WELCOME. Trends & technological innovations changing the face of food & beverage processing. GEA Africa (Pty) Ltd 26 October 2017 JACO COETZEE

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1 WELCOME Trends & technological innovations changing the face of food & beverage processing GEA Africa (Pty) Ltd 26 October 2017 JACO COETZEE

2 Order intake (EUR) 4,674 million Employees (FTEs) 16,937 Operating EBITDA (EUR) 566 million Operating EBITDA margin 12.6% Revenue (EUR) 4,491 million GEA engineering for a better world GEA is one of the largest suppliers of process technology for the food industry and a wide range of other industries. The international technology group focuses on process technology and components for sophisticated production processes in various end-user markets. The company is listed on the German MDAX stock index and included in the STOXX Europe 600 Index. In addition, the company is listed in selected MSCI Global Sustainability Indices. Earnings per share (EUR) 1.48 GEA at a Glance 2

3 GEA Africa (Pty) Ltd Tunisia Morocco Western Sahara Algeria Lybia Egypt Senegal Mauritania Mali Burkina Guinea Bissau Guinea Benin Ghana Sierra Leone Cote d'ivoire Liberia R & C: 272 FTE Togo Equatorial Guinea BA-S_APC Uilities: 22 FTE BA-S_APC Cross: 9 FTE BA-S_SER: 1 FTE GCC-FIN: 22 FTE GCC-HR: 3 FTE Total in Cluster: 329 FTE Niger Nigeria Cameroon Gabon DRC Chad Angola Namibia Central African Republic Congo Botswana Northern Sudan South Sudan Zambia Zimbabwe Uganda Rwanda Burundi Tanzania Malawi Kenya Mozambique Eritrea 130 FTE Ethiopia Djibouti Somalia 11 FTE Madagascar South Africa 110 FTE Source: GEA LIFE GEA Africa (Pty) Ltd 3

4 Our applications in touch with GEA every day Dairy Farming and Processing Approx. one quarter of processed milk comes from GEA production systems Every fourth liter of human blood is handled by GEA equipment Pharma Food Every third chicken nugget is produced by GEA technology Around every third process line for instant coffee was installed by GEA More than one third of all polymer producer are using GEA Drying technology Each industry we serve utilizes GEA s industrial refrigeration technologies Chemical Utilities Beverages Approx. every second liter of beer is brewed with the aid of systems and process solutions from GEA Every second container ship in the world sails with GEA marine equipment on board Marine GEA at a Glance 4

5 Our ambition be your no. 1 choice We strive to be the world s leading global technology group in supplying smart solutions for sophisticated process industries. Our goal is to be the customer s preferred partner in the industries we serve. GEA at a Glance 5

6 Megatrends understanding and taking advantage of opportunities URBANIZATION WITH GROWING MIDDLE CLASS Growing demand for processed food and medication GREATER FOOD SAFETY AND QUALITY Readiness of industry to invest more for greater process reliability ENERGY SCARCITY AND STRICTER ENVIRONMENTAL REGULATIONS Greater interest in efficient and resource-saving production processes GEA offers components and process technology for processed food, ready meals, fortified lifestyle beverages and food, medications GEA offers certified hygienic/aseptic processes and components to meet the strict standards of the industry GEA offers intelligent engineering processes for resource-economical technologies, energy-saving machines and processes, as well as heat recovery GEA at a Glance 6

7 Groundbreaking innovations recent examples Dairy Farming Food Beverage GEA prolong multiple use means cost benefit GEA ColdSteam ColdSteam Defroster GEA Sugar Clarification Alternative sugar clarification process High heating of milk leads to a more or less significant loss of organoleptic and nutritional quality of the milk Elimination of undesirable constituents like dirt, blood, somatic cells, bacteria and spores A controlled process for fast thawing of meat by means of low pressure steam and indirect heating in order to reduce defrosting time and improve hygiene, logistics, shelf life and increase yield in consumer prod. GEA has been researching alternatives to state of the art clarification GEA at a Glance 7

