandconcentratedinaseparatortoclarifythejuice.

Optimizingtrubprocessing

Sixtytoeightypercentofthistrubsedimentconsistsofrecoverablejuice.Phaseseparationcanbeperformedcontinuouslybydecanterwithoutauxiliariesandinasealedsystem.Theoptionofprocessingveryquicklymaintainsthejuiceatoptimumquality.Eighty-fivetoninety-eightper cent o f the sol ids a re separated o ff,guaranteeing that the juice returns directlyto themain flow. The solids themselves canbedumped.

It is important that the trub which forms isprocessedfreshandhasnotstartedtoferment.If the trub has started to ferment, this canconsiderablyreducetheclarifyingperformanceofthedecanterasaresultofthecarbondioxidewhichforms(trubfloats).

GEA Westfalia Separatorecoforce decanter.


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4.3 Concentrating retentateRetentateisaby-productofcross-flowfiltrationandessentiallyconsistsofretainedtrubparticles,whichwereunabletopenetrate themembrane,andvaluablefruitjuice.Thecharacteristicsoftheretentate(ahighCODvalue,forexample)oftenresultincorrespondinglyhighdisposalcosts.

Ahigherconcentrationofsolidsintheretentateleadstoaloweroverallvolumeofretentate.Therearesystem-relateddifferencesbetweenpolymerandceramicmembraneshere,ceramicallowingagreaterdegreeofconcentration.

1.Secondarycurrentseparationoftheretentate

circuitbyseparator

Depending on the system, the circulatingperformanceoftheretentatecircuitis5to25timesgreaterthanthefluxrate(permeateflow).

Theretentatebecomesincreasinglyenrichedwithsolidsand,fromacertainconcentrationfactor,requiresfurtherprocessinginbatchestorecoverthevaluablejuice.

Cleaningcyclesaredeterminedbytheformationofalayercoatingthemembranes.Ifaseparatorisusedinthesecondarycurrenttotheretentatecircuit,cleaningintervalsandpermeateoutputcanbeconsiderablyimproved.Atasecondarycurrentoutputof1020percentofthecirculationoutputoftheretentate,solidsarecontinuouslyseparated

andtoogreataconcentrationisprevented.

Asimilareffectcanbeachievediftheseparatorisinstalledinthefeedtotheoperatingtankoftheultrafiltrationunitandinitialclarificationiscarriedoutonthewholeofthejuicebatch.

Inthiscase,theseparatoroutputhastobeadaptedtothepermeateoutput.Withsecondarycurrentseparationintheretentatecircuit,thecentrifugecanbesmaller.

22


Fig. 21 Retentate treatment using a decanter

Retentate tank approx.50 60 % (by vol.)

Juice < 0.5 %(by vol.)

DecanterSolids 25 30 % D.S.

Dilution with waterto 25 30 % (by vol.)

Heating 80 85 C


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Thesolidsfromthecentrifugecanbedisposedofwiththepomace,sodonotformaseparatewasteflow.However,retentateisstillproducedinthefilter,evenifinconsiderablysmallerquantities.As an alt ernat ive t o the s eparator, th edecantercanalsobeused.Itismoretolerantof abrasive media such as bentonite and isa lso suitable for elevated trub content inthejuice.

2.Concentratingtheretentateinbatches

usingadecanter

Afurtheroptionforprocessingretentateistocollectitinaseparatetankattheendoffiltrationandtoclarifyitinparallelwithregulardailytasks.

Theretentateisdilutedwithwater,thenheatedto8085Candclarifiedinthedecanter.Theclarifiedjuicethenhasaresidualsolidscontentofapprox.0.5percentbyvol.andcanberoutedbackintocurrentproduction.Thehardsolidscanlikewisebedisposedofwiththepomaceagain.Thedrysubstanceofthesolidsisintherangeofupto30percentD.S.

Asaresultofthisprocessrunninginparallelwiththeregularjuicingoperation,thehourlyrateofthislinecanberelativelysmallandinvestmentconsequentlylow.

23



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5.1 PineappleBothdecantersandseparatorsareusedtoprocesspineapplesintojuice.Inprinciple,twodifferentproductsareobtainedso-calledmilljuice(frompineappleskin)andbeveragejuicefromfleshcomponents.Beveragejuiceisusedasjuice;milljuiceisusedpurelyforcleartoppingsinthecanningindustry.

5.1.1 Processing beverage juiceAfterwashing andsorting,thefruitarrives attheGinacamachinewhereitismechanically

brokendownintothreecomponents:cylindricalflesh(thecylindersarethenslicedastypicallydoneforcannedfruit),peelandjuicematerial.Thisconsistsofthepineapplecore,andtheflesh

obtainedfrombetweentheskinandthecylinder.Somefactoriesdivertsomeofthismaterialtoproducecrushedpineappleakindofpineapplepure.Thefruitisjuicedbythetraditionalscrewpresseswhichgenerateahighproportionofsolidsinthejuice.Screwpressesareusedina3oreven4-stagearrangement.

5. Tropical Fruits


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25


Thedischargingjuicehas1213Brixandasolidscontentofupto35percentbyvolume.Itmaycontainundesiredsolidssuchasbitsofpeel.Asanendproduct,itissupposedtohaveasolids

contentof812percentbyvolumeforlow-pulpjuice.Forhigh-pulpjuice,solidscontentsof1218percentbyvolumeareusual.

Clarification normally takesplace at elevatedtemperatures.Therearetwoprocesstechnologyvariants.

Initial clarification is performed by finishers(strainers)whichremoveallcoarsefibers.Thejuiceisthenclarifiedbyseparators.Solidscontentsinthejuiceproducedmaybesettobetween218

percentbyvolumeorlower.

Thejuicecomingfromtheseparatorcanbesettothedesiredsolidscontentbycontrollingthethroughput.

Alternatively, the juice can also be clarifiedbydecanter.Thismakesitpossibletoreduceconsiderably the number of process stagesrequiredforclarificationbecausethefinishers(strainerunits)areomitted.

Thejuiceproducedinthiswayisevaporatedtothedesiredconcentrationinmulti-stagefalling

filmevaporators.

A specific variant for producing high-qualitypineapplejuiceistousedecanterswitha2-geardrivetoextractjuicedirectlyfromthepineapplemash.ThisprocessisbasedontheGEAWestfaliaSeparator frupex methodwhich uses fewermachines.Thepotentialsavingsareconsiderablehere,andthequalityoftheendproductcanalsobe improved, as theprocess time at elevatedtemperatureisshorterandassociatedheatdamageandoxidationarereducedconsiderably.

