bucher

From nature to taste

New and Optimised BUCHER UNIPEKTIN

Hydraulic Fruit Press HPX 6007

Juice World 2012, St. Petersburg


Agenda:

1. Introduction of Bucher Unipektin company

2. Scope of supply

3. Product presentation Bucher Unipektin

hydraulic press HPX 6007


hydraulic press HPX 6007

4. Optimized Mash Preparation

5. HPX: pressing results

6. Comparison HPX Press � Belt Presses

- Yield / Throughput

- Costs

- Economical Comparison

7. Summary


since August 2010

Juice World 2012, St. Petersburg page 3

Scope of Supply Juice Industry

Product reception, mill Press

page 4

Filtration Adsorber /

Ion exchange

Aroma recovery /

Concentration


Scope of Supply Evaporators

Evaporators for citrus, fruit

puree, milk, coffee, malt,

yeast, pectin

page 5Juice World 2012, St. Petersburg

Scope of Supply Dryers

• DryCab vacuum drying cabinets

• DryBand Vacuum belt dryers

• Zeodration Zeolite water adsorbers

page 6Juice World 2012, St. Petersburg

Scope of Supply Sludge Dewatering

Technology

HPS Presses



Product presentation

BUCHER UNIPEKTIN Hydraulic

Fruit Press HPX 6007

HPX 6007 Improvements

Optimized

drainage

systemHigh reliable

hydraulic

system

page 9

Hygienic,

closed juice

exit and tankProcess-

control with

tele service

Comfort option

for protection

guard


Looped drainage elements, continuous

rotation

x

HPX 5005 iP HPX 6007

Rotation during

loosening,

No rotation

while pressing

Rotation while

loosening &

pressing

page 10

xx

Advantages:

• Improved loosening

• Better pomace discharge

Lower maintenance cost (encreased life time

of brakes, wear-free juice outlet)

• Hygienic closed juice tank


Drainage system: Improved loosening

Strong forming

of blocs

Optimal

loosening

HPX 5005 iP HPX 6007

page 11

Field trials HPX 5005iP vs HPX 6007, Switzerland 2010


Drainage system

Pressure plate

front side:

Pressure plate

back side:

page 12

Clean pressure plate on the

back side

Higher filling volume (500 –

800kg)

-> higher capacity (ca. 5%)1)

1) Field trials, Switzerland, 2010

Apple, no mash enzymes used:


Looped drainage elements, continuous

rotation

Advantages:

• Higher capacity due to better pomace loosening

• Higher capacity due to higher press volume

• Higher efficiency and lower maintenance cost (life time of rotation brakes , no

page 13

telescopic pipe seals)


Hydraulic system

Pressure filter• Improved oil

quality

«Sealkant» -Seals• Improved long time

page 14

• Improved long time

tightness

Oil cooler with air• Cooling without using

water

Separate blocs for press

piston and basket

functions• Easier diagnosis,

• Better accessability

• Reduction of pressure loss

Pressure sensor instead of

switches• Higher reliability

• Easier diagnosis


Oil cooling variants

Max.

Ambient

temperature: T max < 32 °C T max > 32 °C T max > 32 °C

page 15

Air cooler

No water

consumption

Air- & Water cooler

(Optional)

Reduced water

consumption

Water cooler

T max< 30°C: 0.25 – 0.4 m3/h

T max 30–40°C: 0.3 – 0.5

m3/h


NetService – Worldwide access

page 16

Worldwide access

to all Bucher Unipektin

machines and plants


Process control

Process diagnosis

System diagnosisImproved support for

page 17

Operation


Process control

Advantages:

• Improved reliability with PLC system from Siemens (S7);

• Long availability for spare parts

• Interface to an overall control PC for external operation and data transfer

page 18

• Tele service with Bucher Unipektin «Net Service» concept

• Optimised, robust process loops improve the control and flexibility for adaptations to

different product characteristics

• Automatic press cleaning program with interface to external chemical dosing system

• Sensor analysis for extended system diagnosis


Protective guards:

Access possibility via

back side door.

Door analoguos to the

operation side.

(Supervision:

OPTIONAL)

page 19

No Access via

back side door.

Door mechanically

locked

(STANDARD)

OPTIONAL)


Bucher Unipektin Extraction Line

- Technical Details

- Economical Calculations


Introduction

Challenges for AJC producers:

• Tough competition for apples

• Quality assurance

- GMP-standards- GMP-standards

- TAB

• Clients Audits

- Hygiene

- Safety

- Documentation / Traceability


Introduction

Fruit (Raw Material)

70 – 80 % of total AJC production costs

�Yield: Decisive for Economical Efficiency

� 5 % w/w more yield reduces the total

AJC production cost by 3.5 - 4 % !