8 GEA prolong multiple use means cost benefit

9 Bacteria removal Some microorganisms are forming heat resistant spores that can survive higher heating processes than other microorganisms. Thus the use of Bacteria Removing Separators is necessary especially for products that require low heat processes such as some cheese milks. The mechanical separation of spores and somatic cells is based on the different densities: whole milk 1,011 g/ml skim milk 1,016 g/ml vegetative bacteria cells 1,070 g/ml 1,115 g/ml aerobic spores 1,130 g/ml anaerobic spores 1,132 g/ml Bacteria removing can be done in skim milk, standardised or whole milk and in skim whey. 9

10 Advantages of bacteria removal vs. heat treatment Heat destroys bacteria cells but not spores when cell wall breaks enzymes, inhibitors and spores come into product Cells remain in product Still negative influence on product, reinfection possible! inhibitors spore enzymes Separators remove cells and spores no reinfection enzymes and inhibitors are removed with the cells no flavor or vitamin losses 10

11 ESL-Milk and UHT-Milk High heating of milk leads to a more or less significant loss of organoleptic and nutritional quality of the milk like: Cooking flavour (in connection with serum protein denaturation) Loss of vitamins (thiamine B 1 / riboflavin B 2 ) Colour change because of Maillard reaction (browning) Reduction of nutritional usability of the essential amino acid lysine 11

12 Bacteria Removal Clarifiers Elimination of undesirable constituents like dirt, blood, somatic cells, bacteria and spores! Bacteria removal clarifiers are used for the clarification of cheese milk since 1970 GEA offers bacteria removal clarifiers from l/h l/h. Ecoclear CSE 140 CSI

13 Safe and gentle double bacteria removal with GEA prolong Inflow first bacteria removing separator Raw milk contains bacteria and spores (even heat resistant ones) which have to be removed with respect to the shelf life of milk. Inflow second bacteria removing separator During the first stage of bacterial removal a reduction of the total bacteria count of about 90 percent and of Bacillus cereus of about 80 percent is achieved. Recirculation for renewed bacteria removal Recirculation for renewed bacteria removal All-in-all a reduction of the total bacteria count as well as removal of Bacillus Cereus by about 99 percent is achieved. The minimum storage life of fresh milk is prolonged to a minimum of 21 days. First bacteria removing stage Second bacteria removing stage 13

14 GEA prolong Efficiency Germ count Germ gram negative Spores High efficiency of the Reduction bacterial clarifiers Reduction from GEA Reduction Reduction Reduction (overall) Entero- bacteria Pseudo- Bacillus Cereus Monades Bacterial Removal Clarifier I 96.9 % 99.6 % 99.2 % 99.7 % 80.0 % Bacterial Removal Clarifier II 99.5 % 99.9 % 99.8 % 99.9 % > 99.0 % Conclusion: If there is a need for the most efficient bacteria removal two bacterial clarifiers have to be installed. 14

15 GEA prolong Shelf Life GEA prolong pasteurised drinking milk ESL Milk MF ESL Milk directly heated ESL Milk indirectly heated days 15

16 GEA prolong Advantages Proof of heat treatment heated indirect heated direct micro filtrated milk prolong milk pasteurized milk whole milk whole milk pasteurized milk prolong milk micro filtrated milk heated direct heated indirect ß-Lactoglobulin (mg/kg) As an amino acid, ß-lactoglobulin has an essential nutritional significance. For vitamin A and selenium it is an important transport protein. 16

17 GEA prolong Advantages Proof of heat treatment heated indirect heated direct micro filtrated milk prolong milk pasteurized milk wohle milk wohle milk pasteurized milk prolong milk micro filtrated milk heated direct heated indirect Lactulose (mg/kg) A high lactulose value due to the heat treatment of the milk has a negative influence on the sensory acceptance. Higher contents in lactulose cooks taste is possible. 17

18 Benefits of GEA prolong Essential nutrients and vitamins remain in the product No organoleptic or nutritional impairment of quality due to additional heating Gentle treatment maintains the authentic fresh milk flavour Clearly extended shelf life of natural fresh milk Multiple use of double bacteria removing separation Easy integration into existing plants Lower operating costs 18

19 GEA DEFROSTING with ColdSteam T 19

20 Defrosting/tempering solutions in the market Defrosting in open vats with running water Long defrosting time Loss of meat juice (yield loss) Food safety issues Drain / sewer issues Defrosting cabinets with hot air fans Long defrosting time Loss of meat juice (yield loss) Uneven defrosting temperatures Low guarantee of food safety Microwave tunnels with radio frequency waves Only suitable for tempering (max C) Difficult to defrost uniformly (above +0.0 C) - product heat spots High cost of ownership and maintenance 20

