healthy dairy & food products: quality • traceability • safetyproducts but also traceability...

1C4 1M4 1Y4 70% 70% CMY B C M Y 70% CMY B C M Y CM CY CMY B C M Y 70% CMY B C M Y MY CMY CMY B C M CMY 2B4 2C4 2M4 2Y4 70% 70% CMY B C M Y 70% CMY B C M Y SLUR CMY B C M Y 70

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Healthy Dairy & Food Products: Quality • Traceability • SafetyHygiene • Analysis • Processing • Ingredients • Packaging

DANISH

DAIRY & FOOD INDU

STRY…

worldw

ide 2005: Healthy Dairy & Food Products: Quality · Traceability · Safety

Trepko A/S, Kuldyssen 15-17, P.O.Box 128, DK-2630 TaastrupTel: +45 43 99 22 44, Fax: +45 43 99 26 55, E-mail: [email protected], www.trepko.com

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Danish Dairy Omslag 2005 06/09/05 12:42 Side 1

Our most important one is inspiration

Ingredients

Chr. Hansen A/S · Bøge Allé 10-12 · 2970 Hørsholm · Tel.: 45 74 74 74 · Fax: 45 74 88 88 · www.chr-hansen.com

Of all the ingredients available from Chr. Hansen

the most important one is inspiration. You’ll find

it in everything we make, from probiotic cultures

with clinically documented health benefits to

natural ingredient solutions for beverages and

snacks. You’ll experience it in person, too, every

time you need a hand adapting one of our products

to your process. The challenge of enhancing the

taste, texture, appearance and performance

of food and dairy goods is what drives us at

Chr. Hansen. Because we know that making them

more appealing to consumers is what inspires you.


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Oesterled 20 - 26DK - 4300 HolbaekDenmark

Phone + 45 59 43 14 79Primodan Food MachineryTelefax + 45 59 44 22 30Email [email protected] www.primodan.dkFood Machinery A/S

Filling and coagulation plant for UF cheese in canisters.Capacity according to client demand.

Filling and coagulation plant for UF cheese in plastic cups.Standard capacities 2000 - 6000 cups /hour.

Primodan Food Machinery A/S is manufacturing equipment for the dairy and foodprocessing industries, specially cup filling / sealing machines for liquid and semi-liquid products.

Besides manufacturing of machinery, the company is active in engineering design from first concept to final installation and testing.

Food Machinery A/S

Suppliers of complete UF cheese plants and filling machines for the food industry

Multiline - large-scale in-line cup filling and sealing machines with capacities of up to 40.000 cups/hour for use in productions where high capacity and efficiency are essential.

Rot-O-Min - a compact filling and sealing machine.Capacities up to 10.000 cups / hour.


Danish Dairy & Food Industry... worldwide 2005 1

Denmark - September 2005

Healthy dairy and food products manufactured inorder to secure quality, traceability and safety of thefinished goods is the major theme of Danish Dairy &Food Industry ... worldwide this year.

The food industry of today has become morecomplex and international. Often various food in-gredients are transported around the world beforebeing used in the production of finished goods. Af-terwards, these high profile dairy and food products may travel anoth-er long distance before reaching the final end-consumers. Thereforeconsumers all over the world demand not only safe and high qualityproducts but also traceability within the international dairy and foodproduction. Moreover, food regulations from i.e. EU and US on the mat-ter of safety and traceability are on the agenda.

Danish companies within the fields of food products and food ma-chinery, processing and analyzing equipment, advanced hygiene con-cepts, ingredients and packaging have a leading international positionin the field of food production. Therefore, it is only natural to promoteDanish dairy and food industry as being at the forefront of new devel-opments. Consequently, Danish Dairy & Food Industry ... worldwide fo-cuses on; hygiene, analysis, processing, ingredients and packaging in re-lation to produce healthy dairy and food products of high quality, trace-ability and safety.

Besides studying this magazine our readers also have the opportuni-ty to meet representatives from the Danish dairy and food industry atlarge international exhibitions held in 2005 and 2006 as for example: FiAsia in Kuala Lumpur September 27th - 29th, Anuga in Cologne 8th - 12th

of October, Worldwide Food Expo in Chicago October 26th - 29th,FoodTech Scandinavia in Herning, Denmark November 15th - 17th, Fi Eu-rope in Paris November 29th - December 1st, and Anuga FoodTec inCologne April 4th - 7th 2006.

The Danish Dairy Managers Association and the Danish Dairy Engi-neers Association own and publish Danish Dairy & Food Industry ...worldwide. It has been published since 1976 and this issue is the 15thin succession informing you about Danish dairy and food industry.

Danish Dairy & Food Industry ... worldwide is distributed in morethan 120 countries in 12.000 copies. Our experience tells us that about100.000 dairy, food and marketing specialist worldwide study this jour-nal every year.

You are always welcome to contact us for further information.

K. Mark Christensen Anna Marie ThøgersenChief Editor Sub-Editor

15SEPTEMBER 2005

The background of the cover is lit-upby the Milky Way. Furthermore, thecover shows a lure. This instrumentdates from the Danish Bronze Age(about 600 B. C.). It has only beenfound in Denmark and the former Danish territories. Today it forms partof the Danish Quality sign known asthe "Lure-brand", used on dairy products for export.

Circulation: 12.000 copies

Readership: Leading personnel in thedairy and food industry in more than120 countries together with all theDanish embassies and consulate-gene-rals, Government advisers and repre-sentations of marketing councils.

The editorial staff ofDanish Dairy & FoodIndustry ... worldwide:Chief editor, M.Sc.K. Mark ChristensenSub-editor, M.A.Anna Marie Thøgersen

Litographed by:Grafisk Data CenterOdense, Denmark

Printed by:Helmer Jensen Aps, Odense, Denmark

Editorial officeand distribution:Danish Dairy & FoodIndustry ... worldwide"The old Dairy"Landbrugsvej 655260 Odense SDenmarkTel.: +45 66 12 40 25Fax: +45 66 14 40 26www.maelkeritidende.dkE-mail: [email protected]

ISSN 0904-4310

Reprint permission to interestpublications providing their creditand tear sheets to the publisher.

HEALTHY DAIRY & FOOD PRODUCTS: QUALITY TRACEABILITY SAFETY

K. MarkChristensen

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Danish Dairy 2005 indhold 06/09/05 13:05 Side 1

Alfa Laval Nordic, BaselineOptimises Cooling and Heating, by Mogens Espensen ..................... 08

APV UHT & Aseptic Group, AreComputers Poised to Take over the Dairyman’s Job? by JørgenØstergaard Iversen ........................ 38

Arla Foods, Arla Foods KeepsHealth and Safety High on theAgenda, by Ulla Kjer ................... 06

Centre for Advanced Food Studies, Successful Priority of Food and Knowledge-Based Science, by LisbethMunksgaard ............................... 56

Chr. Hansen, Rapid Test KitsDelivers Accurate Readings in only Five Minutes, by Karen S. Frost ........................................... 48

Dairy Fruit, Respect for RawMaterials Ensures High Quality, by Betina Hansen ....................... 46

Dalum College of Food andTechnology, Dairy Educations at Dalum Education Centre, by Paul Stein Jensen and Jens A.Ullum ........................................ 58

Damrow, High Quality Equip-ment for Cheese Production, by Jakob Maltha Rasmussen ....... 12

DSS Silkeborg, Hygienic Design,Cleanability and Product Safety, by Jan Sprogø .............................. 20