Fig. 24 Capacity of GEA Westfalia Separator hyvol

separators in pineapple processing


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26


5.1.2 Mill juice productionMilljuiceisproducedinaseparateprocessingline.Themilledstartingmaterial(peel)isjuicedinascrewpressandthejuiceproducedispre-clarifiedinadecanter.Separationofanygreenbitsofpeelisveryimportantatthis stage.Followingthisclarificationstep,enzymesareaddedtothe

juice,activatedcarbonisaddedtoremovecolorandthejuiceisthenclarifiedintheultrafiltrationunit.Theproductobtainedisacolorlesssugarsolutionwhichiseasytoconcentrateandisusedasatoppingforcannedproducts.Aparticularissuehereistheoveralleconomyoftheprocessaby-productreplacesanexpensiveproduct(sugar)inthetoppingliquid.

Overall,itshouldberememberedthathardlyanypartofthefruitremainsunusedintheprocessingofpineapple.Theseparatedsolidsareusually

processedintobranswhich,inturn,areusedasanimalfeeds.

5.2 MangoMangosarealmostalwaysprocessedintopuresorconcentratedpures.Todothis,thefruitiswashed,possiblytreatedwithsteamandsubjectedtoasubsequentmaturingprocess.Thefruitisthencoarselymilledandheatedinaheatedscrew.Incountrieswhereitisgrown,thefruitisoftenstoreduntilfullyripeandthencutupbyhand.Thestonesarethenremovedbya2-stagefinisher(strainer)

andthefleshstrained.Thepureisheatedandtheclassificationprocessinthedecanterremovesundesired solids. Fragmentsof stone, brownspecksandblackspeckscanalsoberemovedbythisprocess.Thedecanteralsoprotectstheevaporatordownstreamfromblockagesduetosolids.Mangopurecanonlybeproducedinapracticalwaywithoutadecanterifcultivationconditionsareidealandifvirtuallyfiber-freevarieties(e.g.Kensington,Alfonso)areprocessedandthereisnoconcentrationintheevaporator(single-strengthpure).

If theraw pure is very heavily loaded withfragments of stone because of either poorequipmentorprocessingvarietieswhichhavestoneswhichfractureeasily,itmaymakesensetoputinaseparatordownstreamofthedecantertoremovethefragmentsentirely.

5.3 BananaAsmallproportionoftheworldsbananaharvestisprocessedintolong-lifeproductsonanindustrialscale processing primarily banana juice

andpure.

The objective during processing is to avoidoxidationanddiscolorationbyblanketingwithCOand/oraddingvitaminC.Themashisthenbroughttoatemperatureforaddingenzymesusing tubular heaters. In order to preventpolyphenol oxidase activity at this stage, themashcanbeheatedtotherelevantinactivationtemperatureandthen cooleddownto enzymereactiontemperature.Theappropriateenzymesallow a drastic reduction in viscosity to be

achieved.Oncepreparedinthisway,themashistheneasytoseparateinadecanter.

Therearetwoslightlydifferingprocessvariantsdependingontheendproductrequired.

5.3.1 Banana juiceImmediately afterwards, the mash to whichenzymeshavebeenaddedandwhichhasbeeninitially clarified inthe decanterneedsto beclarifiedagaininaseparatortoobtainaclearjuice.Theproductrunsthroughanultrafiltration

processtoremovethestillcolloidalcomponentsofthejuice.

Evaporation and sterile filling then follow.Theendproductisusuallysoldasanaturalfruitsugarconcentrate.


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5.3.2 Banana pureComparedtothepreviousmethod,theseparatorisnotrequiredwhenmakingpure.Theprocesscontinues by evacuating air from the pure,pasteurizing it and fil ling it under sterileconditions.

Throughputswhenprocessingbananas:

5.4 PomegranateThepomegranateoriginatesfromWesternandCentralAsia,butthisfruithasalsobeencultivatedintheMediterraneanregionforhundredsofyears.Yearsago,itshighnumberofseedswasthoughttoberesponsibleforitshealthyproperties,todayweknowthatthiseffectisduetoahighcontentofpolyphenolsandotherbioactivesubstances.

Underthethickskinareupto7compartmentsenclosed by membranes which contain thenumerousseeds.Eachseedissurroundedbya

soft,fleshy,transparentpinktodarkredaril.

Fig. 26 Process for making clear banana juice

Manual peeling andinspection

Heater

Clarifier

Addition of enzymes

Decanter

EvaporatorCross-Flow Filtration

Milling

Initial evaporation


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28


ProcessingFollowingtheobligatorycleaningandpickingoverofthefruit,thefirststepistobreakopenandremovetheouterskin.Thejuicyfruitcellsthusobtainedaregentlyopenedinasqueezingdevice and pumped into the decanter by aneccentricscrewpump.Thedecanterseparatesthe

juicefromtheseedsandremainingsolids.Thisseparationprocessisverygentleontheproductasitinvolvesjuicingveryquicklyinasealedspace.Theverygentletreatmentoftheseeds,whicharehardlydamaged atall,ensuresthatextractionofundesiredpolyphenols(e.g.tannins)canbereducedtoaminimum.

Directlyafterjuicing,thejuiceispasteurizedtoinactivatemicroorganismsandtheenzymesinthefruit.Thesubsequentfining,filtrationandpossiblyevaporationstepsareperformedunder

customaryfruitprocessingconditions,thoughtakingaccountoffruit-specificrequirements.

Fig. 27 Production diagram for producing juice from pomegranates

Fruit in,cleaning

Breaking openand milling

Evaporation Juice

Solids

Decanter

Plate heatexchanger


Addition of enzymes


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6. Production of Vegetable Juices

Variousdifferentprocesstypesareusedtomakevegetableproducts,dependingontherawmaterial.Factorieshavedifferentmethodsforpreparing

produce,makingthemash,obtainingjuiceandfinishingtheproduct.

Withmosttypesofvegetables,especiallytuberousandrootvegetables,apeelingorcleaningstepfollowsanintensive,multi-stagewashingprocess.Ausuallymulti-stagemechanicalprocessthenfollowstopreparethemash,withmechanicalmillingusuallybeingsupportedbythermaland/orenzymaticbreakdownoftheplanttissue.Insomecases,thevegetablemashisfermentedwithalacticacidculture.

