GEA Mechanical Equipment

Jan Bunk Market Development Engineer

Westfalia Separator proplusMore milk protein for higher yield

GEA Mechanical Equipment

Historical development of dairy centrifuges

2 BL Dairy Technology

4,3 % Cream

3,5% Protein

4,7% Lactose

86,7% Water

0,8% NMS

The developments of the past were focused on skimming efficiency

Skim

Milk

Cream

Non-Milk-Solids

new focus

Light phase

Heavy phase

Solids

GEA Mechanical Equipment

The innovative approach of this project

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The new development is focused on the reduction of protein losses

3,5% Protein

0,8% NMS

Standard

The reduction ofProtein losses

creates additionalprofits

GEA Mechanical Equipment

Milk solids

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GEA Mechanical Equipment

New approach: Reduction of losses and ressources

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GEA Mechanical Equipment

Milestones

Ecocream Separator

Standardwith proplus

Increased protein yield by up to

75%reduction of

ejected solids!

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Capacity minimum 3.000 l/hRated 10.000 l/h

GEA Mechanical Equipment

Solid Wall vs. Self-cleaning

self-cleaning bowlsince 1968

solid wall bowl= take down machine

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GEA Mechanical Equipment

Ejected Solids

Take Down Self Cleaningprocess batch wise continuouscleaning manually periodically + CIPoperation 8 – 10 h > 20 hcapacity up to 20.000 l/h 60.000 l/hefficiency decreasing constantejected solids 0,010% 0,040%non-milk - 0,005% - 0,005%losses = 0,005% = 0,035%

typical values

proplus

0,013%- 0,005%= 0,008%

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GEA Mechanical Equipment

Flow in Skimming Bowl

whole milkcreamskim milk

solids

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GEA Mechanical Equipment

Flow in Skimming Bowl with proplus

whole milkcreamskim milk

solids

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GEA Mechanical Equipment

Flow in Bacteria Removing Separator Bowl

raw milk

recirc. conc.clarif. milk

solids

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GEA Mechanical Equipment

Flow in Bacteria Removing Separator Bowl with proplus

raw milk

recirc. conc.clarif. milk

solids

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GEA Mechanical Equipment

Technical solution

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•Modified Solid holding space

•Modified disks

•Modified separation disk

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GEA Mechanical Equipment

Difference between Standard & proplus Sludge

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GEA Mechanical Equipment

The operation ofdediciated thermal treatment unit for

the sludge isnecessary

w/o proplus w proplus

A dediciated thermal treatment unit forthe sludge is not

required

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Difference between standard & proplus

GEA Mechanical EquipmentBL Dairy Technology16

Conclusion

GEA Mechanical Equipment

Calculation Example ecocream Separator

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basic data:average capacity 10 000 l/hproduction time 8 hours/dayproduction time 340 days/yearcapacity 27 200 m³/yearcapacity 80 m³/day

partial ejection intervals (dependent on milk quality)Normal Separator 25 minutes (15-30 minutes)PROPLUS 60 minutes (30-90 minutes)ejection volume 10 kgwater consumption 25 l/ejection

Normal SeparatorProduct losses 65 280 kg/yearfresh water consumption 163 200 kg/year

PROPLUS:Product losses 27 200 kg/yearfresh water consumption 68 000 kg/year

GEA Mechanical Equipment

Calculation Example ecocream Separator

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POSSIBLE SAVINGS PROPLUSproduct (raw milk) 38 080 kg/yearraw milk price 4.000 ZAR/kg please check dataproduct savings 152 320 ZAR/yearfresh water and waste water 95 200 kg/yearfresh water 3.00 ZAR/m³ please check datawaste water treatment 3.00 ZAR/m³ please check datawater savings 685 ZAR/yearTOTAL savings & additional profit 153 005 ZAR/year

ROI PROPLUSInvestment ZARadditional profit / year 153 005 ZARROI - years