FOSS Analytical, The Big Squeeze, by Richard Mills ........... 44

GEA Liquid ProcessingScandinavia, State of the Art Dairy Processing, by Bjarne Darré .......................................... 26

Gerstenberg Schröder, Control and Traceability in a MargarineProduction Facility, by PernilleGerstenberg Kirkeby ..................... 10

Keofitt, Gam Bling or Sam Pling? by Henrik Lysgaard Salomon ...................................... 50

Niro, The Niro A/S TIXO-THERM™ Process, by Ejnar Refstrup ...................................... 30

Novadan, Food Safety andDocumentation, by Torben Jensen ......................................... 28

Olssons Machinery, Quality,Flexibility and Efficiency, by Ole Olsson ................................... 18

Orana, Quality Management - A Way to Healthy Dairy and Food Products, by Joan Karlsen .. 42

Scanima, Turbo Mixing in the Food and Dairy Industry, by Erik Petersen ................................ 36

Scan-Vibro, Global Leader inVibration Technology, by AnnaMarie Thøgersen .......................... 34

Steins Laboratorium, FutureSolutions for the Analysis Field, by Jesper Bagge Pedersen .............. 54

Superfos, Packaging - A Guarantor of Product Quality, by Annette Göttsche ....... 52

Tetra Pak Processing Systems, What does a Traceability SystemMean? by Björn Olsson .............. 14

The Danish Ministry of Food,Agriculture and Fisheries, NewChallenges in a Global World, by Hans Chr. Schmidt ................. 04

Trepko, Adjusted Hygiene in the Filling Process, by Jesper Bjørn Hansen .............................. 24

2 Danish Dairy & Food Industry... worldwide 2005 NR. 15

Index to Advertisers

Contents

Alfa Laval . . . . . . . . . . . . . . . . . . 53Anuga FoodTec . . . . . . . . . . . . . 59APV Invensys . . . . . . . . . . . . . . 55Arla Foods . . . . . . . . . . . . . . . . . 15Bourdon-Haenni . . . . . . . . . . . . 41Chr. Hansen . . inside front coverDairy Fruit . . . . . . . . . . . . . . . . . 47Dalum College of Food and Technology . . . . . . . . . . . . . . . . 09Damrow . . . . . . . . . . . . . . . . . . . 13

DSS Silkeborg . . . . . . . . . . . . . . 21Einar Willumsen . . . . . . . . . . . . 11FOSS Analytical .. . . . . . . . . . . . 45GEA Filtration . . . . . . . . . . . . . . 29GEA Liquid . . . . . . . . . . . . . . . . . 49Gerstenberg Schröder . . . . . . . . 05Hydro-X . . . . . . . . . . . . . . . . . . . 57Keofitt . . . . . . . . . . . . . . . . . . . . 51Niro . . . . . . . . . . . . . . . . . . . . . . 33Novadan . . . . . . . . . . . . . . . . . . 23

Orana . . . . . . . . . . . . . . . . . . . . . 43Olssons Machinery . . . . . . . . . 19Primodan . . . . inside back coverScanima . . . . . . . . . . . . . . . . . . . 37Scan-Vibro . . . . . . . . . . . . . . . . 35Steins Laboratorium . . . . . . . . . 25Superfos . . . . . . . . . . . . . . . . . . . 17Tetra Pak Processing Systems . . 3Trepko . . . . . . . . . . . . . back cover


Danish Dairy & Food Industry... worldwide 2005 3NR. 15

Tetra PlantMaster™ is an innovative and modular plant automa-tion solution based on open industry standards and our produc-tion know-how. Unlike most other automation systems, thisallows Tetra PlantMaster™ to break through all the barriers togood communication within a food processing plant. Althoughour technology is vendor-independent, it can include, for exam-ple, control systems and human-machine interfaces fromSiemens, ABB or Rockwell Automation, as well as InvensysWonderware. This enables fast plant installation and amazingautomation versatility. And as its name implies, Tetra PlantMas-ter™ creates harmony from the labyrinth of plant automation.

Choose Tetra Pak as your partner in safeguarding your invest-ment.

Unlimited Plant Automation for the Food Industry


New Challenges in a Global World

An important roleAgriculture and the associated foodindustry play an important role inthe Danish economy. This is truewith regard to GDP, employment,the balance of payments, etc. It istherefore the objective of the DanishGovernment to provide the best pos-sible business environment for thissector - not only for the benefit ofthe sector itself, but also for the be-nefit of Danish society as such.

GlobalisationThe concern of improving the busi-ness environment applies not onlyto the food sector, but also to otherindustries in Denmark. It becomesever more important, in light of thepressures of globalisation. For Den-mark as for many other countries,globalisation is becoming a major is-sue.

It is an ambition of the DanishGovernment - of course, in heavycompetition with other countries -to place Denmark among the mostattractive countries in the world,when it comes to business environ-ment in terms of e.g. regulations, aflexible labour market, education,

know-how, innovation, and science.These are important parameters forkeeping Denmark among the mostcompetitive countries of the world.

Global growthFrom my point of view, globalisationis of course a challenge. However, itis also - and above all - a promise.Denmark does not have a largehome market. We therefore need alarger and a freer market, in bothagriculture and other fields. This willnot only create growth in our owncountry, but freer trade will alsostimulate growth globally. - And mostsignificant in that sense: Growth andprosperity in the third world is essen-tial for stability and democracy.

The Danish Government is there-fore a strong advocate of the liberal-isation of trade, - also in agriculturalproducts. To this end, the reform ofthe EU Common Agricultural Policyand the prospects for the WTO-ne-gotiations are very important.

We want agricultural policies tobe more market oriented and wewant to significantly reduce tradedistorting agricultural support. Wewill also continue to emphasize sus-tainability in agricultural produc-tion. The CAP-reform brought us farin these respects. A good conclusionto the Doha-round will bring us fur-ther and give clear benefits to all.

Tough competitionLiberalization of course means newchallenges, not least for the agricul-tural sector and certainly not leastfor the dairy industry. Competitionwill be tougher. Our focus will haveto be on quality and innovation -identifying and seizing the opportu-nities in the market, both in the EUand globally.

We will have to try even harder to

produce foods of high value andquality. The aim is the export marketand in particular, the high qualityand high price segment of it.

For this to happen we must forgeahead on research in biology, micro-biology, food safety and quality.These are areas, where the public andprivate sector can work together.

It is in fact an ambition for theDanish Government to use one per-cent of Gross National Product onpublic research and science. Know-ledge gained from research in thefood industry must be put to practi-cal use.

New challengesGrowth in the agricultural sectoralso means new challenges, especial-ly within environmental effects, an-imal welfare and food-safety.

Our tested - and proven - premiseis however, that there does not haveto be a conflict between on the onehand growth and on the other envi-ronment, animal welfare and food-safety.

To realize our ambition, we arenow in the process - in close dialoguewith industry and other relevantparties - of developing a strategy forsustainable livestock production.Danish agriculture is subject to per-haps the strictest regulations in theworld, when it comes to food safety,animal welfare and environment.

It is however essential that theconcerns of food-safety, animal wel-fare, environmental responsibilityare based on a public-private part-nership, where the common ambi-tion is to maintain high standards inDanish food production. Ultimately,we have a common aim, which isthat consumers - in Denmark as wellas abroad - may continue to trustand enjoy Danish food. ■■

By Hans Chr.Schmidt,DanishMinister ofFood,Agricultureand Fisheries



Customer needs in the food industry are highly

individual and this is why we deliver solutions made

to meet any specific demand. But fulfilling today’s

standards is not enough if you want to keep your

competitive edge. That’s why we work continuously

to establish advanced technological and scientific

benchmarks for the new millennum.