Apples

CM-50 MillEnzymes

(50 – 80 mL/t Mash)

Optimized Mash Preparation

Mash Heater

HPX

25 – 30° C

1 or 2-Step Leaching

(15-25 % w/w Water/Mash)

Mash Holding30 - 60 min


Apples

CM-50 MillEnzymes

(50 – 80 mL/t Mash)


Mash Heater

HPX

25 – 30° C





HPX 5005i PH: Pressing Results

HPXi PH: Capacity-Yield Correlation

90

95

100

1-step Leaching ( 15 % w/w Water/Mash)Product: Apples

page 28

70

75

80

85

90

0 5 10 15 20 25

Throughput (incl. dumping) [t/h]

Yield [% w/w]

25°C Mash

Temperature

30°C Mash

Temperatur

No Mash

Enzyme

Treatment

Mash Enzyme

Treatment„With OMP“

„Without

OMP“


HPXi 5005 PH: Pressing Results

Capacity-Yield Correlation: China, 22. - 23.09.04

90

95

100

10.7 t/h;

94 %

w/w

page 29

70

75

80

85

90

0 5 10 15 20 25 30 35 40Throughput [t/h]

Yield [% w/w]

HPX 5005i “Power“-

Hydraulic


Apples

CM-50 MillEnzymes

(50 – 80 mL/t Mash)

HPX 6007: Pressing Results

Extraction Results:Mash Heater

HPX 6007

25 – 30° C

1-Step Leaching

(15 % w/w Water/Mash)


Extraction Results:

Throughput: 10 t/h

Yield: 93 % w/w


HPX 6007: Pressing Results

Apples

CM-50 MillEnzymes

(50 – 80 mL/t Mash)

Extraction Results:Mash Heater

HPX 6007

25 – 30° C

2-Step Leaching

(25 % w/w Water/Mash)


Extraction Results:

Throughput: 8 t/h

Yield: 95 % w/w


Comparison: Bucher HPX �� Belt Presses

Three Extraction Systems Dominate AJC Market:

• Bucher Unipektin Hydraulic Presses > 1´200 pcs.• Bucher Unipektin Hydraulic Presses > 1´200 pcs.

• Belt Presses > 500 pcs.

• Decanters


HPX Presses: Features

• Highest primary yield of all extraction systems: 84 – 90 % w/w

• Simple process, one or multiple additional extractions

(“leaching“) within the same press;

total yield: 92 – 95 % w/w

• Highly automated, “self optimising“, comprehensive process • Highly automated, “self optimising“, comprehensive process

data recording

• Flexible process, multi purpose system

• Reference juice quality

• Hygienic design

• Highest investment


Belt Presses: Features

• Primary yield: 72 – 80 % w/w

• Acceptable yields only as 2 staged system with water

extraction � belt press “cascades“

total yield: 86 – 91 % w/w

• High throughput: up to 25 t/h• High throughput: up to 25 t/h

• Standard juice quality, but high sediments

• Difficult to clean, poor hygienic design

• Low automation, no automatic process adaptation

• Not suited for stone fruits, berries

• Low investment


8060%

70%

80%

90%

100%

Comparison:

Bucher Unipektin HPX �� Belt Presses

3 3 3

1710

97

8087

0%

10%

20%

30%

40%

50%

60%

Mash Belt Press HPXi

Juice Yield

Juice in Pomace12 Bx

Insoluble Solids

1. Extraction


60%

70%

80%

90%

100%

Water

Dilution of juice:

12 Bx �� 4.8 Bx

Comparison:


3 3 3

1710

25

15

3

1017

0%

10%

20%

30%

40%

50%

60%

Belt Press HPXi Belt Press HPXi

Water Addition

Juice in Pomace

Insoluble Solids

Water

Addition


60%

70%

80%

90%

100%

Total

Yield:

80.0% + 10.0%

= 90.0 %

Total

Yield:

87.0% + 6.0%

= 93.0 %

Comparison:


3 3 3

42

2517

10

30%

10%

20%

30%

40%

50%

60%

Belt Press HPXi Belt Press HPXi

Juice in Pomaceapprox. 5 Bx

Insoluble Solids

2. Extraction

Additional

Yield:

25 %w/w

10.0 %yield

Additional

Yield:

15 %w/w

6.0 %yield


Yield: 2-step leaching with HPX

8760%

70%

80%

90%

100%

1st Leaching 2nd Leaching

Total

Yield:

87.0% + 5.5% + 2.5%

= 95.0 %

Additional

Yield 1:

3 3 3 3 3

10 10 10 9

3

10 10

12.512.5

87

0%

10%

20%

30%

40%

50%

1st p

ress

Pom

ace

1

1st l

each

Pom

ace

2

2nd le

ach

Pom

ace

3

Water Addition

Juice in Pomace

Insoluble Solids

Dilution of juice:

12 Bx �� 5.3 Bx

Dilution of juice:

5.3 Bx �� 2.3 Bx

Yield 1:

12.5 %w/w

5.5 %yield

Additional

Yield 2:

13.5 %w/w

2.5 %yield


Alternative Process: Belt Press + HP

• Mash preparation (with CM50 mill)

• 1st extraction with belt press

• Warm water (50°C) addition to pomace

• Enzyme treatment (1 hour)• Enzyme treatment (1 hour)

