westfalia separator proplus more milk protein for higher...

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