The consumers want the best and the latest.

Together with you we are ready to develop

new technologies and tempting tastes within

our core business the scraped surface heat

exchangers and emulsification equipment.

Having a strong weapon in the fierce battle

for the consumers’ satisfaction and loyalty

will be even more crucial in the 21st century.New and pleasurable tastes will become one of the key competitive elements for tomorrow’s new fastidious consumer.

100 years of experience wouldn’t do us much goodif we weren’t already preparing for the next

The GS container plant is the all-in-one compact solution designed to take on the challenges of the new millennium. Ready to go. Easy to handle.

PA

RA

ME

DIA

09

58

/7I

www.gerstenbergschroeder.com · Tel: +45 4327 7000 or +49 451 37 09 0

Engineers of Food Processing Technology

958_gs_ann_7I_T1 1 02/06/05 17:15:33


Arla Foods KeepsHealth and Safety

In June 2005, Arla Foods combinedforces with other large Danish foodcompanies and scientific institu-tions (including the University ofAarhus) to form a new scientific cen-tre to conduct research into healthyand safe food products. The objec-tive of the so-called Nanofood Con-sortium is to strengthen collabora-tion between the food industry andpublic research initiatives and thuscontribute to the development ofhealthier, safer and nutritious food.

The term for a billionth of a unit,nano technology enables research intominiscule dimensions and could beof huge importance to the food in-dustry where research, for example,could lead to the invention of sur-faces that reject bacteria coating onfood or technology that could estab-lish when milk has turned sour.

Obesity influences productdevelopmentAt a more basic level, developing pro-ducts with reduced fat and sugar con-tent continues to play an importantrole. As the number of people suffer-ing from obesity is rising steadily, pre-ventive measures against "rich man’s"diseases have, for quite some time,been part of Arla Foods’ product de-velopment.

"Arla Foods is committed to de-veloping alternatives to dairy prod-

ucts with a high fat and sugar con-tent - particularly concerning obesi-ty in children," explains MereteMyrup Christensen, head of ArlaFoods’ Nutrition Department. "Withregard to fat and sugar, the dairies’primary task is to reduce the contentof fat in food. However, in our opin-ion, food should be seen in context.Full-fat cheese can well be part of ahealthy diet as long as you cut downyour fat intake elsewhere."

Danish and Swedish consumerscan currently find a broad selectionof reduced fat versions of dairy pro-ducts in their supermarket chilled

counters - and, in many cases, salesof such products are rising.

To meet consumer demands forreduced fat products, Arla Foods re-vised its payment system for its co-operative members in 2003. Thenew payment model means thatmilk producers are paid a premiumfor the protein content ratio in themilk supplied compared to fat, thusmotivating producers to develop amore fat-reduced raw material.

In recent years, the debate aboutsugar in food products has, however,overshadowed the fat issue and somemedia have criticised dairy products


By Ulla Kjer,Journalist, Arla FoodsCorporateCommunica-tionsDepartment

Since Arla Foods every day of the year, supplies dairy products tomillions of people across the world, taking responsibility for qualityand food safety as well as nutrition and health is deeply embedded indaily life at Arla. This is reflected in all levels throughout the Group -from cattle feed to research into nano technology.

The milk’s composition is one of four cornerstones of the quality programme Arlagården.


High on the Agenda

such as yoghurt, chocolate milk anddrinking yoghurt for having toomuch sugar.

Despite the fact that Danes onlyintake 5% of their overall sugar fromdairy products, Arla Foods is focus-ing on reducing sugar levels in anumber of product areas.

"The problem with eliminatingsugar from the products is that con-sumers are used to - and, in general,prefer - a sweeter taste," says Devel-opment Technician in Arla Foods In-novation, Ingermarie Jensen.

"You could say that taste levelswere determined when there wasless emphasis on sugar in food," sheadds. "At that time, the average con-sumer did not consume so muchsugar as they do today when con-sumption of, for instance, confec-tionary and soft drinks has risentremendously."

Quality begins at ArlagårdenIncreasingly, however, consumers arealso considering issues other thanhealth when shopping for dairy prod-ucts. Today, animal welfare, traceabil-ity and safety are all part of "food qual-ity." Launched in 2003, the qualityprogramme Arlagården aims at inspir-ing consumer confidence in ArlaFoods’ dairy products.

The Arlagården programme wascreated in a close partnership withArla Foods’ co-operative membersand includes all milk producers whosupply milk to Arla. The programmeis founded on four cornerstones: themilk’s composition, animal welfare,environmental conditions and tra-ceability. Arlagården also sets outmore far-reaching requirements thanlegislation prescribes in areas such asanimal feed, infection prevention,cleaning etc.

Moreover, Arlagården has madetraceability more transparent in allareas. The origin of feed can, for in-stance, be traced back from the sup-plier’s invoices and delivery notesand milk samples are taken fromeach farm on an ongoing basis. Theregistration system can also identifywhich farm has supplied the milk,which tanker has transported it andthe dairy that has received it.

Before April 1, 2006 all Arla farmswill have received introductory vis-its during which quality inspectorsand owners review the farms’ opera-tions and where the inspectors assistfarmers in meeting the stipulated re-quirements. The results from thesevisits will determine whether a farmis "approved," "approved with an ac-tion plan" (which must be imple-mented before the next ordinary vis-it) or receive a "follow-up visit."

Quality systems harmonizedQuality management, of course, con-tinues at the dairies. Although allArla Foods’ dairies comply with oneor more internationally recognisedquality management standards, therehave been minor variations in theway the systems at the individualplants are designed. In order to har-monise the systems and provideconsistent documentation, Arla Foodsdrew up a common Foods Safety Poli-cy from early 2005.

This policy aims at creating ajoint food safety platform for all ArlaFoods’ production sites - initially inthe UK, Denmark and Sweden. Tosupport the policy a Code of Practiceis continually updated, includingrules governing personal hygieneand hygienic design of machinery.The Food Safety Policy and the Codeof Practice are expected to be fullyimplemented by 2007. ■■


Arla Foods’ product development takes place in close collaboration with consumers. Atthe Group’s Development Centre near Århus, consumers are trained to make tasteprofiles of the products. (Photo: Niels Åge Skovbo).


High qualityA millimetre can be very importantfor a food manufacturer if it consti-tutes an increase in the channeldepth of a plate heat exchanger. AlfaLaval has developed a new model inits well-known Baseline range ofheat exchangers with a plate depththat has been increased from 3 to 4millimetres. By quick calculationthat is an increase of 33 per cent,which is palpable. However, the im-portance for the quality of food pro-duction processes is significantlyhigher.

The design makes the new heatexchanger a very competitive alter-native for heating/cooling and smallflow rates and the best choice for du-ties in processes and utilities. Espe-cially in connection with dairy, bre-wery, beverage and viscous productsand for some applications also inconnection with pasteurisation.

Gentle treatmentThe increased channel depth im-plies a more gentle treatment of theproduct and increased flexibility inthe flow. In large-scale or continu-ous food processing, heating andcooling are as central to good tasteand quality as the recipe.

All Baseline parameters, i.e. theinlet and distribution of the liquidover the plates and the heating/cool-ing in the heat exchanger, are de-signed to improve the flow of theproduct. It is important to achieveeasy passage in the inlet, as bad pas-sage entails pressure, which maydamage the product.

