SECAGEM E RESFRIAMENTO DE ALIMENTOS
EXTRUSADOS E PELETIZADOS
II CONGRESSO CBNA SOBRETECNOLOGIA DA PRODUÇÃO DE ALIMENTOS PARA ANIMAIS
CENTRO DE EVENTOS EXCELLENCE - MARINGÁ - PR
4 de setembro de 2013 – quarta-feira
Diego Clivio – GEELEN COUNTERFLOW
Agenda:
1) Short Company Introduction
2) Short Speaker Introduction
3) Feeds Pellets - Cooling process
4) Petfood & Aquafeed – Drying & Cooling
a) Moisture Uniformity
b) Energy Efficiency
c) Sanitation Degree
Agenda:
1) Short Company Introduction
2) Short Speaker Introduction
3) Feeds Pellets - Cooling process
4) Petfood & Aquafeed – Drying & Cooling
a) Moisture Uniformity
b) Energy Efficiency
c) Sanitation Degree
• Exclusively engineering, building and servicing of counterflow dryers and coolers, since 1980
• Sales 2012 : +/- € 24 millon
– 50% dryer, 50% coolers
– 95% export, > 50% out of Europe
• Sales and Service offices in USA, China and Argentina
• Full time employees: +/- 85
• +/- 400 new dryers/coolers per year
• > 7500 references worldwide
Geelen Counterflow
Aquafeed &
Petfood
Feeds
• Higher flexibility.
• Production on order.
• New plate material production and handling machines.
• > € 1.000.000,= investments.
Agenda:
1) Short Company Introduction
2) Short Speaker Introduction
3) Feeds Pellets - Cooling process
4) Petfood & Aquafeed – Drying & Cooling
a) Moisture Uniformity
b) Energy Efficiency
c) Sanitation Degree
•1989 – 1996, Foods & Industrial Engineer career.
•1994 – 1999, mechanical and electrical installations in several industries. Industrial automations.
•1999 – 2006, worked for Molino Chacabuco – Argentina, technical area, producing feed pellets and petfood –Experience using horizontal and vertical dryers.
•2006 – present, Geelen Counterflow Latin America Sales Manager
Diego Clivio – Industrial Engineer
Agenda:
1) Short Company Introduction
2) Short Speaker Introduction
3) Feeds Pellets - Cooling process
4) Petfood & Aquafeed – Drying & Cooling
a) Moisture Uniformity
b) Energy Efficiency
c) Sanitation Degree
• Avoid product deterioration due to high temperature
• Avoid condensation on product storage silos
• Avoid condensations on final product bags
• Condensation means free water => Higher Water
Activity (Aw)
Why do we need to cool feeds?
• Invented in 1978 for
animal feed industry
• Now almost standard in
fish feed and petfood
industry
• Low air volume levels
• Little maintenance
• Clean operation
Geelen Counterflow Cooler
• Filling with product
Principle of counterflow cooling
• Start product flow
• Discharging
• Reaching level
Principle of counterflow cooling
• Discharging after pre-set time
• End of production run:• start total emptying
• Deck 100% open in order to clean out
• Fire protection
– Thermostate/PT100
– Fire valve
Safeties in counterflow cooler
• Overfilling cooler protection– Overflow sensor cooler
• Door switch– Disconnect all power
• Overflilling hopper protection– Overflow sensor hopper
• Air Volume
– Product Temperature
– Evaporation
– % Coating / Specific Heat of product
• Air Speed in Cooler
– Product Size & Density
• Retention Time
– Product Diameter
Cooler Sizing, depends on:
Watch the
animation
•Swivel valve discharge cooler
Agenda:
1) Short Company Introduction
2) Short Speaker Introduction
3) Feeds Pellets - Cooling process
4) Petfood & Aquafeed – Drying & Cooling
a) Moisture Uniformity
b) Energy Efficiency
c) Sanitation Degree
• Avoid product deterioration due to high Water
Activity, need to keep Water Activity below 0,62
Why do we need to dry extruded
feeds (Petfood-Aquafeed)?
