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From nature to taste
New and Optimised BUCHER UNIPEKTIN
Hydraulic Fruit Press HPX 6007
Juice World 2012, St. Petersburg
From nature to taste
Agenda:
1. Introduction of Bucher Unipektin company
2. Scope of supply
3. Product presentation Bucher Unipektin
hydraulic press HPX 6007
Juice World 2012, St. Petersburg
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
From nature to taste
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
Juice World 2012, St. Petersburg
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
Juice World 2012, St. Petersburg page 7
Juice World 2012, St. Petersburg page 8
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
Juice World 2012, St. Petersburg
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
Juice World 2012, St. Petersburg
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
Juice World 2012, St. Petersburg
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:
Juice World 2012, St. Petersburg
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)
Juice World 2012, St. Petersburg
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
Juice World 2012, St. Petersburg
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
Juice World 2012, St. Petersburg
NetService – Worldwide access
page 16
Worldwide access
to all Bucher Unipektin
machines and plants
Juice World 2012, St. Petersburg
Process control
Process diagnosis
System diagnosisImproved support for
page 17
Operation
Juice World 2012, St. Petersburg
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
Juice World 2012, St. Petersburg
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)
Juice World 2012, St. Petersburg
Bucher Unipektin Extraction Line
- Technical Details
- Economical Calculations
Juice World 2012, St. Petersburg page 20
Introduction
Challenges for AJC producers:
• Tough competition for apples
• Quality assurance
- GMP-standards- GMP-standards
- TAB
• Clients Audits
- Hygiene
- Safety
- Documentation / Traceability
Juice World 2012, St. Petersburg page 21
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 % !
Juice World 2012, St. Petersburg page 22
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
Juice World 2012, St. Petersburg page 23
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
Juice World 2012, St. Petersburg page 24
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
Juice World 2012, St. Petersburg page 25
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
Juice World 2012, St. Petersburg page 26
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
Juice World 2012, St. Petersburg page 27
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“
Juice World 2012, St. Petersburg
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
Juice World 2012, St. Petersburg
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)
Mash Holding30 - 60 min
Extraction Results:
Throughput: 10 t/h
Yield: 93 % w/w
Juice World 2012, St. Petersburg page 30
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)
Mash Holding30 - 60 min
Extraction Results:
Throughput: 8 t/h
Yield: 95 % w/w
Juice World 2012, St. Petersburg page 31
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
Juice World 2012, St. Petersburg page 32
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
Juice World 2012, St. Petersburg page 33
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
Juice World 2012, St. Petersburg page 34
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
Juice World 2012, St. Petersburg page 35
60%
70%
80%
90%
100%
Water
Dilution of juice:
12 Bx ���� 4.8 Bx
Comparison:
Bucher Unipektin HPX ���� Belt Presses
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
Juice World 2012, St. Petersburg page 36
60%
70%
80%
90%
100%
Total
Yield:
80.0% + 10.0%
= 90.0 %
Total
Yield:
87.0% + 6.0%
= 93.0 %
Comparison:
Bucher Unipektin HPX ���� Belt Presses
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
Juice World 2012, St. Petersburg page 37
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
Juice World 2012, St. Petersburg page 38
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
Juice World 2012, St. Petersburg page 39
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
Juice World 2012, St. Petersburg page 40
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*
_
_/
Juice World 2012, St. Petersburg page 41
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/
Juice World 2012, St. Petersburg page 42
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
Juice World 2012, St. Petersburg page 43
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
Juice World 2012, St. Petersburg page 44
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
Juice World 2012, St. Petersburg page 45
Economics: Conclusion
�
BUCHER UNIPEKTIN HPX Press:
� Superior Economical Efficiency
� Short ROI Time for Additional Investment
Juice World 2012, St. Petersburg page 46
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
Juice World 2012, St. Petersburg page 47