The increased plate depth in Base-line makes the heat exchanger suit-able for products containing solidparts, e.g. foodstuffs, as solid partscan pass unhindered and efficiently.

This is important in a time whereconsumers want food to taste ashomemade with fresh ingredientsand demand flavour and other phy-sical properties such as a good"mouth feel" or texture. Equally im-portant is the need to kill micro-bac-teria, but still retain vitamins andminerals and colour.

Achieving these characteristics ina food product places special de-mands on the heat exchangers andprocessing equipment.

Increased flexibilityFurthermore, a new frame has beendeveloped for Baseline. It has beendesigned to work with up to 10 baragainst only 6 bar in the former ver-sion.

Alfa Laval has lengthened theframe so that it is now possible tomount 80 per cent more plates in aplate pack. In this way, the capacityof the heat exchanger is increased bymore than 50 per cent.

And flexibility has also been tak-en into consideration. The glue lessclip-on-gaskets can be replaced quick-ly and easily on site with the plateshanging in the frame. The foodgrade gaskets can be delivered in arange of materials (NBR, EPDM) fordifferent temperatures and applica-tions. The units are held together bysturdy, pressure-graded frames withmany clever, hygienic and labour-saving features. All frames offer greatflexibility to expand and rebuild theplate heat exchangers.

The frame is made from 100 percent stainless steel in order not tocompromise the hygiene if the me-tal should become scratched or dam-aged during use.

Food processing plates The design of the Clip Plate range isbased on many years of practical ex-perience of what is really needed infood applications, the result being awell-balanced accommodation of allthe requirements of the trade in theshape of a range of plates custom-de-signed for efficient thermal treat-ment of liquid food and sensitiveproducts.

Food manufacturers will benefitfrom the thermal advantages of AlfaLaval’s heat exchangers. The uniquedistribution pattern ensures an evenflow over the entire plate, which op-timises the heat utilisation and inturn ensures an increased heat trans-fer capacity. Furthermore, Alfa La-val’s plate design with the two in-verse flows ensures high heat utilisa-tion. Generally, the heat utilisationof plate heat exchangers is morethan 30 per cent better than that ofother types of heat exchangers.

The plate heat exchanger allowsCIP (cleaning in place) with the flowthat is also used in the main process


Baseline Optimises and Heating

By MogensEspensen,Manager ofSanitarySolutions, Alfa LavalNordic A/S

Channel depth of Baseline heatexchanger is increased from 3 to 4mm. Thus, Baseline optimises thecooling and heating of dairy, bre-wery, beverage and viscous pro-ducts as well as the pasteurisationprocesses.


Cooling

- no need for special pumps or addi-tional units.

TraceabilityAll Baseline heat exchangers arepressure tested before they leave AlfaLaval. The technical documents de-scribing the operating conditions ofthe individual heat exchanger fol-low the heat exchanger togetherwith the instruction manual. ■■


Alfa Laval has developed a new model in its well-known Baselinerange of heat exchangers with a

plate depth that has been increasedfrom 3 to 4 millimetres.

Alfa Laval in the foodindustry

Alfa Laval is a world-leading supplier ofheat exchangers for a wide range ofsanitary applications within the food,dairy, beverage, bio-pharm and perso-nal care industries. Our equipment isdeveloped not only to meet your spe-cific demands for safety, efficiency andhygiene, but also to ensure carefulhandling of your products.

Alfa Laval is a genuine partner tocustomers in the food industry, sup-plying components for all stages ofyour process. Besides heat exchangers,our sanitary range includes valves,pumps, installation material, and tankequipment.

Our worldwide organisation worksclosely with customers in almost 100countries to help them stay ahead oftheir competitors.

Visit www.alfalaval.com for moreinformation.

Dalum College of Food and Technology

The high standards of Danish dairy and foodtechnology are recognised and appreciatedworldwide. Dalum College of Food and Tech-nology has played an important part in devel-oping and maintaining this excellence. Ourinternational activities focus on the integrationof food education and are based on our fun-damental concept "from soil to table".

Dalum College of Food and Technology offerstailor-made courses for the global dairy sectorand food industry.

Dalum College of Food and Technology alsohouses the only dairy college in Scandinavia:The Dairy Training Centre of Denmark, whichspecialises in courses in dairy technology, labo-ratory techniques, maintenance of dairy equip-ment, environmental engineering, energy sav-ing, quality control management, and runningdairy plants.

Our mission is to continue to expand our inter-national courses and contacts.

Please contact us for more information.

Landbrugsvej 55 ● DK-5260 Odense S ● Tlf. +45 63 13 20 43 ● www.dalumuc.dk ● [email protected]


Control and Traceability - in a Margarine Produc

Traceability with GS LogicToday, margarine, like other foodproducts, is in many factories pro-duced under strict traceability proce-dures. In order to be able to reactfast, food manufacturers need to beable to trace the origins of the ingre-dients in case of contaminations ofthese. The traceability procedurescovering the ingredients, the pro-duction and the final product notonly result in an enhanced food safe-ty but also in a constant food quali-ty since the raw materials have tomeet distinct specifications and theproducts are manufactured and dis-tributed under defined conditions.

The traceability demands can easi-ly be implemented in the control sys-tem of the factory. Apart from com-plete processing lines to the indu-stry producing margarine and othercrystallized fat products, GerstenbergSchröder deliver the GS Logic systemwhich is designed to control, record,and document important parametersconcerning the complete manufac-turing process. The system helps toimprove plant performance by creat-ing a consistent processing environ-ment. The GS Logic exists in three ver-sions: GS Logic Basic, GS Logic Ad-vanced and GS Logic Professional; thelatter version includes a web-basedrecipe editor and a web-based reportsystem with traceability for each com-ponent controlled by the system.

Raw material quality controlMargarine and crystallized productslike butter and spreads are charac-terized as water-in-oil (w/o) emul-sions for which the water phase isfinely dispersed in the continuousfat phase. The ingredients used formargarine production can be divid-ed into water-soluble and fat-solubleingredients and obviously the docu-mentation is linked to these phases.The subsequent processing is divid-ed into the following productionsteps: emulsion preparation, pasteu-rization, crystallization and filling orpacking - please see the process flowin figure 1.

All raw materials are subject toquality control when received andcan only be used in productionwhen it has been verified that theymeet the specifications. E.g. the sol-id fat content (SFC) profile which de-

scribes the amounts of solids at giv-en temperatures for a fat is typicallychecked when fats are delivered.Batch numbers of the individual in-gredients can be registered in thespecific margarine batch for trace-ability. The specific margarine pro-duction is recipe-controlled and theproduction is typically divided intoseveral batches of the same recipe.Hereby, the final margarine productcan be linked not only to the recipebut also to the individual batches ofthe product-related production.

When the emulsion is created inthe premix tank by adding the melt-ed emulsifier blend to the meltedfats and oils and adding the waterphase subsequently, flow meters orweight cells control and ensure thatthe correct amounts of the variousingredients are added. The controlsystem registers and files these

NR. 1510 Danish Dairy & Food Industry... worldwide 2005

By PernilleGerstenbergKirkeby,Manager ofTechnologyandMarketing,GerstenbergSchröder

Additives Additives

Oils

Stock

Palletising

Cartonising

Packing Remelt

Crystallisation

Pasteurisation

Buffer

Premix

Emulsifier Water phase

Figure 1: Process flow.


amounts for later reports along withthe tank temperature of the incom-ing phases and final emulsion. Theemulsion is pasteurized prior to pro-cessing mainly to guarantee destruc-tion of any unwanted micro-organ-isms and of all pathogenic bacteriabut the pasteurization process alsoensures a constant and stable inlettemperature that facilitates the laterprocess control.

