Process Technology for the

Fruit Juice and

Primary Industries

Process Engineering

GEA TDS GmbH

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GEA TDS
is established on an interna-

GEA TDS possesses the necessary know-

tional level as a specialist for

how for the design and manufacture of

technically and economically

hygienic, aseptic and sterile plants for the

production of liquid products. For project

optimised process technology

engineering and customer service, GEA

in the treatment of milk

TDS offers international attendance and

products, food and juice.

short reaction times by local presence and,

of course, After-Sales-Service. Experienced
and competent expert teams deliver technical solutions tailored to the customer`s
needs.

Product programme for the fruit juice

and primary industries
Concentrate and juice processing
complete process lines
valves, pumps, components
plate heat exchangers
tubular heat exchangers
homogenisers
flash pasteurisers
deaeration technology for juice and water
mixing plants
CIP plants
automation

Fruit and vegetable processing

to juice and concentrate
complete process lines
heating of mashes
evaporation plants
aroma extraction
concentrate cooling
tank farm equipment
automation

Plate Heat Exchanger VARITHERM N40,

capacity 24 m3/h

STHT Plant (PHE) for cold aseptic filling,

capacity 24 m3/h

STHT Plant (THE) for fruit juice,

capacity 20 m3/h

Tubular Heat Exchanger VARITUBE P for

semi-finished concentrates, capacity 15 m3/h

Process Engineering
Are you planning a complete

From isometric drawings to pipe class

fruit juice plant or a new pro-

specifications, from detailed engineering

cessing room or an extension?

to project management, GEA TDS takes

charge of the projects on site, on the

Whether your project is a new

client's premises or in our technology

greenfield plant, conversion

centre. GEA TDS is now part of the

or modernisation of an exist-

international systems engineering sector

ing process plant, GEA TDS

engineers, with their complex

of the GEA Group. This provides access

to a variety of components and units
made by members of the group which

know-how, are there to back

can be integrated to create high-quality

you up with excellent service.

processing systems.
The use of modern CAE tools for detail
engineering is common throughout the
company.

For project planning and engineering

the main focus points are:
preliminary design
support in approval planning
preliminary planning and layouts
selection/dimensioning of process
equipment
production of tender documents
for process plants

Detailed engineering
layout planning and detailed

technical description of the processes

coordination/clarification of details

quality assurance and quality control

inventory taking on site

monitoring of time schedules

design of pipe layout and

cost control

instrumentation

supervision of construction and

arrangement of components

installation work

calculation of material requirements

commissioning of plant components

and technical specifications

supervision of commissioning

definition of interfaces

technical support for production

configuration and dimensioning of

process optimisation

instrumentation and control equipment

documentation

Assembly and After Sales

GEA TDS services also include

The GEA TDS After-Sales programme

the assembly of entire plants.

includes a permanent support service:

A comprehensive range of

taking care of service and maintenance

directly after hand-over of the plant.

services is available throughout

the entire service life of your

Customer support also includes

plants all designed to achieve

defined maintenance and individual

maximum productivity and

economic efficiency.

inspection agreements to ensure faultfree and reliable operation and to keep

your plants, running efficiently for
years.

Valves and Components

For product-oriented intermediate
buffering, storage and process management it is necessary to set up tank farms.
The GEA Tuchenhagen delivery programme includes the optimum process
technology and a wide range of well
proven components both for production
and CIP/SIP processes.

1. VARIVENT Mixproof Valves

2. STERICOM Double Seal Valves
3. Butterfly Valves
4. Shut-off Valves
5. VARIVENT Mixproof Bottom Valves
6. VARICOVER Product Recovery Systems

7. Piggable VARIVENT Mixproof Valves

8. VARINLINE Measurement
and Control Equipment
9. VARIPURE Static, Rotating
and Orbital Cleaners

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Mix-Processing
One of the key production

The raw materials are introduced to the

lines can take place in parallel with the

steps in the fruit juice and

valve node either individually or from

mixing process.

primary industry is product

a storage tank, depending upon the

customers requirements. The small

For product mixing using weighing

quantities that are prepared in advance

technology the individual component

the individual raw materials

(solids, flavourings, etc.) are similarly

lines, contrary to the GEA Varimass

are blended in exact propor-

introduced to the mixing node exactly

principle, are not integrated at a valve

in accordance with the recipe, as are the

node, but at one or more weighing

container materials from the container

tanks. In the weighing tanks the

station. A very high level of flexibility

individual components are weighed

is achieved by constructing the valve

one after another and conveyed to the

node using VARIVENT Mixproof

appropriate mixing tanks. In a variant

Valves that are secure against impact

of the mixing process, using weighing

Basic mixing takes place in batch mode,

loads. By means of this design, and by

technology, the mixing tanks are

i.e. a particular quantity of a certain

the valves integrated lifting actuators,

directly fitted with load cells.

product is manufactured. For exact

cleaning of the component and mixture

mixing. In the mixing process

tions with each other, and

mixed to form a marketable
product.

determination of the weight of the

individual components either scale

Intake bay

Raw material tank storage

balances or mass flow rate meters

M

Container Aromas

small
volumes

can be used as required in the fruit

small
volumes

juice industry today it is normally

mass flow rate meters that are used.

