Engineering for a better world Product examples
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1 Engineering for a better world Product examples Düsseldorf, May, 2015 GEA Group Aktiengesellschaft
2 s made by GEA help industrial clients to launch new innovative products GEA Juice Freeze Concentration Continuous process to withdraw water by freezing instead of evaporation Impact on product quality Natural flavor can be preserved in the concentrate (e.g. juices, coffee, milk) s Better taste and aroma of end product justifying higher price Higher overall equipment efficiency due to less demanding cleaning in place (CIP) 2
3 s made by GEA help industrial clients to reduce total cost of ownership GEA Niro MSD Spray Dryer Size 4000: Up to 700 tonnes milk powder per day Use scale-up algorithm based on computational fluid dynamics (CFD) modelling and deep process know-how to design the world s largest milk powder plant Impact on costs Compact spray dryer chamber Simpler operation Lower energy cost Equivalent of ~300 truckloads of raw milk per day 1 Approximately 10% lower total cost of ownership (TCO) 1 based on assumption of 15,000 litres raw milk per truckload (4.4m litres of raw milk shall be processed to 700t milk powder) 3
4 Energy-efficient solutions made by GEA help industrial clients to reduce energy and water consumption GEA Heat Pump By coupling a refrigeration system and a heat pump cold and heat are provided efficiently at the same time Impact on production costs Lower energy and water costs Benefit for an industrial customer in numbers (real sample) >50% reduction in water usage >20% less electrical energy for cooling >50% reduction in gas usage 4
5 s made by GEA help industrial clients to minimize dehydration losses GEA HVF-series freezer Uniquely designed high-velocity air jets quickly reduce the outerlayer temperature of food and break the insulating boundary layer, thereby minimizing dehydration losses Value loss with conventional freezer Basic calculation: 25,000 kg of hamburgers per day 1.2% weight loss by freezing 300 kg x 3 /kg market value = 900 value loss per day Benefit of GEA HVF-servies freezer for industrial customer 50% reduction in weight loss Benefit of 135,000 per year Amortization after 1.7 years 5
6 s made by GEA help industrial clients to reduce energy consumption GEA ecoforce decanter Highest g-volume achieved by high rotating speeds and available bowl volume for clarification purposes Energy optimized design with less electrical components for energy recovery or belt drives, i.e. less circulating power Impact on costs Less installation space needed in comparison to former design principles by still maintaining clarification efficiency Lower energy costs provided by several design features and several options for upgrades and modifications during life-time Reduction in specific energy consumption by ecoforce decanters of up to 50%* Scalable design principle in modular design to optimize service handling, training and spare parts and upgrade logistics * in comparison to older series from same supplier 6
7 s made by GEA help industrial clients in environmental-friendly ballast water treatment GEA BallastMaster ultrav 250 Two-stage system combining a mechanical filtration system with subsequent disinfection by UV radiation Inactivation of microorganisms by UV-C and integrated ultrasonic cleaning to achieve the best UVT rate in the industry of around 45% Impact on environment Avoidance of carry-over of alien species, including bacteria, microbes, eggs and larvae into non-natural habitats, e.g. Chinese crab eggs in German waters No contamination of the environment by chemicals or other hazardous materials and residuals No additional initial costs for cleaning agents or fresh water and also avoiding additional storage area Closed system with low total cost of ownership by most efficient operation and avoidance of disposal costs for process effluents 7
8 s made by GEA help industrial clients to produce zero waste GEA clearamic beer filtration Ceramic membranes form the centerpiece of this cross-flow filtration The material is absolutely food neutral and can be regenerated during life time of about 10 years Impact on environment No need for filter aids such as kieselguhr No waste, no replacement during life time No waste. Pure taste Purest beer quality brewed in a way that is sustainable and reduces costs 8
9 s made by GEA help farmers to turn liquid manure into compost or green bedding GEA XTract and XPress The horizontal dewaterer Xtract can process in one minute ¾ to 1x the amount of daily manure produced by 1 cow The Xpress presses fiber so that it can be manageably piled and the percentage remaining in the fiber is well suitable for composting or green bedding Benefit for the farmer 9
10 s made by GEA help industrial clients to keep their products longer fresh GEA Westfalia Separator prolong Two bacteria removal separators are used in series during the fresh milk production process to separate bacteria up to 99.9% reliably The prolong separation process gives fresh milk an extended shelf life up to minimum three weeks Impact on environment and costs Energy savings by avoidance of high temperature treatment and preservation of the full flavor and original taste of a fresh product Positive effects in terms of consumer demands by maintaining cost saving potential in transportation and stock-keeping Better taste and aroma of extended fresh life (EFL) provide preconditions for trading up and hence higher margins Optimized utilization of assets by flexible operation in similar processes including further advantages, e.g. quality of cheese 10
11 s made by GEA help industrial clients to protect the ozone layer Compressors with natural refrigerants Our refrigeration components (e.g. compressors) are used in conjunction with natural refrigerants like ammonia and carbon dioxide as opposed to ozone destructive CFC or global warming effecting HFC refrigerants Impact on environment No contribution to the depletion of the ozone layer and no significant influence to the greenhouse effect Sustainable and environmentally friendly production 11
12 s made by GEA help industrial clients to minimize energy consumption Redesign of a screw compressor series GEA Grasso M Our screw compressor, designed for natural refrigerants, is the first one with pressure activated check valve for lowest pressure drop. Due to the optimized flow and the extended control range the energy consumption gets minimized. Impact on environment Lower energy consumption and therefore less CO2 emission No contribution to the depletion of the ozone layer and no significant influence to the greenhouse effect Energy savings 3-7% in full load Energy savings up to 15% in part load Less maintenance due to less mechanical parts Wider range of applications 12
13 Energy-efficient solutions made by GEA help industrial clients to minimize the total cost of ownership GEA Grasso BluGenium High efficient ammonia chiller optimized for full and part load operation with compact dimensions Impact on environment Minimum carbon footprint due to low power consumption of the GEA Grasso V reciprocating compressor Global warming potential of zero by using the natural refrigerant ammonia Minimum total cost of ownership due to Maximum energy-efficiency with an ESEER >9 (European Seasonal Energy Efficiency Ratio) Low maintenance costs by extended service intervals 13
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