The juicing process plays a key part in theproductionofvegetablejuices.Theuseofhighly-developeddecantertechnologyresultsinrapid,continuousandlow-oxidationjuicing.Thismakesitpossibletoproducehigh-qualityjuicesathighyields under hygienic condit ions. A definedquantityoftrubcanalsobeaddedcontinuouslyand directly to thejuicefraction. Ifmachineparametersareadjusted,thedecantercanquicklyandflexiblybeadaptedtorawmaterial-specificproductrequirements.Cleaningcyclesforthe

sealed process system and setup times areminimized,asdecantersarefitforCIPwithoutanyrestrictions.Thisensuresconsiderablehygienebenefitsandresultsinanoptimumproductfromamicrobiologicalviewpoint.

Therawvegetablejuiceobtainedisconventionallyprocessed.Itisusuallypreservedbybeingheatedinacontinuousprocesswithsubsequentsterilestorage.Itisalsopossibletoperformlacticacidfermentationorconcentrationofthejuice.

In European factories,the primary juices arecarrot,beetrootandcelery.Smallquantitiesofjuicesandbeveragesarealsomadefromasparagus,rhubarb,whitecabbage,spinach,onions,potatoes,cucumbersandcerealmashes.

Theseproductsarealsoprocessedusingseparatorsanddecanters.Thesameappliestotheproductionofjuicesfrommedicinalplantssuchasvalerian

ornettle.

Ajuicingprocessisnotnormallyusedintheproductionofvegetablepulp.Thismethodofextending shelf life and intermediate storageissimilartotheproductionofvegetablejuicedescribed.

6.1 Carrot juiceThe short shelf life of carrots and the juicemadefromthemmakesprocessingparticularly

awkward.Therequirementformodern,quality-focusedprocesses,i.e.convertingtherawmaterialintosemifinishedorfinishedproductsinashorttimeattopproductqualityandwithminimaluseofprocessandcleaningwatercanonlybepartiallymetby conventional press techniques. As analternative,highlyefficientdecantertechnology,hasprovenitshighdegreeofeconomy,efficiencyandflexibilityintheproductionofcarrotjuice.

Fig.30showsaprocessvariantforthemanufactureofcarrotjuice.Intheprocessshown,thewashed,

steam-peeledandselectedcarrotisfirstmilled.Asitthenpassesthroughatubularheater,themashisheatedto8085Candisbrokendownfurther by intensive dispersion in a toothedcolloidmill.Thefinelymilledmashhasaverysmallparticlesize.

Theabilitytojuicethisfinemasheffectivelyhasraiseddecantertechnologytothestateoftheart.Afurtherbenefitisthecontinuous,sealedmethodofoperation,whichfacilitatesrapidandhygienicprocessing.


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Theprocessshownwithintensivemillingisaimingtoextractasmanysecondaryplantmetabolitesaspossible.Astheconventionalpresstechnologyrequires a coarserdegree ofmilling to allowphaseseparationthroughdrainageroutesinthepomacecake,thedecantercanprocessextremelyfineparticles.Asaresult,thereismoreintensive

extraction of valuable constituents like beta-caroteneinthedecanter.Thecarotenoidsofthecarrot can be foundin chromoplastsand arepresentintheformofcrystallinestructures.Asthecarotenoidsareextractedmoreintensively,thejuicesfromdecantersaremuchmoreintenselycoloredthancomparablepressjuices.Thepomaceitselfiscorrespondinglylessintenselycolored.

Carrot juices are characterized by ah igh total carotene con tent . Dependingon var iety, the concentration f luctuates

between 3 and 16mgof carotene per 100 gfreshweight.Themainproportionofthesetotalcarotenoids is represented by beta-carotene,whichmakesup between60 and 90percent oftotal carotene. Beta-carotene has nutritionalsignificance as provitamin A and a naturalantioxidant,which interrupts the free radicalchainreactionandthuspreventsnewfreeradicalsfromforming.

Anotherformofthecarrotistheblackcarrot.Thishasahighersugarcontentandahighercontent

ofanthocyanogens.Theseanthocyanogensbelongtothegroupofsecondaryplantconstituentsandhavemanypotentialuses.Inprinciple,thistypeofcarrotisprocessedunderthesameconditionsasthoseforconventionalorangecarrots.

Another process technology benefit of usingadecanteristhedirectadjustmentofthepulpfractioninthejuice.

Commercial juices are supplied with a pulpfractioncontentofbetween2and15percentbyvolume. When conventional press technologyisused,vegetablepulphastobeproducedina

separateprocessinwhichenzymesarethenaddedandthepulpismixedintothelow-trubjuice.Thereisadirectlinkbetweenpulpfraction,thetorqueofthescrew,thedrysubstanceinthepomaceandthedifferentialspeedofrotationbetweenthebowlandthescroll.Thelatterdeterminesthedwelltimeofthemashinthebowlandthusthedrysubstanceinthepomace.Itissettotheideallevelatthestartofprocessingasafunctionofprocessandproductandregulatesitselfautomat-icallyasconditionschange.

Pulpfraction(trub)intheclearphaseisclearlydependentontorque.Inproducingclearjuice,ontheotherhand, scrolltorqueisminimized.Ifahigherpulpfractionisrequired,thiscanbeachievedbyincreasingtorque.

Fig. 28 Left: pomace from decanter,

right: pomace from press


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31


Fig. 30 Process for producing carrot juice

Product in Steam peeler Washer

Post-washerInspection beltMillingMaceration

Heating

Fine-millingDecanter

ClarifierKZEStorage

Washing bowl withbrushes

Stone / earthremoval

Initial wash

6.2 Producing beetroot juiceThebeetrootarefirstmilled.Themashobtainedinthiswaycaneitherberouteddirectlytothedecantercoldorfollowingabriefheatingsteptobreakdownthetissue.Oneoptionistofine-millor addenzymesto theproductbeforethephaseseparationstep.Thedecanterseparatesthebeetrootmashintoclearjuiceandpomace.Dependingonthedesiredtrubcontentoftherawjuice,fineclarificationcanbeperformedusingaself-cleaningseparator.

Theproductisgivenashelflifeandstoredundersterileconditionsbytheconventionalmethod.