Distribution

Product mixing using scale balances

is normally used in mixing processes

Drum flipping

where there are many components and

Valve block
Water

the quantities involved are small.

Mixing tanks

GEA TDS offers the ideal equipment

Water
Pasteurisation

rate meters in the form of the GEA

integrated at a valve node using a vary-

Homogenizer
Water

Varimass System. With the Varimass

System the various components are

MDM

for product mixing using mass flow

Valve block

Filling
Two component
mixer

Filter

ing number of mixing lines, according

to their mixing duty. Their quantities
are registered by means of mass flow
rate meters.

Principle flow scheme of a continuous mix-processing line

MDM

Mix-Processing
A further variant of the

In this procedure a semi-concentrate

product mixing process is

is manufactured and mixed in the two-

provided by two-component
mixing technology.

component mixer with water to form

the finished product, directly before
final processing. By means of this technology the storage time and capacity
in the mixture storage facility can be
increased.
A mixing plant that is optimised and
matched to customer requirements
increases the efficiency and reliability
of the product mixing process. This
enables customers to react with a high
degree of flexibility to the rapidly
developing requirements of the market
and to achieve considerable cost
reductions. Our aim is to create and
offer optimised plant designs to meet
individual customer requirements.

Juice tank line

Valve matrix for mixing

Small volume mixing system

Pasteurising
Fruit juices as well as beverage

This task is achieved by thermal treat-

The heating temperature may be

bases require a long shelf life.

ment of the product using a pasteuriser.

differently high for different products;

In a short time heating plant (STHT

as a rule they can be classified into

plant) the product is heated for a short

three different groups:

Conservation of the product

shall be achieved by efficient

time to the required temperature and

processing without affecting

rapidly cooled down. Plate or tubular

Group I

the product quality.

heat exchangers at choice are used to heat

Temperature: 58 C to 75 C

the product to the required pasteurisation

insusceptible beverages (pH < 5.0)

temperature.

Beer, lemonades with additional protective factors (alcohol, carbon dioxide)

The heat treatment system to be used

depends first of all on the properties of

Group II

the product to be treated. The correct

Temperature: 75 C to 105 C

design of the pasteuriser as well as the

susceptible, acidic and non-carbonated

selection of appropriate components

beverages (pH < 5.0)

allow the treatment of the following

Fruit juice susceptible to moulds and

products:

film-forming yeasts

mashes
fruit juices with and without cells,

Group III

pulp and CO2

Temperature: 105 C to 130 C

vegetable juices

sensible beverages (pH < 5.0)

beverage bases

Vegetable juice susceptible to bacteria

and chlostridients

STHT Plant with automatic

control of the pasteurisation
temperature

VARITHERM
Plate Heat Exchanger
The core piece in process plants

As a central module in thermal process

are heat exchangers they are

technology, the plate heat exchanger has

used for cooling, heating,

always been the cornerstone in systems

engineering: design and development are

pasteurising or UHT heating.

continuously adapted to the needs of the

GEA TDS use plate and tubular

changing market and trends in product

heat exchangers depending on

specifications.

the plant configuration.

The advantages at a glance:
thermal treatment of products
containing cells and fruit pulp
efficient heat transfer,
i.e. small heat exchange area and
thus low investment costs
high degree of heat recovery
(up to 96 %), this means low energy costs
low space requirements due to large
heat transfer surface in a compact
assembly
easy adaptation to changed capacity
Functional scheme of a plate heat exchanger

parameters by expansion or reduction

of plates, i.e. high-flexibility
short dwelling times in the heat
treatment section, thus gentle product
treatment

STHT Plant

Standard system VARITHERM and NT

for clear and turbid products
with/without CO2
max. fibre length 0.5 mm to 1 mm
System N
for clear and turbid products and
products containing fibres of 5 mm
length max. and 1 mm in diameter
System FREEFLOW
for clear and turbid products and
products containing fibres of 12 mm
length max. and 1 mm in diameter

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VARITUBE
Tubular Heat Exchanger
The VARITUBE Tubular

VARITUBE S

Heat Exchanger is specifically

the single-tube heat exchanger for

designed for the thermal

indirect heat exchange for the treatment

of products containing pieces. Product

treatment of low- to high-

recovery is possible using pigging tech-

viscosity products and for

nology.
Corrogated and plain inner tubes

products containing particles,

pulp and fibres.

The VARITUBE system is

VARITUBE M
the multi-tube heat exchanger for

mainly used in heating,

indirect heat exchange is also suitable

cooling and aseptic systems.

for products containing particles of

approx. 18 mm length

VARITUBE P
for the direct product/product heat
exchange of smooth, fibre-containing
and viscous products

VARITUBE SK
for the direct product/product heat
exchange of fibre-containing products
up to a length of 30 mm

VARITUBE HS
the multi-tube heat exchanger for
indirect heat exchange, suitable mainly
for hot water generation and heating
of CIP media

Vacuum Deaeration
For not affecting the quality
through oxidation, the product

Vacuum Deaeration Plant for fruit juice

with integrated aroma recovery,
capacity: 24.000 l/h

undergoes a vacuum-deaeration
which partly takes place during
the pasteurisation process.