Historic data loggingThe GS Logic system is equippedwith a password system and featureshistoric data logging of all tempera-tures, pressures, loads and speeds ofthe units involved in the margarine

processing line including the capac-ity and output of the high pressurepump (liters/hour and back pres-sure), product temperatures (includ-ing pasteurization process) duringcrystallization, cooling temperatures(or cooling media pressures) of thescraped surface heat exchangers(SSHE), speed of the SSHE and thepin rotor machines, load of the mo-tors running the high pressure pump,SSHE and the pin rotor machines.

Processing parameters for specificproducts are set in the recipe editorand these parameters depend onproduct type and recipe. If the pro-cess parameters during processingare out of limits, the system will sendan alarm which has to be acknowl-edged manually by the operator andactions according to procedures canthen be taken. All alarms are storedin a historic alarm system for laterview. When the product leaves theproduction line in a suitably packedor filled form, it is apart from theproduct name typically marked witha date, time and batch identification

number for later tracking. Qualitycontrol of the final product involv-ing sensoric and analytical proce-dures follows after 1-7 days of stor-age (the length depends on the na-ture of the product) and the productis hereby ready for shipment.

Fully process controlThe complete history of all the pro-duction steps involved in manufac-turing margarine and crystallised fatproducts is thus filed for the securityof the producer and the end user, theconsumer. Now the manufacturerhas control of the ingredients in-volved in the production of thefood, the process is fully controlledand the end product is marked forlater trace. The GS Logic system of-fers the needed documentation ofthe process in order to identify andcorrect potential problems quickly.This not only helps to save money inthe process by getting back on linerapidly, but also ensures productquality, consistency and security. ■■

tion Facility


EINAR WILLUMSEN-partner with the food and beverage industry

A/S Einar Willumsen Abildager 23-25, DK-2605 Broendby, Denmark Phone: +45 4345 2244, Fax: +45 4345 9400AB Einar Willumsen Betselgatan 3,Box 9213, S-20039 Malmoe, Sweden Phone:+46 40670 1900, Fax:+46 4022 0401Einar Willumsen«s sales office,Norway Murgarden,Postboks 34,N-2688 Lom,Norway Phone:+47 6121 9110, Fax:+47 6121 9109Einar Willumsen«s sales office,Finland Aurakatu 1C,3 Kerros, Fl-20100,Turku, Finland Phone:+358 2251 6599, Fax:+358 2251 6598 E-mail:[email protected]

www.einarwillumsen.com

� Beverages

� Spirits

� Confectionery

� Bakery Products

� Dairy Products

� Convenience Foods

� Processed Fish Products

The Flavour SpecialistsReady-to-use flavour and compound solutions for:


Production of processing equipmentfor the food industry has always hadto comply with ever increasing de-mands in respect to hygiene, relia-bility and safety.

The technological developmentsover the last decades have added tothese demands and today full pro-cess documentation as well as com-plete traceability, from raw materialto finished product, must be regard-ed as a standard facility in any pro-cess line within the general food in-dustry.

InnovationInnovation has always been a focusarea in Damrow´s activities andsince its foundation over 100 yearsago, CPS Damrow has invented se-veral types of equipment for thecheese producing industry, the mostimportant one being the enclosedDouble-O Cheese Vat. This inven-tion alone set new standards for hy-giene in cheese production.

Continued innovation and devel-opment in order to meet new de-mands and standards will remain akey focus area for CPS Damrow, asthis is the only way to maintain ourposition among the preferred sup-pliers to the cheese producing in-dustry.

Traceability and documentationIn order to fulfill today's demandsfor product traceability and full do-cumentation of process data, CPSDamrow have in corporation withour automation partners, securedthat all of our control units can storethe needed data and present these inalmost any form our customers maywish, and/or transfer the processdata to all of the most widely usedmanagement information systems.

Always using the latest technolo-gy for securing process data for trace-ability purposes is a natural and con-tinuous process for CPS Damrow, asthe cheese manufacturing industryhave always been used to tag theproducts with dates, batch numbersetc.

Case storyBeing the leading supplier of processequipment for the production ofcottage cheese, a large part of CPSDamrow development resources isput into these process lines.

Part of the cottage cheese produc-tion involves draining of the wheyand subsequent washing and cool-ing of the curd, the washing andcooling part typically done in tanklike "cooling towers" resulting in ex-cessive water consumption and un-necessary fines losses.

At CPS Damrow we decided to fo-cus on this problem, to reduce waterconsumption, to secure a gentlerhandling of the product and to min-imize fines losses.

Consequently, we developed theDamrow Drainer Washer, a speciallydeveloped machine for the cottagecheese industry.

In one single pass through themachine the whey is effectivelydrained off, the curd is washed andcooled and can be easily pumped to


High Quality Equipment Cheese

By Jakob MalthaRasmussen,Sales Manager,Damrow A/S

Damrow A/S - the Danish part ofCarlisle Process Systems, suppliesthe highest quality equipment forany type of Cheese Processing,using the newest design and tech-nologies and in compliance withUSDA and EHEDG standards.

Damrow Drainer Washer.


for Production

subsequent blending and/or pack-ing.

During the development of themachine, we decided not only to fo-cus on the process advantages butalso on hygienic design, safety andreliability in operation and easymaintenance.

This has resulted in a cottagecheese draining and washing pro-cess that gives a minimum 3-5% in-creased yield due to reduced fineslosses (in some cases up to 10%) a re-duction in water consumption in ex-cess of 30% compared to the tradi-

tional cooling tower and with theadditional benefits of a better struc-ture in the cheese grains, better tastedue to non-contamination from coo-ling tower water and less risk of bac-teriological contamination.

Simultaneously we have securedthat design and construction havebeen made in accordance with EH-EDG and USDA standards enablingCPS Damrow to market a machinethat is in compliance with all thestandards and demands of today'scustomers (and tomorrows.) ■■


● Enclosed Cottage Cheese Vat● Drainer Washer● Drainer Creamer

CompleteCottage Cheese lines

Damrow A/SCarlisle Process System

Frichsvej 15, DK-8600 Silkeborg

Tel.: +45 7550 5499Fax.: +45 7550 5489

[email protected] www.damrow.dk

Cheese Technology

- World leader in Cheese Equipment

CPS Damrow

CPS Damrow is part of the CarlisleProcess Systems group of companies.CPS Damrow is an engineering companyspecializing in process equipment forthe cheese industry worldwide and istogether with CPS companies Wincan-ton (UK) and Scherping (USA) marketleader in supply of process equipmentfor production of cottage cheese andcheddar as well as among the leadingsuppliers of cheese processing equip-ment in general.

At CPS Damrow we take pride inbeing a leading supplier of processequipment to the cheese manufacturingindustry and we strive to ensurecontinued development and innovationas well as providing our customers withupdated know-how and unparallel ser-vice.

CPS Damrow in Denmark currentlyemploys 15 people and has an annualturnover of Euro 10 mill.