Various processing routes are used to makevegetable products, depending on the rawmaterialinquestion.Individualfactorieshavevariousdifferentmethodsofpreparation,mashproduction,obtainingthejuiceandcompletingtheproduct.


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6.3 Producing pulp concentrate andjuices with a dened pulp fractionAsalreadydescribedunderitem3.5Productionofpure,apureorpulpcanalsobepreparedfromvegetables.Thepulphasafinehomogeneousand pasty consistency and has a greatmany

applications.

Vegetablepulpproductsliketomatopure,forexample , reach the consumer asproducts in their own right. In manyc ases, pulp product s and especiallyvegetablepulp concentratesareused invariousbranchesofthe food industry assemifinishedproducts.Vegetablejuicesareoftenmixedwitha definedpulp fraction to create high-qualityindependentproducts.Forexample,carrotjuiceswithapulpcontentof515percentaresold(seeSection6.1).Thejobofseparationtechnologyisnowtoseparateoffundesiredparticlessuchaspips,peel,seedsorhardpiecesoftissue.Vegetablepulpisthusahomogeneousvegetableproductwithacomparativelyhighproportionofsolids.Withconventionalpresstechnology,twoprocesslinesandthecorrespondingsupplementaryunitsarerequiredtoproducejuiceswithahightrubcontent.Thefirstproductionlinemakespressedjuiceswitha low trub content; the second line makesvegetable pulp. The intermediate products are

thenmixedinanadditionalstep.

If a high-performance decanter with torque-dependentdifferentialspeedcontrolisusedtomaketheseproducts,oneprocesslineissufficient.Ifthedecanterparametersaresetappropriately,itispossibletoadddefinedpulpfractions(finefractions)continuously to the juicewhile thevegetablemashisbeingjuiced.

Asaconsequenceofthecommonprocessingandstorageofbothproductcomponents,thereare

benefitssuchas:SimplificationoftheprocessReducedcostsImprovedquality

The useof decanters on the modified serumprinciple allows production processes to beoptimizedintheproductionofpulpconcentrates.Oncetherawmaterialhasbeenprepared,themashobtainedistreatedwithheatandwithenzymes.Enzymaticmacerationisintendedtoimprovethe

phaseseparationofserumandpulp(thesolidpartofthepulp).Followingactivationoftheenzymesbyheat,themashisstrainedandfedtoadecanter.Thecentrifugalforcesdischargethesolid(pulp)andtheliquid(serum)fromthedecanterseparately,allowing themto be processed separately(cf.Fig.32).

The serum is then concentrated in suitableevaporators and the flavor is recovered. Theserumandflavorconcentrateobtainedinthiswayaremixedbackintothepulpfromthedecanter.Thisprocessresultsinawholeseriesofbenefitscomparedtotheconventionalprocesses:Lowthermalstressmeansgentleconcentrationoftheserum(liquidfraction)

Flavorrecoveredfromtheserumfractionandreturnedtotheproductinfull

Gentleconcentrationofthepulpfraction(solid)

Concentratelineoperatesforalongtime(reducedloadingwithsolids)andisconsequentlyeconomical

Asflavoriscompletelyreturnedandthermalloadisless,thesensoryqualityoftheproduct(color,smell,taste)isimproved.


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Pulp

Addition of enzymes

Decanter

Pulp concentrate

Concentration /

flavor recovery

Extraction of air

Concentrate

Thermal treatment

to lengthen shelf life

Sterile storage

Pretreatment

Raw material

Pulp

Consistency adjusted by

adding fresh pulp

Serum

Fig. 32 Process for making vegetable pulp concentrate


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Anincreasinglyhealth-consciousapproachandthesearchfornewapplicationsareleadingtoarisingdemandforhealthproductsinthejuicemanufacturingindustry.Foodswithquitespecificfunctionalcharacteristicsarecalledfunctionalfoods.The effectson healthascribed tothemcanusuallybeattributedtospecificconstituents.The enriching substances include secondaryplant metabolites, vitamins, minerals or

bacterialcultures.

Theflexibilityofdecantersmakesthemperfectforextractingsecondaryplantmetabolitessuchasbeta-carotene,lycopene,phenoliccompoundsandbetalain.Thesesubstancescannotbeproducedby human beings themselves, and thereforehavetobeabsorbedinthefood.Inchemicalterms,secondaryplantmetabolitesareaveryheterogeneousgroupofconstituentswhichareusedonthebasisofeitherprovenorsuspectedhealth-promotingproperties.

Inadditiontofactorssuchasfruitandvegetablevariety,degreeof ripenessand processing alsoplayasignificantroleintermsofthequantityandqualityofthesedesiredconstituents.

Thedecanterisakeyelementintheextractionofthevarioussubstances:afocusistheextractionofradicalscavengerssuchasbeta-carotene(fromcarrots)andlycopene(theredcolorintomatoes).Phenoliccompoundslikeresveratolareextractedfromredgrapes.Betalaingivesbeetroottheirtypical color and is used as a natural foodcoloringinthemeatandconfectioneryindustries.Areportfromthefoodindustryresearchgroup

Forschungskreis der Ernhrungsindustrie e.V.((FEI)(AIF-FV12431BG))showedthatforapples,forexample,alongermashstandtimeleadstoareducedoverallphenolcontent.

Thedecantercanreducethislossbecausejuiceisobtainedcontinuouslyandquickly.Thesealedsystemfurtherminimizesadditionalundesiredoxidationoftheproduct.

7. Secondary Plant Metabolites fromNatural Raw Materials


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Informercenturies,plantslikedandelionandnettle had a permanent placein cooking andmakingmedicinalproducts.Havingthenfallenintodisuseforawhile,theyarenowmakinganimpressivecomeback.Itisnowimpossibletoimaginethebeveragerangewithoutthesespecialjuicesintheformofhealth-promotingdrinksornutraceuticals.

Nettle and dandelion are particularly rich innaturalmineralsandvaluabletraceelements.Nettlejuiceisconsideredtobediuretic,cleansingandgoodfortheblood,juicefromdandelionisseenprimarilyasadrinktopromotedigestionandstimulatethemetabolism.Atotalofsome30differentspecialjuicesareknownandalsolicensedasdrugs.

Toobtainthejuice,theoutputsfromthedecanterandtheseparatorarecombined.Aftertheplantshave been thoroughly washed, they are firstchopped,blanchedandmacerated.