21 Considerations we make every day: Fresh ColdSteam Frozen Time (quick) Space Production planning Price Availability Flexible Easy logistics Low space Frozen Rates No protein loss (drip) Natural quality Price Shelf life Logistics still a contradiction? 21

22 ColdSteam T A controlled process for fast thawing of meat by means of low pressure steam and indirect heating in order to reduce defrosting time and improve hygiene, logistics, shelf life and increase yield in consumer products

23 Let s bring you back to reality again 23

24 Examples on overall process gain Product Process Yield % 125% 120% 115% 110% 105% Earnings Taste Quality 100% 95% ColdSteam Note: 90% Frozen Thaw Drip Injection Curing Filling Cook and Chill Traditional An improve yield will be expected, as protein will be kept in the meat, during the ColdSteam process. This will improve the water holding capacity! (proteins can hold 3.3 times their own weight) 24

25 Defrosting of beef products Product: Beef Cuts Process time: 8 hours Added steam: 5 % Product: Beef Knuckles & Topside Process time: 8 hours Added steam: 3 % 25

26 Defrosting of chicken products Product: Chicken Wings Process time: 5 hours Added steam: 5 % Product: Chicken Breast Process time: 5 hours Added steam: 5 % Product: Whole Chicken Process time: 6 hours Added steam: 3 % 26

27 Benefits to remember Increased capacity compared to conventional defrosting techniques Gentle defrosting technology with elimination of purge (no drip loss) Substantial reduction of manual handling. Limiting the Human Factor Verified food safety by TNO (Institute of Applied Scientific Research) Small blueprint Short, automatically controlled process High food safety and traceability Low cost of ownership (no yield loss, low operating costs) High end product quality (bacteria killing process) 27

28 28 Non-alcoholic beverages processing GEA Sugar Clarification

29 Sugar clarification - general Sugar clarification for non-eu projects EU sugar clarity regulated by Council Directive 2001/111/EC Sugar clarification is planned for non-eu projects no regulation Costumers require colourless and odourless sugar (<35 ICUMSA Units)(International Commission for Uniform Methods of Sugar Analysis Ltd) Possible processes Ion-exchanger Membrane filtration/separator Refined sugar sugar appr. 100 ICUMSA Activated Carbon (AC) with Kieselguhr as filter aid Activated Carbon (AC) without Kieselguhr GEA DI SUGAR CLEAR sugar appr ICUMSA 29

30 Alternative sugar clarification process GEA has been researching alternatives to state of the art clarification Analysis of sugar and AC to optimize the use of AC Method of clarification without activated carbon and kieselgur Separator and microfiltration clarification achievable, high CAPEX (separator and filtration) high OPEX (electrical consumption) Method of clarification without kieselgur (preferred) Special filter solution Very good clarification Moderate CAPEX Low OPEX 30

31 Sugar clarification Proven Technologies AC Filter 2 AC press AC Filter 1 31

32 Sugar clarification Benefits of new development Analysis of Sugar and AC Optimization of AC usage depending on sugar impurities No Diatomaceous earth Save OPEX Less handling Activated carbon can be re-used partly Re-dosing with fresh AC Processed for other uses (palletisation heat generation) 32

33 Sugar clarification Why GEA? GEA offers a solution to clarify sugar with the lowest running costs. No other system on the market from other suppliers are able to follow. Combining proven technologies OPEX saving of EURO/year NET Basis of the calculation: 13 t/h, 24 hours/day, 5 days/week, 50 weeks/year 63 brix, appr. 0,2% adding of Kieselguhr+pre-coating Saving: appr. 2,56 Euro/tonne clarified sugar 33

34 Sugar clarification Why GEA? Very high heat recovery, more than 80% Almost no product losses Highest usage of syrup due high accuracy of Brix Environmental friendly: less waste, CO2 savings Excellent cleaning, hygienic design according EHEDG Low usage of activated Carbon, can be used more times Low maintenance and operation costs Long running time between cleaning of filters (depends on sugar quality) Optional Activated Carbon press and dryer for optimum usage of sugar Independent cleaning of filter during production: 24/7 34

35 gea.com