GEA Group Aktiengesellschaft
Düsseldorf, May, 2015
Engineering for a better world Product examples
engineering for a better world
Innovations made by GEA help industrial clients to launch new innovative products
• Continuous process to withdraw water by freezing
instead of evaporation
GEA Juice Freeze
Concentration
Innovation
Impact on product quality
• Natural flavor can be preserved in the concentrate
(e.g. juices, coffee, milk)
• Better taste and aroma of end product justifying higher price
• Higher overall equipment efficiency due to less demanding
cleaning in place (CIP)
Benefit for industrial customers
GEA product examples on sustainability 2
engineering for a better world
Innovations 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
GEA product examples on sustainability 3
Equivalent of ~300 truckloads
of raw milk per day1
• 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
Innovation
• Approximately 10% lower total cost of
ownership (TCO)
Benefit for industrial customer
Impact on costs
• Compact spray dryer chamber
• Simpler operation
• Lower energy cost
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)
engineering for a better world 4
Energy-efficient solutions made by GEA help industrial clients to reduce energy and water consumption
• By coupling a refrigeration system and a heat pump cold and heat
are provided efficiently at the same time
GEA Heat Pump Innovation
Impact on production costs
• Lower energy and water costs
• >50% reduction in water usage
• >20% less electrical energy for cooling
• >50% reduction in gas usage
Benefit for an industrial customer in numbers (real sample)
GEA product examples on sustainability
engineering for a better world 5
Innovations made by GEA help industrial clients to minimize dehydration losses
• Uniquely designed high-velocity air jets quickly reduce the outer-
layer temperature of food and break the insulating boundary layer,
thereby minimizing dehydration losses
GEA HVF-series freezer Innovation
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
• 50% reduction in weight loss
• Benefit of 135,000€ per year
• Amortization after 1.7 years
Benefit of GEA HVF-servies freezer for industrial customer
GEA product examples on sustainability
engineering for a better world 6
Innovations made by GEA help industrial clients to reduce energy consumption
• 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
GEA ecoforce decanter Innovation
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
Benefit for industrial customer
* in comparison to older series from same supplier
GEA product examples on sustainability
engineering for a better world 7
Innovations made by GEA help industrial clients in environmental-friendly ballast water treatment
• 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%
GEA BallastMaster ultraV 250 Innovation
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
Benefit for industrial customer
GEA product examples on sustainability
engineering for a better world 8
Innovations made by GEA help industrial clients to produce zero waste
• 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
GEA clearamic beer filtration Innovation
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
Benefit for industrial customer
GEA product examples on sustainability
engineering for a better world 9
Innovations made by GEA help farmers to turn liquid manure into compost or green bedding
• 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
GEA XTract and XPress Innovation
Benefit for the farmer
GEA product examples on sustainability
engineering for a better world 10
Innovations made by GEA help industrial clients to keep their products longer fresh
• 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
GEA Westfalia Separator prolong
Innovation
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
Benefit for industrial customer
GEA product examples on sustainability
engineering for a better world 11
Innovations made by GEA help industrial clients to protect the ozone layer
• 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
Compressors with
natural refrigerants
Innovation
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
Benefit for industrial customer
GEA product examples on sustainability
engineering for a better world
• 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
12
Innovations made by GEA help industrial clients to minimize energy consumption
• 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.
Redesign of a screw
compressor series –
GEA Grasso M
Innovation
Impact on environment
• 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
Benefit for industrial customer
GEA product examples on sustainability
engineering for a better world 13
Energy-efficient solutions made by GEA help industrial clients to minimize the total cost of ownership
GEA Grasso BluGenium Innovation
Impact on environment
Benefit for industrial customer
• High efficient ammonia chiller optimized for full and part load
operation with compact dimensions
• 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
GEA product examples on sustainability
Top Related