Safety and process optimisation A requirement to be met by modernindustrial data acquisition systems isthe safeguarding of production. Asound production guarantees a con-stant food quality and thereforebrand value. Today the protection ofa brand and thus the manufacturer’simage are more important than ever.Unforeseen events in productionmust therefore be kept to a mini-mum.

In the meantime, the regulatoryframework has been changed so thattraceability is now firmly enshrinedin law. Under Regulation (EC) 178/

2002 the food industry was obligedto set up systems for the tracking ofproduction processes by 1 January2005.

Manual documentation systemand manual traceability can be anexcellent solution for certain foodmanufacturers. It can be practicalwith volume production, discipli-ned personnel who record values orin situations where a company hasjust a few suppliers or customers. Assoon as one departs from these con-ditions, the information flow ex-plodes, which prevents productionoverview, rapid analysis or an effec-tive limitation of a recall.

An electronic system such as TetraPak’s Work Tracking has many ad-vantages over a conventional systembased on manual documentation.On the one hand, the recorded data

can also be used to optimise process-es, therefore often enabling a refi-nancing of investments in a shorttime, if the system is used consis-tently. On the other hand, the re-sponse time in relation to public au-thorities and customers in the eventof faults is much shorter than in thecase of manual documentation. Be-ing able to respond quickly helps tomaintain confidence in the brand.

A batch-based process with pro-ductions separated by cleaning cy-cles is relatively easy to track. It is adifferent matter with regard to con-tinuous and semi-continuous pro-cesses. This is where the Work Track-ing has its main focus and helps theuser to achieve a consistency andtransparency that is otherwise onlypossible in batch processes.


Figure 1: In Work Tracking, each production can be represented graphically in a tree diagram.

What does a Traceability System Mean?

By Björn Olsson, Tetra Pak Processing Systems AB

➔



Joy of eating



Logging production dataEverything that occurs in the au-tomation system can be logged au-tomatically in a database and taggedwith a specific identity. This meansit is possible to automatically com-pare parameters between produc-tion runs by producing a report,which will probably reveal any qual-ity problem that has occurred in aspecific period. In this way, it is pos-sible to solve problems concerninginconsistent quality or difficulties inrunning a particular product. In ad-dition, it is possible to automaticallyproduce a report defining all targetand actual values during production- all events and any errors that oc-curred during a particular produc-tion run. Laboratory data can beadded and connected directly to thetagged output.

Reports The evaluation of the historical op-erations recorded by the Work Track-ing module is done with the Tetra

navigator. The navigator is web-basedand runs under Internet Explorer. Bymeans of various search keys, such asdate, unit name and Work ID, the rel-evant production can be quicklyfound worldwide from any Internetprovided PC, of course only with thecorrect access and safety.

Each production can be repre-sented graphically in a tree diagram(see figure 1), from the reception sta-tion up to the exit point of the plant,e.g. to the filling station. Detailed re-ports can be produced at the push ofa button and contain all data rele-vant to the production, such as pro-duction time, operator, quantitiesproduced, etc.

Traceability - a demand andopportunityExamples of added value are: supportactivities and increased visibility inproduction processes that give mea-surable profits in the use of resources(like increased capacity), positive gains(like high product quality) and better

coordination and efficiency (like re-duced manual reporting and increa-sed online follow-up).

Transparency in the value chainis an important result of traceability,particularly in the long run when allthe pockets of information are con-nected. This means that consumers,distributors and producers and sup-pliers of raw materials can show crit-ical data to each other, which in turnwill lead to better products, betterprognoses, better services and high-er quality for all participants in theadded-value chain.

The automation modulesRegardless of which level of automa-tion complexity you might be at to-day or plan to be in the future, it isessential to secure that various Au-tomation Modules (see figure 2) bothhardware-wise and software-wise havea reliable and "built-in-future" struc-ture, all in order to protect the in-vestment and production capabili-ties.

Figure 2: Automation modules.


Typical Automation Modules with-in a Plant Automation solution are:● The User Interface makes visible all

food plant equipment and func-tions, and presents information ona colour monitor in an easily un-derstood format, self-instructivestructure and the compliance withinternational standards.

● The Process Control with its trueopenness, scalability and built-infuture allows you to control singlemachines or build up a total con-trol and management system andas well secures your investment forfuture extensions.

● The Data Acquisition enables smartdata acquisition from the ProcessControl module and the User In-terface module to the database in arobust manner and utilizes as wellbuilt-in fault tolerance and theability to optimize reading andwriting of plant data.

● The Production Dispatching enablesyou to download orders from your

ERP system to the automation sys-tem or the possibility to create or-ders manually from the automa-tion system all in accordance withthe World Batch Forum’s guide-lines.

● The Production Reporting providesinformation on how products andmaterials have been transported inthe plant as well as monitoring ofCritical Control Points and CIP in-formation, all in an easy and user-friendly matter. Moreover, since itis a WEB-based tool, all reports canbe viewed from any PC with Inter-net connection worldwide withthe correct access and security.

● The Production Analysis enables youto build up data on key perfor-mance indicators (KPI’s) so that overtime the analysis of stored data canhelp you make an entire processingplant more productive.

● The Work Tracking described in pre-vious chapters, presents immedi-ately in an easily understood way

on screen and/or as various printedproduction flows, reports and trendsall in compliance with stricter regula-tory demands concerning food safe-ty. Actually, it goes beyond today’s re-quirements. ■■

Comment from one of our key-cu-stomers, Arla Foods Rødkærsbro, whorecently installed a new automationsystem from Tetra Pak:

"These software modules help usto achieve e.g. cost-effective CIP,minimal water and electricity con-sumption and most important rapidcorrection of any faults found inproduction."


You probably know our customers better than you

know us, but our products are everywhere, and their

content is being used everyday at home or at work...

– part of your day


Customer oriented solutionsOlssons-Machinery, founded in 1955,strives to establish it self as one of theworlds leading suppliers of machineryto the dairy and food industry.

Our major products are; cheesewaxing machines, cheese-packingmachines, cheese-cutting machines,and aseptic "bag in box" filling ma-chines. Furthermore, we also con-struct and manufacture; custom fit-ted pneumatic seat valves in stain-less steel AISI 316, non-return valvesto build in unions DIN, DS, SMS andfinally build in valve for tanks.

The features in Olssons productsand solutions are based upon: Qual-ity, Flexibility and Efficiency.

With more than fifty years of ex-perience as supplier to a wide range offood industries, Olssons is well awareof, what fine craftsmanship supple-mented with the latest technologyand high level of quality mean to amodern and efficiency company.

Cheese waxing machinesOur fully automatic wax coating ma-chines for cheese employ the brandnew technology that includes spray-ing, bottom waxing rollers, andbrushes. The cheese is transportedthrough the system on a speciallydesigned wire mesh belt, which al-lows spraying from below. The sys-tem facilitates the use of differentwax colours by having interchange-able wax tanks. These wax tanks aredesigned to prevent overheating andscorching of the wax and product.

The system is available in morewidths and the machine inlet andoutlet can be tailor-made to meet thedairy’s requirements.

Cheese cutting equipmentYou will get the widest range of cut-ting and portioning equipment forany type of cheese from Olssons-Ma-chinery.

For hard cheese, our product ran-ge includes fully automatic cuttingand semi automatic machines with

up to three cutting stations. The ma-chines are offered in several differentwidths. Fantastic flexibility is achiev-ed by having interchangeable cut-ting frames and cutting blocks.Changing the cutting equipment toa different size can be done in lessthan 60 seconds. Either wire orknives can do the cutting.