Duringthejuicingprocess,thedecantergentlyseparatesoffthecoarsersolidsbeforeaseparatorperformsfineclarification.Thejuicesarethenpasteurizedandfilled.

Theresultisaqualityjuicefromwhichnoneofthefundamentalactionoftheconstituentshasbeenlost.

8. Herb Extracts / Special Juices /Nutraceuticals


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9.1 DecantersWhenclarifieroperationisnolongerfeasibleduetohighproportionsofsolidsinthesuspensiontobeprocessed,decantersareused.Thedecanterdesign

isbasedondecadesofexperienceincentrifugalseparationtechniquesaswellasintensiveresearchanddevelopmentbyGEAWestfaliaSeparator.Decantershavebeendevelopedforhighclarifyingperformanceandthemaximumpossibledegreeofsolidsdewatering.

For effective performance and dewatering,highbowlspeedandanenormouslyhighscrolltorque,inconjunctionwithacontrolsystemtosynchronizedifferentialspeedandsolidsloadarerequired.Theproductfordecantingentersthedecanterthroughthefeedtubeandthedistributorconveysitintotheseparatingchamberwhereitisacceleratedtooperatingspeed.Theactionofcentrifugalforcequicklycausessolidparticlestosedimentonthebowlwall.

Thebowlisofacylindrical/conicalshape.Inthecylindrical section,this shapeallows effectiveclarificationoftheliquid,whileintheconicalsection,thesolidsareeffectivelydried.

Thescrollrotatesslightlyfasterthanthebowlshellandconveysseparatedsolidscontinuouslytowardsthenarrowendofthebowl.Duetotheconicalshapeofthebowlhere,thesolidsarelifted

outoftheliquidand,onpassingthroughthedryingzonewhichisnolongerfilledwithliquid,freedfromanyadheringliquidbycentrifugalforce.Thesolidsarethendischargedintothecollectingchamberofthehousingthroughopeningsintheendofthebowl.Theliquidflowsoutbetweentheflightsofthescrolltotheotherendofthebowl.Theslightimpuritiesstillintheliquidarespunoutbycentrifugalforceastheliquidflowsthroughtheclarifyingzoneandis pumpedbythescrolltothesolidsdischargepointtogetherwiththesolidswhichhavealreadybeencollectedinthefeedzone.Theclarifiedliquidleavestheseparationchamberunderpressurebymeansofcentripetalpumps.

Depending on the decanter type, it may bedriven by a 3-phaseACmotor for controlledtorquestartingoralternativelybythree-phaseACmotorswithfrequencyconverter.Thisallowsstart-upcurrentandcurrentpeaksonstart-uptobereduced.Thepoweristransferredbybelts.

9. Systems for the Juice-Making Industry

Fig. 33 GEA Westfalia Separator ecoforce

Outlet

Feed

Solids


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9.1.1 GEA Westfalia Separator varipond reliable mastery of solids concentrationGEA Westfalia Separator varipond meansvariable ponddepth withmachine running.

Eveniffeedconcentrationvariesdramatically,thesystemcontrolstheliquidlevelinthedecanterbowlsoaccuratelythattheconcentrationoftheconcentratedsolidscanbesettoaconstantvalueandmaintainedexactly.

GEAWestfaliaSeparatorvaripondfacilitatesmuchlower-energyoperation,becauseadaptingtheg-forcetofeedconditionsandtheassociatedreductioninspeedallowselectricalenergytobesaved.Abrasiononthecomponentsisreducedandtheirservicelifeisincreased.

9.1.2 Drive systemsGEA Westfalia Separator decanters have

speciallydesigneddrivesystems.

2-geardrive

With this drive, themaindrivemotordrivesthebowlandthehousingoftheprimarygear.An additional secondary gear allows part ofthe power required for the scroll driveto beprovidedbythesecondarymotor.Thecurrentof thismotor serves as ameasure of torque-

dependentdifferentialspeedcontrol.Thedriveiselectronicallymonitoredandcanberestarted.Downtimesduetooverloadingareruledoutandsmoothoperationisguaranteed.Decanterswiththisdriveareusedwhenhightorquesarerequiredformaximumyieldsatlowdifferentialspeeds.

Differentialgeardrive

Thedifferentialgeardriveisrecommendedwhenautomaticcontrolofscrollspeedisrequiredinadditionto bowl speedcontrol.Thisis madepossiblebytheuseoftwogears.Thesecondary

motordrivesthecentralinletshaftandgeneratesthedifferentialspeedproportionaltoitsownspeed.A second inlet shaftwith no speed isconnectedtothehousing.Thismakesdifferentialspeedindependentofbowlspeed.Differentialgear drives are used primarily for the lowerdifferentialspeedrange.

Fig. 34 GEA Westfalia Separator varipond

Fig. 35 2-gear drive

Fig. 36 Differential gear drive


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9.2 Clariers high productquality and yieldExpertisegatheredfromdecadesofexperiencehasenabledGEAWestfaliaSeparatortoadaptthedesignofitsseparatorstosuittherequirementsofthejuiceindustry.Self-cleaningseparatorsareusedforjuiceclarificationandthesenaturally

satisfytherequirementforacontinuousprocess.

Theseparatorsareequippedwithadiskbowlandslidingpiston.Theliquidisquicklyandgentlyclarifiedinadiscstack,thesolidsbeingspunoutwards into the solids chamber. Once theoptimum emptying point has been reached,theslidingpistonisopenedhydraulically.Onceoperatingspeedisreached,thesolidsaresuddenlyejectedandtheslidingpistonreturnstotheclosedposition.Theclarifiedliquidistakenawaywithoutfoamandunderpressurebycentripetalpumps.

Iftheliquidshouldnotcomeincontactwiththeoutsideair,theseseparatorscanbesuppliedinahydrohermetic(liquidseal)variant.

Hydrohermeticvariant

Withtheseseparators,theproductsealtotheatmosphere is achieved without using sealssubjecttowearbymeansofanimmersiondiskarranged above theproductcentripetal pump.Thispreventsthespunproductcomingincontactwiththeoutsideair.

High-performanceclarifiers

Separatorsofthisseriescanbesuppliedinahydrohermeticvariant.Useofnew,high-strengthmaterialsmeansthatcentrifugalforces15,000timesthoseoftheaccelerationduetogravitycanbeachieved.Thismeansthatsolidsparticlesuptoanorderofmagnitudeofapprox.0.5mcanbeseparated.