Moisture uniformityInfluenced by:
Product dimensions
Pellet ingredients
Retention time
Drying air temperature
Moisture % in and out
Dryer type
Uniformity air temperature
Uniformity air volume
Uniformity product layer
Uniformity % product in
Air temperature control
Air volume control
Retention time control
% Inside pellet
Sample to sample
Samples in time
Pellet to pellet
Moisture control system
Extruder
coater
Dryer
Cooler
moisture %
Dryer control Target %
dryer
Target %
End productmoisture %
Capacity+moisture
Meal
Water
Steam
Fat
Water
zone 2
zone 1
etc
• NIR (Near Infrared)
(off- and online)
• Loss in weight system
(offline)
• Micro wave
(off- and online)
Moisture measuring systems
Applications
Sensorhead:
Temperature up to
140°C
Example
(Max-min)/2 = 0,47
6. Moisture uniformity over time
Setpoint `
Setpoint
Time
Moisture
Max.moisture
•Worst case results in moisture uniformity over time……..
•……determine setpoint, to avoid excessive moisture……..
•…….if moisture uniformity over time can be improved….
•….…we can move the setpoint closer to target.
Agenda:
1) Short Company Introduction
2) Short Speaker Introduction
3) Feeds Pellets - Cooling process
4) Petfood & Aquafeed – Drying & Cooling
a) Moisture Uniformity
b) Energy Efficiency
c) Sanitation Degree
Definition Dryer Efficiency
Efficiency of a dryer is being defined as “the
amount of energy in kJ that has to be added
in order to evaporate 1 kg of water”.
Goal Dryer Efficiency
Calculation for 1 kg water:
T product into dryer : 85 oC
Specific heat water : 4,2 kJ/kg/oC
Energy to heat up to 100 oC : 4,2*1*15=63 kJ
Energy to evaporation : 2260 kJ
Total (2260 + 63kJ) : 2323 kJ
Goal: 2300 – 2700 kJ/kg water
Efficiency measuring systems
Two ways to measure energy efficiency:
1. Measure gas or steam consumption
2. Measure product and air parameters
1. Measure gas consumption
Install gasmeter (1 per heater)
Measure not only gas consumption but also
capacity, moisture into the dryer and moisture out
of the dryer to define kJ/kg evaporated water
2. Measure product and air data
Measure all product and air data:
• Data product entering the dryer
• Data product leaving the dryer
• Data air entering the dryer
• Data air leaving the dryer
Remark: please ask Geelen to assist while doing these measurements
Measurements
See dryer as black box.
Energy consumption dryer =
(energy product out – energy product in)
+ (energy air out - energy air in)
+ energy radiation
Measurements
Measure data product entering the dryer
• Capacity; in general recorded by extruder: dry meal + added steam + added water (in conditioner + extruder)
• Or capacitiy: measure 1 minute output of extruder
Measure data product entering the dryer
• Moisture after extruder (incl. flash off)
• Or Moisture into dryer (excl. flash off)
• Be sure that during sampling, storage and grinding no moisture disappears!
Measure data product entering the dryer
• Measure by continuously moving the temperature sensor
Measure data product leaving the dryer
• Be sure that during sampling, storage and grinding no moisture disappears
Measure data product leaving the dryer
• Measure by continuously moving the temperature sensor
Measure data air entering the dryer
• Measure dry bulb temperature and RH (Relative Humidity)
• Or measure dry bulb AND wet bulb temperature
Measure data air leaving the dryer
• Measure air speed with pitot tube or anemometer
• Or measure airvolume by measuring the power consumption of the motor of the fan
Measure data air leaving the dryer
• Measure dry bulb temperature and RH
• Or measure dry bulb AND wet bulb temperature
Measurements
Online efficiency indicator
• Geelen introduced the online energy efficiency indicator to give the operator an indication how much energy is being used.