The inlet and outlet can be adapt-ed to suit your factory and full au-tomation can be supplied to ensurethat our machine will work withyour existing equipment.

Aseptic "Bag-in-Box" fillingOur Aseptic "Bag-in-Box" Machine isdesigned for sterile filling into bags.Our machine is equipped with aDanfoss mass flow meter, whichgives a system accuracy (tolerance)less than 0,1% of the current flow.

The filling amount and choice ofprogram is performed on the front ofthe machine by a finger touch screen.

As sterilization during the fillingcycle, a barrier of sterile air and 4%hydrogen peroxide (H2O2) is spray-ed over the filling head throughstainless steel nozzles. A filter is in-stalled to make the air sterile. Thisfilter can be sterilized by using satu-rated steam.

The aseptic "bag in box" fillingmachine from Olssons has an ad-justable roller table, and is con-structed with a connection unit forCIP-cleaning and water separator forsteam sterilization.

The machine is working semi au-tomatic thus, the operator manuallyplace the bag in the machine andpres the start bottom. The rest of theoperation runs automatically; Corkof, Filling, and Cork on. The fillingcan be done either through a sterilepressure tank or through a monopump and eventually a by-pass valve.


Quality, Flexibility and

By Ole Olsson,ProductManager,Olssons-Machinery,Denmark

Olssons Aseptic "Bag-in-Box" Machine.


EfficiencyThe capacity depends on the bag

size and product viscosity - from1000 - 5000 l/h. When filling juiceand milk products the capacity is ap-proximately:

3 bags of 20 kg/min5 bags of 10 kg/min7 bags of 5 kg/minFor delivery of aseptic bags, we

are cooperating with several leadingcompanies in Europe.

Pneumatic seat valvesRecently, Olssons-Machinery has laun-ched a new generation of custom fit-ted stainless steel pneumatic seat

valves. Our high quality seat valvesare designed in stainless steel AISI316. The valve head is supplied witha heat resistant seal ring and closeagainst a stainless steel seat. Thevalve stem is sealed by viton rubberseals for using in many applications.

By Olssons you can get the design"tailor-made", in the exact configu-ration you want.

High quality and efficiencyOlssons fully customised "tailor-made" solutions to the food industryare created as a result of very closecooperation with the food process-ing companies and customers allover Europe. ■■


Olssons Cheese Cutting Machine.


We experience that higher and high-er demands are made on the engi-neering standards for hygienic de-sign, cleanability and product safetyin the manufacturing of processingplants for the dairy industry.

Engineering and manufacturingof processing plants combine manybranches of knowledge like choice ofconstruction materials and compo-nents, process design, plant engi-neering and, naturally, plant finishlike weldings and surfaces.

At DSS Silkeborg, we make greatdemands on the plants that we de-

liver. We relate to national and in-ternational standards of our specificfield of expertise, and on top of this,we develop our own standards thatare carefully observed also by oursub suppliers.

Many of our customers also havetheir own set of standards, and inthat case we cooperate closely in or-der to adjust the plant to their spe-cific demands.

Today, most recognized plant sup-pliers have sufficiently high stan-dards for engineering and manufac-turing, and focus is moved on to oth-er areas. Among others, attentionhas been drawn to the area of "foodsafety" with specific emphasis for in-stance on contamination preven-tion, product traceability, data log-ging and optimization of cleaningprocedures and process water quali-ty.

Simple and reliable data loggingIn order to supervise and optimisethe operation of a membrane filtra-tion plant, log sheets with key pro-cessing parameters are always filledin. Thoroughly completed log sheets


The DSS Data Reporting System auto-matically contains a Daily Log, a Pro-duction Log and a CIP Log. The systemprovides an unlimited possibility of ana-lysing and monitoring data.

Hygienic Design,

By Jan Sprogø,MarketingManager, DSS SilkeborgAS

To ensure an optimal plant and pipingdesign as well as a smooth and accurateplant installation, all DSS plants areengineered using 3D computer modeling.


contribute to the overall producttraceability and are invaluable in theprocess of troubleshooting. Most logsheets are manually filled in andstored by the plant operators.

By means of a communicationcard in the plant PLC-control, datafrom a DSS membrane filtrationplant can be collected and presentedin the general data collection systemof a specific dairy.

With a DSS Data Report Systemlinked to the DSS membrane filtra-tion plant control, log data duringproduction and CIP can be automa-tically collected and presented in anMS windows environment.

When a DSS Data Report Systemis installed in a new DSS plant, theadditional price is only €5.900,-. De-pending on plant instrumentationand control system, the system canalso be connected to an existingmembrane filtration plant.

Membranes are traceable tooIn the production of DSS mem-branes there is great emphasis onproduct quality and traceability. EachDSS membrane has its own identifica-tion number and, by means of a thor-ough test and quality assurance sys-tem, each element can be tracedback through the production pro-cess and to its original raw materials.

Safe process water recyclingIt is more and more common to re-cycle process water, and generally,recycling is always required on newinstallations. Process water may con-sist of RO permeate or evaporatorcondensate, which – depending onthe specific process - typically has aCOD content of 200-2000 ppm. Dueto the high COD content, it is oftennot feasible to discharge the waterdirectly, and the risk of bacteriologi-


Cleanability and Product Safety

When new DSS elements are mounted in a plant, a log is kept over each element’sspecific placement. In this way full traceability is ensured also with regards tomembranes.


cal growth is simply too high for thewater to be stored and recycled.

The solution to this problem is touse an RO plant for polishing of theprocess water in order to remove or-ganic material. Depending on thefeed composition, its pre-treatmentand the concentration degree in theRO plant, the COD in the purifiedprocess water is often too low to bemeasured precisely (<30 ppm). Andin any case, the water will be purifiedto a degree, which ensures safe recy-cling. ■■


DSS Silkeborg AS

DSS is a specialised engineering com-pany developing and supplying mem-branes and membrane filtration systemsfor dairy processing worldwide. The majo-rity of the 35 employees have workedwith membrane filtration and dairyprocessing since the beginning of the1980’s.

The strategy is to keep attractingand developing the industry's mostqualified membrane and dairy proces-sing experts and to contribute activelyto dairy processors' competitiveness bysupplying innovative, state-of-the-artmembrane solutions and by maintaininga far-sighted, open-minded working re-lationship with the customers.

In the past five years, DSS has in-stalled 150 complete membrane systemsand supplied membranes for an evenlarger number of plants. The referencelist counts more than 300 dairy com-panies.

Projects

Know-how

Plants

Membranes

We know what it takes

We know what it takes to be successful inthe dairy industry. That is why the leadingEuropean dairy manufacturers rely on ourexpertise over and over again.

Frichsvej 21 · DK-8600 Silkeborg · Tel. +45 8720 0840 · Fax +45 8720 0890 · www.dss-silkeborg.com

On new RO plants, like here in connectionwith WPC production, it is standardprocedure to add an RO polisher plant topurify and use the RO permeate as processwater. Since the feed for the polisher isquite easy to process, it is most common touse 8" RO membrane elements. In order toobtain an even higher product safety, DSSoffers RO polisher membranes that can behot water disinfected at 80°C.


Adjusted hygieneWhereas, previously there seemed tobe a clear divider between normalfilling machines and aseptic fillingmachines, these years we see a fad-ing, where the hygiene becomes op-timised for the specific product andthe specific needs.