Theperformancefactoriscalculatedfrom:BowlspeedDiscangleNumberofdiscsDiscdiameter

The separators are designed for the greatestpossibleeffectivecapacity,buttherearelimitstotheoptimizationofcapacityfactors.Bowlspeedis limited by thepermittedmaterial loading.

Discangle,discdiameterandnumberof discshavetobematchedtothedifferentproducts.

Atarelativelyhighloadingwithsolidsinthefeed,e.g.infruitjuiceclarification,effectivecapacityalsodependsonthesizeofthesolidschamberandpossibleejectionfrequency.

Effectsonclarification

Many factors inf luence the eff ic iency ofcen tr ifugal c la ri fi ca ti on . Both product -specific and mechanical parameters have aneffect. The first group includes particle size,specific density, viscosity and the proportionof sol ids in the l iquid to be c lari fied . Inmechanical terms, i t is primari ly g-force,equivalent clarification area and the solidsstorage volume of the bowl which are thekeyfactors.

Onaspecifiedseparator,thereareoptionsforimproving degree of clarification. Measuresfrequentlyusedinclude:ReducingcapacityAddingfiningagentstoformparticlesIncreasingtemperaturetoreduceviscosityDilutingwithwatertoreducedensityandviscosity

9.2.1 The GEA Westfalia Separator hyvoland hydry generations of machines cover

the full capacity rangeBoth hyvol and hydry machines cover theful l range o f capac it ie s in the beverageindustry with optimum machine sizes foreach application. The separators have beenoptimizedintermsofcustomerbenefitandrapidintegrationin ausersindividual process.TheprincipleofGEAWestfaliaSeparatorhyvolistoprovidemaximumeffectivecapacityforthespecifiedvolumeofinvestment.

GEAWestfaliaSeparatorhyvoliswhatGEAWestfalia Separator calls separators with anejection system for piston valves. Use of thehydrohermetic feed minimizes the negativeimpactofshearforcesandguaranteesoptimumseparatingefficiency.


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Separation performance and product qualityareconsequentlyideal.Thehydrohermeticsealpreventstheproductfrombecomingcontaminatedbyambientair.Thissealsimultaneouslycombinesoptimum compatibility for CIP with noneedformaintenance.

A final feature shared by all GEAWestfaliaSeparator hyvol systems is their very fastejectionvalves.Thefocuswiththesemachinesisonaveryhighhourlyoutput.

The focus in develop ing GEA West fa li aSeparatorhydryseparatorswasonachievingthegreatestpossibledrysubstancecontentinthe solids.With thesemachines, the greatest

content of dry substance is in the normalrangethanks to the GEAWestfalia Separatorhydrostopejectionprinciple.Theoptimumsolidsconcentrationisreflectedinveryshortpay-backtimes,especiallyif,asinthejuiceindustry,largequantities of liquid have to be processed.Product losses are extremely low. All GEA

Westfa lia Separator hy dry

and hy vo l

separatorsareequippedwithbeltdrives.Theyare characterized by their ability to be putto multifunctional use. The benefits of GEAWestfaliaSeparatorhydryseparatorsbecomeparticularlyclearwhentheobjectiveistoclarifyhigh-qualityproducts.Theminimizedproductlosses can lead to a short pay-back time forthelines.

Fig. 38 Clarifier GSC 150 with

GEA Westfalia Separator hydrostop system

Fig. 37 Different degrees of separation at different outputs


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9.2.2 GEA Westfalia Separator ecoplus separators for economic production of

juice in the low capacity rangeGEAWestfaliaSeparatorhasdevelopedanewgenerationofseparatorsforsmall-scaleproduction.Thisrangeofmachines,soldunderthenameGEAWestfaliaSeparatorecoplusEconomy

andmorerepresentsagood-valuealternativeto existing solid/liquid separation systems inthejuiceindustry.ThetypeGSC15andGSC25separators,inparticular,havebeenoptimizedforsmallerfactoriesandspecializedproducts.Thesemachines,developedinaccordancewiththenewstandardizationconcept,canbeusedincapacityrangesofbetween500l/hand3000l/h.ThebasicmodelshavemanyofthefeatureswhichhavemadeGEAWestfaliaSeparatormachinesirreplaceableinjuicemanufacture.PartofthenewdevelopmentconceptisthetraditionalGEA

Westfalia Separator hydrostop system. Thissystemtakesspunparticlesofsolidsoutofthemachineinaparticularlydrystate.Theadvantageforthejuiceindustryismaximumjuiceyield.Nootherseparatorsystemcanbeusedtocreatesomuchvalue.Anotherhighlightisthehydrohermeticliquidsealwhichpreventstheproductcominginto contact with the outside air and thusabsorbingoxygen.

9.3 Rotary brush strainer andhydrocycloneInitialseparationofcoarseandabrasivesolids

Ifthestartingproductforprocessingcontainsahighquantityofabrasiveandcoarsesolids,theseimpuritiesneedtobeseparatedoffbeforehandso that the continuous separation process is

guaranteedandseparatordamageduetoabrasionandothermalfunctionscanbeavoided.

DependingonthequalityofthestartingproductsRotarybrushstrainersorHydrocyclonesmaybeused.

Rotarybrushstrainersshouldalwaysbeusedupstreamtoremovecoarseconstituents,asthisrelievesstrainontheseparator.Itmakessensetouseahydrocycloneifthestartingproductforprocessingiscontaminatedwithanincreased

proportionofsand.

Ifbothdevicesareused,itisessentialtoobservethecorrectinstallationsequence.Therotarybrushstrainershouldalwaysbefittedupstreamofthehydrocyclonetopreventthehydrocyclonegettingblocked.Thisrulesoutanyimpactfromseparatorejectioncyclesorfluctuationsinsolidscontent.

Fig. 39 Diagram of a rotary brush strainer

Feed

Discharge,

clarified liquid

Fig. 40 Diagram of a hydrocyclone

Feed

Discharge, clarified

liquid

Discharge, solidsDischarge, solids


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9.4 Ceramic membrane ltration

Filtration of juicesA filtration step is required to produce clearjuices.Colloidaltrubmaterialaswellasparticleshave to be removed to prevent the juice orconcentratefromsubsequentlybecomingturbid.Diatomaceousearthfiltration(DEfiltration)wasusedinthepast,butcross-flowultrafiltrationhasnowbecometheestablishedstandardfor

polishingapplejuice.TheDEtechniqueisstilloftenusedforfilteringcoloredjuices.Asmorestringentrequirementsareplacedonthetypeofmembraneintheseapplications,theceramicmembraneiswelltriedandtestedinthefield.