• Based on real time energy calculation, performed by the PLC.
• Geelen won the “VICTAM GOLD Award” for this improvement.
How improve energy efficiency?
• For bigger pellets: increase retention time
• Decrease heater temperature in first drying zone
• Decrease heater temperature in last drying zone
• Re-use cooling air
Energy efficiency
Vertical dryer more efficient because of :
• Internal recirculation
• Less open area’s where hot air passes
• The driest product comes in contact with the
driest air
• Use of energy in cooling air improves
efficiency
Conclusion
• Typical energy consumption for belt dryers is
between 3000 and 4500 kJ/kg evaporated
H2O due to higher exhaust air volumes and
higher exhaust temperatures.
• If cooler air is used as make-up air for the
dryer, energy consumption of a counterflow
dryer is below 2700 kJ/kg H2O
Agenda:
1) Short Company Introduction
2) Short Speaker Introduction
3) Feeds Pellets - Cooling process
4) Petfood & Aquafeed – Drying & Cooling
a) Moisture Uniformity
b) Energy Efficiency
c) Sanitation Degree
Food Safety – Why?
Easy to clean, inspect and repair without entering the equipment
Minimize penetrations, moving parts, ledges, seams & dead spaces
Geelen Food Safety equipment design features & improvements
•Dryers
• Easy inspection & cleaning access
• Doors on each deck
• All product contact surfaces visible
• Spot cleaning with hose or air wand
• Gravity flow is self cleaning
Dryers
•Easy maintenance access
• Low amount of moving parts.
• Minimal need for confined space entry
• Clean-In-Place compatible.
• Quick startup/shutdown.
Coolers
• Under most Food Safety process analyses coolers are considered a high risk environment for microbial activity and require a higher level and frequency of cleaning/inspection.
• In addition to the features shown for dryers Geelen has recently developed the following Food Safety options for
coolers.
•Large access panel doors
Geelen Food Ssafety equipment design features & improvements
Coolers
•Large hopper access door
•Rounded hoods, exhaust & collection trough. Stainless steel flat bar structural
ribbing.
Coolers
•CIP nozzle configurations
•CIP delivery system
•Clean-In-Place, CIP
• Thermal – dry
• Thermal – wet
• Chemical
• Water – hot/cold
• Air
•Video
Geelen Food Safety Equipment Design Summary
• Geelen is ready to provide equipment features to meet the next generation of animal food process standards and regulations:
• Easy inspection and cleaning
• Exposed product contact surfaces.
• Minimization of process down time.
• Integration of Clean-In-Place systems.
•The benefit for our customers is :
• Lower risk of food safety related incidents
• Improved traceability & recall if/when an incident occurs.
• Lower net cost of incident response expenses and liabilities
• Enhancement of market perception as a “Trusted” brand.
•Food Grade Design
• Also the (aqua)feed and petfood industry has a growing awareness for hygiene and food safety.
• Geelen Counterflow dryers and coolers already have a major advantage in this field due to their principle, with few moving parts, gravity flow and easy access.
• By applying the knowledge gained with our new food design dryers to other industries, even further improvements are possible.
•Hygiene
• The cooling step is one of the most critical spots in yourproduction line for(re)contamination.
• Temperature and moisturelevels often are ideal forgrowing undesired organisms.
•Salmonella
•Food-Chain
•Audit
•Food Grade Design
•Food Grade Design
•Food Grade Design
•Food Grade Design
•Food Grade Design
• Alto Grau de Sanitização
• A melhor Eficiencia Energética
• Excelente Uniformidade da Umidade
• Baixa manutenção
• Automatismo
•Food Grade Design
Geelen Counterflow Dryingsolutions:
• Continuos dryers (video)
• Batch dryers (video)
• Sanitary Design Cooler (video)
• Dryers&Coolers decks (video)
Diego Clivio – GEELEN COUNTERFLOWE-mail: [email protected]: +549-236-441-8899Skype: diego.clivio