• 2nd extraction with HP


Alternative Process: Belt Press + HP

Pcs. per press t/h Total t/h Yield % w/w Comment

Belt press 2 15.0 30.0 75.0 Mash A

Belt presses for 1st extraction; Bucher Unipektin HP presses for 2nd

extraction HP presses

Belt press 2 15.0 30.0 75.0 Mash A

Water addition 25.0% 3.8 7.5

Mash B 15.0

Bucher HP 2 7.5 15.0 75.0 Mash B

17.0 relative to Mash A

Total Yield 92.0


Line Yields and F/C-Ratio

• Line yield = Press yield – line losses

• Line losses: filtration, general juice handling

• Line losses with belt presses: 3 % due to high suspended

solidssolids

• Line losses with Bucher Unipektin HPX: 2 % due to low

suspended solids

• F/C-Ratio: fruit/concentrate ratio, kg fruit required per kg

concentrate

=−

kg

kg

YieldLineFruitBrix

eConcentratBrixRatioCF

%_

%100*

_

_/


Belt Press + Bucher Unipektin HP:

Line Yields and F/C-Ratio

=

°

°=−

kg

kg

Brix

BrixRatioCF 55.6

%0.89

%100*

12

70/

Bucher Unipektin HPX with

1 Leaching:

Bucher Unipektin HPX with

2 Leachings:

=

°

°=−

kg

kg

Brix

BrixRatioCF 41.6

%0.91

%100*

12

70/

=

°

°=−

kg

kg

Brix

BrixRatioCF 27.6

%0.93

%100*

12

70/


Economics: Concentrate Earnings

Capacity 30 t/h

2x Belt Press

Cascade

2 x BP

+ 2x HP

4 x HPX

1 Leaching

4 x HPX

2 Leachings

Total Processed Apples: t/year 65'000 65'000 65'000 65'000Total Processed Apples: t/year 65'000 65'000 65'000 65'000

(line capacity 30 t/h; 100 days/year)

F/C-Ratio: t/t 6.73 6.55 6.41 6.27

Total Concentrate: t/year 9'658 9'924 10'140 10'367

(calculation: Apples t/y / F/C-Ratio)

Total Concentrate Earnings: EUR/year 14'487'370 14'885'496 15'210'608 15'550'239

(Concentrate Price: 1’500 EUR/t) 1500


Economics: Water Evaporation

Capacity 30 t/h

2x Belt Press

Cascade

2 x BP

+ 2x HP

4 x HPX

1 Leaching

4 x HPX

2 Leachings

Total Processed Apples: t/year 65'000 65'000 65'000 65'000Total Processed Apples: t/year 65'000 65'000 65'000 65'000

(line capacity 55 t/h; 120 days/year)

Leaching water % 25 25 15 25

Additional water evaporation t/year 6'500 6'500 0 6'500

Additional water diafiltration

(= retentate volume *2) t/year 3'714 3'714 0 0

Total additional water evaporation t/year 10'214 10'214 0 6'500

kg/kg) t/year 2'554 2'554 0 1'625

Additional steam costs (15 EUR/t) EUR/year 38'304 38'304 0 24'375

15


Economics: Summary

Capacity 30 t/h

2x Belt Press

Cascade

2 x BP

+ 2x HP

4 x HPX

1 Leaching

4 x HPX

2 Leachings

Total Concentrate Earnings: EUR/year 14'487'370 14'885'496 15'210'608 15'550'239

Additional steam costs: EUR/year -38'304 -38'304 0 -24'375

Total earnings: EUR/year 14'449'066 14'847'193 15'210'608 15'525'864Total earnings: EUR/year 14'449'066 14'847'193 15'210'608 15'525'864

Additional earnings: EUR/year 0 398'126 761'542 1'076'798

Investment: EUR/year 1'500'000 1'500'000 3'000'000 3'000'000

Interest (7 % on 50 % of investment): EUR/year -52'500 -52'500 -105'000 -105'000

Depreciation (within 10 years): EUR/year -150'000 -150'000 -300'000 -300'000

Additional financing costs: EUR/year 0 0 -202'500 -202'500

Net additional earnings: EUR/year 0 398'126 559'042 874'298

Additional Investment: EUR 0 0 1'500'000 1'500'000

Return on Investment (ROI): years 0.00 2.68 1.72


Economics: Conclusion

�

BUCHER UNIPEKTIN HPX Press:

� Superior Economical Efficiency

� Short ROI Time for Additional Investment


Summary

• An efficient juice extraction requires optimized mash preparation

• The BUCHER UNIPEKTIN CM50 grinder provides optimum mash

structure

• BUCHER UNIPEKTIN HPX press:• BUCHER UNIPEKTIN HPX press:

- highest yield

- high throughput

- low sediments

- good hygienic design

• BUCHER UNIPEKTIN HPX press has superior economical efficiency


bucher

Documents

m3hjuice world

ip hpx

petersburghydraulic

ip vs hpx

petersburg page

field trials hpx

higher capacity

c t max