Via an especially designed cascade valve,

the product is conveyed at a temperature
between 55 and 60 C into the deaerator
vessel where the major part of the total
gas amount is removed from the product.
The aroma substances entrained by the
degassing procedure are recovered in a
tubular heat exchanger and returned to
the product.

Homogenisation
The Niro Soavi high-pressure

The capacity ranges from 10 to 50,000

homogenisers and microsizers

l/h at a constant operating pressure of

reflect the latest innovative

1,500 bar max. For special applications,

a homogenising pressure of 2,000 bar

developments and show

max. can be achieved. The Ariete series

excellent results in respect to

are capable of processing products at

capacity and reliability.

temperatures up to 180 C. Special

operating conditions, e.g. adherence to
hygienic and aseptic requirements or
treatment of abrasive, viscous or corrosive liquids, can be fulfilled with the
standard treatment programme.

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Homogenisers with a capacity of

50,000 l/h, 180 bar

CIP Plants
CIP (cleaning in-place) is the

Variable CIP systems are available for

Using a modern CIP system ensures

commonly used method for

different cleaning procedures. The diver-

the optimum quality assurance and

sity of products and processes calls for

increases product quality.

plant cleaning during the

different methods for cleaning process

production process where

plants. Variable CIP systems are avail-

hygiene is, of course, para-

able for different cleaning procedures

CIP Recovery Systems

mount.

within the production process where

These CIP systems consist of various

hygiene is paramount.

cleaning medium tanks for drinking

water, cleaning solution and returned

GEA TDS is always striving to find the

water. The system or tank size is adjust-

optimum balance between chemicals,

ed to the cleaning cycles required. The

mechanics, temperature and residence

number of cleaning systems installed

time, with additional focus on environ-

determines the cleaning frequency, the

mental protection and down-times.

simultaneous execution of operations

and the number of objects. The systems

CIP Recovery System

are technically equipped and configured

to meet the cleaning objectives defined.

Single Use Cleaning System

with ECOCIP
The system consists of a detergent tank
for the ready-made cleaning solution,
pre-assembled on a base frame.
The cleaning solution is circulated and
heated up to the operating temperature.
Conductivity measurement and in-line
concentrate metering ensure that the
required amount of detergent is added.
The detergent flow rates are adjusted by
the cleaning program. CIP modules are
CIP System

easy to integrate into the process and

offer the most appropriate cleaning
even for demanding
products.

Process Automation
and Integration
Quality assurance and increased

GEA TDS offers a wide spectrum of

productivity drive the steadily

innovative process automation systems

increasing automation of plants

and services that range from the provision of electronic process control up to

and production processes.

integrated, company-wide network

The advantages are obvious:

systems complete with the correspond-

labour and production down-

ing management information systems.

times are reduced and operator

error is safely ruled out. The

Machine control systems, for separators,

homogenisers or filling machines for
example, can be homogeneously inte-

plants are upgraded so that all

grated into the overall automation

essential parameters relevant

system through the bus network.

for the production processes

are automatically controlled,
monitored and documented.

GEA TDS uses the latest industrial standards for all automation projects. In this
respect batch processes are automated
in accordance with ISA-S88a as an
essential factor for a transparent, traceable production.
To adapt existing production plants to
new generations of automation systems
(e.g. when replacing the visualisation
system or upgrading from S5 to S7)
migration strategies will be developed
for you that allow safe conversion while
production continues to run.

Operation and Process Visualisation

All operator interfaces are designed
with logical menu structures that allow
intuitive operation of the plant. The
operator is comprehensively informed
at a glance and guided progressively
through the system.

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CIP curve

Documentation and Process

Reporting and Batch Tracking

Optimisation

The process data is transferred online

The supervisory control system allows

to an SQL database extended with

operators to record measured values

powerful evaluation tools:

and switch status, thus creating the

the report generator can be custom-

necessary transparency for process

ised so you can configure your own

optimisation. Recording of measured

application-oriented reports.

data is supplemented by a database-

batch tracking in graphical or tabular

supported event log with practice-

form helps you to keep track of your

oriented evaluation features. This audit

products in accordance with the

trail allows the tracking of individual

EU regulation 178/2002.

batches or an entire production.

The standardised approach allows
you to introduce a batch tracking
system in manageable steps at a
known cost.

Reception

Recipe report

Signals STHT

Login

To find out more about your

The juice industry produces many

particular process technology

different products and this brochure

application, contact GEA TDS at

could not possibly describe all the

potential process lines available.

www.gea-tds.com

GEA TDS GmbH

Voss-Strasse 11/13 31157 Sarstedt Germany
Phone +49 5066 990-0 Fax +49 5066 990-163
geatds@geagroup.com www.gea-tds.com
Am Industriepark 210 21514 Bchen Germany
Phone +49 4155 49-0 Fax +49 4155 49-2724
Kruppstrasse 3 48683 Ahaus Germany
Phone +49 2561 8602-0 Fax +49 2561 8602-130

424e-11/08 inform-werbeagentur.de

Process Engineering