StructureofCross-FlowFiltration

With this method, the juice is guided alongthesurfaceofthemembraneatatangent.Thepermeatecomesthroughthemembraneandiscollectedinaclearjuicetank.Alooppumpensuresthatthecloudyjuice,theretentate,circulatesin

thefiltrationcircuit.

Thevolumeoffiltratewhichflowsoffisreplacedbycloudyjuice.Thefeedpumpputscloudyjuiceinto thefiltration circuit. Partof theflowofretentateispassedbackintotheprocesstank.Inthe courseof filtration, thesolids becomeconcentratedintheretentatecircuit.

Ceramicmembrane

The core element of these units are ceramicmembraneswithaporesizeof20to200nm.Theyareextremelyresistanttotemperature,pressureandchemicals,easytocleanand,comparedtopolymermembranes,haveaverylongservicelife.Over1000linessuppliedallovertheworld,manyoftheminthefruitjuiceindustry,havealreadybeenworkingataconstantlyhighoutputfortwentyyears.Onlyaceramicmembranemakesitpossibletoconcentrateretentateuntilthereisnofreejuiceleft,asillustratedinFig.42.Thisallowsoperatorstoextendfiltercyclesconsiderablyandtominimizeproductloss.

Fig. 41 Diagram of Cross-Flow ultrafiltration with ceramic membranes

Cloudyjuice

Filtrate /permeate

RetentateFeed


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Fig. 42 Spun-dried apple retentate at the end

of filtration

42


Filtrationofcoloredjuices

GEA Westfalia Separator also uses the sameceramic filtermembrane employed for applejuice forfilteringcolored juices.However, thefundamentallycomplexfiltrationpropertiesofcoloredjuicessuchaselderberryjuice,meanthatoutputisreduced.Theceramicmembranehaskey

advantagesfromthechoiceofmaterialtostartwith.Itisunabletoadsorbcoloringconstituents,asthematerialiscompletelyinert.Ontheotherhand,itsporesizeismuchsmallerthanthatofapolymermembrane,sothatparticlescanonlypenetrate thepore opening to a very limitedextent.Thismeansthatformationofacoatingonthesurfaceisreduced,achievingamuchhigherspecificfluxperunitsurfacearea.

Theuseoffiningagentssuchasactivatedcarbonandbentoniteislikewisepossible.Lineparameters

anddispensingquantitiesofthefiningagentsshouldbetakenintoaccounthere.

Fig.43showsafiltrationlineforprocessingapplejuiceandcoloredjuices.Theoutputwithapplejuiceis10,000l/h.Afurthercharacteristicoftheceramicmembraneisthatfiltrationperformanceisstablethroughoutthefiltrationcycleandonlydecreasesslightlytowardstheendoffiltration.

Combiningfiltrationequipmentwithcentrifuges

Combination with centrifugal separationtechnologyallowsproductlossestobeminimized.Aseparatorordecanterisoperatedinaby-passcircuittofiltration.Thismachineseparatesspun-

driedsolidsandthusslowsdownconcentrationofsolidsintheretentate.Thistopicisdiscussedin more detail in Section 4.3Concentratingretentate.However,inthisconnectionitshouldalsobepointedoutthattheindividualcombinationoffilterandcentrifugedependsontheoverallconfigurationoftheprocessingline.

Fig. 43 Ceramic membrane filter elements


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9.5 Line and control system better from a single sourceThetwoindispensableelementsforsolvingaprocesstechnologytaskarethelineanditscontrolsystem.Onlybymatchingtheseindividuallyandbringingthemtogethercantheybecombinedtoformameaningfulunitandthusmakeanefficientprocesstechnologyline.

Aswellasindividualmachines,GEAWestfaliaSeparatoralsoautomatescompleteprocesslineswithextensiveperipherals.

Avarietyofcomponentsisusedwhichcanbeflexiblydesignedtosuitcustomerrequirements.

Ourautomationdepartmentthenhasthetaskofworkingout the idealautomationsolutionfrom

process,machine,driveandcontroltechnology.Themorecomplexaline,thegreaterthedemandsplacedonautomation.


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10. Summary

Separationofsolidandliquidphaseshasplayedapivotalroleintheproductionoffruitandvegetablejuices.MechanicalseparationtechnologyfromGEAWestfaliaSeparatorsupportsallprocessesandmethods.Highly-purepremiumjuicesaremanufactured as reliably as natural cloudyvegetable juices , trend products made fromsuperfruitsordesignerjuicesfromsecondaryplantmetabolites.Processmanagementcanbeflexiblyadjustedtosuittheproductrequired.

TheGEAWestfaliaSeparator frupexprocessrepresentsanimportantstepforward.Fordecades,juicewasclarifiedexclusivelyaftertraditionalpressing of the different types of fruit. GEAWestfaliaSeparator frupexhasnowrenderedtheconventionalpressingmethod,withitsmanydisadvantages,redundant.Forthefirsttime,theprocessallowsdecantersandseparatorstobeusedinacompleteprocessingline.Continuousprocessmanagementisadaptedonanindividualbasistocovereverystep,fromjuicingthemashto

clarifyingtheretentate.Besidesincreasingyield,thekeybenefitsoftheprocessareitsreliability,flexibilityand productionofpremiumqualityproduct.FruitishandledmuchmoregentlywithGEAWestfaliaSeparatorfrupexthanispossiblewith conventional press methods. The fruitsvaluableconstituentsarelargelyretained.

Inordertobeabletoremoveparticles


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Highyieldsofhigh-qualityvegetablejuicescanbe obtained under hygienic conditions. Thegentle processingmethod maintains valuableconstituents and thus supports a health-givingeffect.

In addition to obtaining juice, mechanicalseparation technology from GEA WestfaliaSeparatorisalsousedtoprocesssecondaryqualityproductsanddealwithwastewatertreatment.

The advantages are recovery of high-qualityconstituentsandreduceddisposalcosts.

Theproductrangealsoincludescomponentssuchas hydrocyclones androtary brushstrainers,puttingGEAWestfaliaSeparatorinapositiontosupply completeprocess lineswith all thenecessaryelements.

To give juice producers additional flexibility,mechanicalseparationtechnologycanbeinstalledonmobilesystems.Themobilecontainerscanbe

useddirectlywherethefruitorvegetablesareharvested,avoidinglongdistancesandhighcostsfortransport.

A summary of the benetsHighthroughputandhighefficiencyOptimumhygieneFlexibleprocessmanagementRapidjuicingandlowoxygenpickupReliabledischargeofsolidsofdramaticallyvaryingconsistencyGentleextractionofcomponentsOptimumseparationeffect,evenwhenfeedoutputfluctuates

ImprovedsensoryqualityofproductMuchhighercoloryieldSimpletooperateLowmaintenanceandoperatingcostsLowwaterandenergyconsumptionMinimaldisposalcosts


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Frucht-undGemsesftenherausgegeben

vonAIJN(AssociationoftheIndustryofJuices

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theEuropeanEconomicCommunity),

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AromavernderunginApfelmaische

nachderZerkleinerungderFrucht,

ZentrumfrGetrnketechnologieund

Aromaanalytik,Wdenswil-Schweiz,2008

3 Beveridge,T.:Decantingcentrifugeapplication

infruitjuiceprocessing,FruitProcessing12/1994

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beimKeltern/DefinitionundBestimmung, ConfructaStudien1988

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StandderHerstellungvonGemsesften

und-trunken,FlssigesObst,56,751764,1989

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Vol.A4,3575;Hrsg.:GerhartzW.etal.,

VerlagChemieWeinheim

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Aromaqualitt,FlssigesObst,Jahrgang59,

Heft12/1992

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FlssigzuckerausDatteln,Zucker,

30,11,612619,1977

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Trenntechnik,FlssigesObst,10, 512514, 2008

11 Flocke,R.,Pecoroni,S.:

Fruchtsaft-undFruchtpreeherstellungmit

demDekanter,FlssigesObst6/2008,

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Retentataufbereitungmittelszentrifugaler

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Seite512514

13 ForschungskreisderErnhrungsindustriee.V.

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nachernhrungsphysiologischenKriterien

zurSteigerungderQualittvonSften,

KonzentratenundExtrakten,AiF-FV13431BG,

Kurzbericht,200514 Franke,W.:NutzpflanzenkundeNutzbare

GewchsedergemigtenBreiten,

SubtropenundTropen,Stuttgart:Thieme,2007

ISBN9783135304076

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De-juicingofvegetablemashesbymeansof

decanter,FruitProcessing8/1993

16 Hamatschek,J.,Pecoroni,S.,Gnnewig,W.:

Productionofberry,grapeandstonefruit

juicesbyuseofmoderndecantertechnology,

FruitProcessing,5/199517 Hamatschek,J.,Pecoroni,S.,FeuerpeilH.-P.:

Centrifugesincombinationwithcross-flow

filtrationsystemsHybridsolutionsforan

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FruitProcessing6/2006,Seite397400

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Applicationofdecantersfortheproductionof

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Seite298301

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ObstWarenkunde,WeilderStadt,2002 (ISBN3775003010

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-sftenausFruchtfleisch,FlssigesObst,57,

8084,1990

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vonFruchtmarkund/oder

Fruchtmarkkonzentrat,FlssigesObst,

57,338340,1990

22 NagyS.,ShawP.,Wardowski,W.:

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Composition,PropertiesandusesLakeAlfred:

FloridasciencesourceInc.,1990

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FruitJuiceProcessingTechnology

Auburndale:AGSCIENCEInc.;1993

ISBN0963139711

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Authorsofthistechnical/scientific

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Dr.StefanPecoroni

RdigerFlocke

WolfgangGnnewig

IngoSchmitt

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desKlrprozessesvonWein,FruchtsaftundBier,

SeparatorsDigest,01/2006

25 Pecoroni,S.,FlockeR.:

DerEinsatzzentrifugalerTrenntechnikzur

ExtraktionvonSekundrinhaltsstoffenaus

ObstundGemse,FlssigesObst7/2005,

Seite34534826 Pecoroni,S.,FlockeR.,HamatschekJ.:

ErgiebigeAusbeuteZentrifugaleTrenntechnik

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Lebensmitteltechnik12/2006,Seite4041

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ErkenntnisseberdieStabilisierungund

analytischeBeurteilungnaturtrber

Apfelsfte,VortragGdCH-Seminar658/94,

Holzminden1994

28 Pecoroni,S.,Gierschner,K.:Trbe

FruchtsfteundfruchtsafthaltigeGetrnkemit schwebestabilenTrubstoffenEinige

GrundlagenzurHerstellungstechnikeines

immerbedeutenderwerdenden

MarktsegmentesderakoholfreienGetrnke,

Getrnkeindustrie4710,1993,Seite788798

29 Schobinger,U.etal.:Frucht-undGemsesfte,

VerlagEugenUlmer,Stuttgart,2001

( ISBN3800158213

30 Sthle-Hamatschek,S.,Gierschner,K.:

TrubzusammensetzungundihrEinflussauf

dieTrbungsstabilittinnaturtrben

Apfelsften,FlssigesObst,Jahrgang56,

9,543557/198931 Stocker,F.:Mischen,Homogenisieren,

EntgasenvonFrchte-undGemsepulpen,

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32 Teubner,C.(Hrsg.):

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33 Zimmer,E.,Pecoroni,S.,Dietrich,H.,

Gierschner,K.:Verfahrenstechnischeund

chemischeGrundlagenderHerstellung

vontrbemApfelsaftunterbesonderer

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naturtrberApfelsfteunterEinbeziehung

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Obst-undGemseverwertung,7911,

405412; 12,426434


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frupex,varipond,hydry,

andhyvolareregisteredtrademarksofGEAWestfaliaSeparatorGmbH.

GEA Mechanical Equipment US, Inc.

GEA Westfalia Separator Division

Headquarters:

100 Fairway Court

Northvale, NJ 07647

201-767-3900

Midwest:

1707 N. Randall Road, Suite 355Elgin, IL 60123

630-503-4700

South:

4725 Lakeland Commerce Parkway, Suite 4

West Coast:

Western Region Customer Support Center

555 Baldwin Road

Patterson, CA 95363

209-895-6300

GEA Mechanical Equipment Canada, Inc.

GEA Westfalia Separator Canada Division

835 Harrington Court

B li t ON L7N 3P3

GEA Group is a global 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.

We live our values.

Excellence Passion Integrity Responsibility GEA-versity

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