At Trepko we have created a con-cept for this demand called "Adjust-ed Hygiene". In this concept the ma-chine is optimised for the productand the need. This is typically donein an Ultra Clean machine or in ma-chines where one or more of theprinciples from the Ultra Clean ma-chine are used.

The "Adjusted Hygiene"-conceptallows a selection from a wide rangeof shelf life prolonging options,whose efficiency are often dramati-cally increased if used in the rightcombination (please refer to table 1).

Especially one option seems in-creasingly popular within the dairysector, as it offers a relatively high ef-ficiency compared to its cost. This isthe sterile air cabin.

The sterile air cabinThe sterile air cabin ensures that thefilling is performed in a filtrated at-mosphere, practically free of harm-ful microorganisms.

Especially two parameters are im-portant to the efficiency of the ster-ile air cabin: The airflow in the cab-in, and the efficiency of the filters.

The air flow For the creation of a clean atmos-phere in the product zone, it is im-portant that the air is constantly re-newed, and that air pockets are pre-vented. With an efficient flow, theairstreams inside of the machine willnot be volatile to drafts in the pro-duction room. Furthermore conta-minated air from when the machineis started up, or after the doors of thecabin have been opened will quickly(in less than 60 sec.) be blown out ofthe machine and renewed with cleanair.

In order to achieve an efficient air-flow inside the cabin, a route for theair to enter and leave the machinemust be decided upon. The naturalway for this, and the way used inTrepko machines, is for the air to en-ter the in the top, and leave from thebottom of the sides (Figure 1).

The new possibilities, which havearisen from computers with increas-ingly fast processors and programswith increasingly efficient algo-rithms, allow efficient use of analy-ses on the airflow inside the ma-chine. These tools combined with3D-CAD systems allow thoroughsimulations of the airflow, with ex-act calculation of vectors based onthe airspeed and direction, in everycorner of the cabin (Figure 2).


Cups Foils Product piping Product zone

Vacuum- UW- CIP-system Sterile air cleaning radiation cabins

Steam Peroxide Aseptic Aseptic treatment treatment valves atmosphere

UW- Vacumationradiation of cups

Peroxide Gas flush of treatment cups

Table 1: Hygienic options.

Figure 1: In Trepko machines the airenters at the top, and leaves from thebottom of the sides.

Figure 2: This "air speed map" allowsthe designer to constantly consider thedesign of the surfaces, enabling himcontinuously to optimise the flow insidethe machine. These tools, which wereunthinkable, only a few years ago, haveenabled the engineers to go into detailsmaking today’s sterile air cabins extre-mely efficient.

Containated air

Adjusted Hygiene in the - Aseptic, Ultra Clean or

By Jesper Bjørn Hansen, Marketing Manager, Trepko A/S


The filters The actual filtration in Trepko's ma-chines is carried out by means ofHEPA-filters combined with pre andpost filters. The efficiency of thehepafilters will be chosen based onthe specific task. Typically, Hepa 14filters will satisfy the need of mostfood producers, but upon requesteven Ulpa 15 filters can be applied,fulfilling the standards applied inmicro-chip-production.

For most food producers, increas-ing the hygiene is a question of in-creasing the shelf life. The mainthreat to the shelf life is fungus,which grows rapidly when exposedto especially alcohol or sugar. Fun-gus happens to be relatively largeparticles (2-30 µm), by applying only

a F7 filter more than 99% of theseparticles will be withheld.

Bacteria and virus particles areother contamination particles, whichthe food producer might have a wishto prevent in the product, eventhough the impact on the shelf lifefrom these sources are next to none.The size of bacteria (0,3-2,0 µm) istypically only a 10th of the size offungus, while virus (0,02-0,3 µm) isonly a 100th of the size of fungus. Itgoes without saying, that filters withefficiencies of catching particles ofthe size of virus is very expensive,and therefore seldom possible to im-plement in a price competitive pro-duction. As bacteria and usually alsovirus will be growing on a media,such as typically dead hair or skin

cells, which are twirled into the air,they will typically be attached toparticles even larger than fungus.This allows the filters to have anoverall efficiency of more than 99%for fungus, bacteria and virus.

On the edge of tomorrowFood production is constantly inten-sified. While input in terms of labouris decreased, output in terms of vol-umes, variety and quality is increased.Trepko is proud of supplying thetools and expertise for this develop-ment. With more than 300 employ-ees, and companies in 3 world re-gions, we constantly supervise thenew trends and develop the prod-ucts optimised for serving these. ■■


Filling Processjust Clean? Trepko 100 Series.

Quality documentation...

In close consultation with our clients, we at Steins develop the milk

analysis and quality assurance solutions of the future.

Steins Laboratorium A/S is an impartial and independent analytical laboratory authorised

and accredited to carry out all main analyses within the segments: Agriculture, Dairy, Food

and Nutrition, Pharma and Industry.

0507.3203Steins Laboratorium A/S, Hjaltesvej 8, 7500 Holstebro, tel: +45 76 60 40 00, www.steinslab.com


State of the Art Dairy

Heavy demandsDuring the past 20 years, the dairyindustry has undergone develop-ment from small, local dairies withvaried product lines to large special-ist dairies with only one producttype.

This development makes heavydemands on hygienically designedprocess equipment, flexibility and ahighly automated process, partly inorder to be able to handle the largeproduct amounts but also to ensurea high and uniform quality level.The demands are put forward by theauthorities requiring a high degreeof food safety and by the consumersrequiring a uniform quality level(recognition).

TraceabilityA modern dairy is also faced with therequirement of collecting informa-tion on the product throughout theproduction process, from the suppli-ers of raw materials through all the

sub-processes in the dairy to the endproduct. This provides traceabilityon a very high level and at the sametime ensures that the requirementsregarding food safety and quality aremet.

FlexibilityA concrete example of this is ArlaFoods production facility for cul-tured products in Linköping in Swe-den. GEA Liquid Processing Scandi-navia A/S was assigned the job ofsupplying Arla Foods with a newproduction facility for cultured pro-ducts, primarily for the Scandina-vian market. The production facilitywas to have the capacity to producemore than 100 different cultured


By Bjarne Darré,Business UnitManager, GEA LiquidProcessingScandinaviaA/S

State of the art CIPdistribution plant.


products with different fat contentbased on different cultures and withseveral types of flavour ingredientssuch as fruit etc. The large productvariety compared to the productionof relatively small series of eachproduct made flexibility, a fast butsafe product change, minimum pro-duct loss and collection of all pro-duction parameters in one centralautomation system key words in theperformance specification from ArlaFoods.

The design concept of GEA LiquidProcessing Scandinavia A/S consist-ed of having the shortest possibleconnecting lines between the sub-processes in order to reduce theproduct loss and minimising thecleaning time of the product lines.

Flexibility was added by usingGEA's mix proof valve technologymounted in valve blocks and con-sisting of VARIVENT type R valvesensuring maximum flexibility andminimum product loss. By usingthis technology, it is possible toclean the pipe strings separately andin this way ensure a swift productchange on one part of the produc-tion line without having to wait forother parts of the same productionline to be ready for CIP.

Cleaning In PlaceIn particular CIP (Cleaning In Place)is one of the keywords when itcomes to food safety and productquality. CIP has been known formore than 40 years, but it is onlywithin recent years that the signifi-cance of hygienic design - meaningthat the process plant and all of itscomponents have been designed forCIP - has been recognised as an im-portant factor. The reasons for thisare multiple, but one of the mainreasons is doubtlessly that a fully hy-gienic plant is associated with high-

er costs. The advantages are, how-ever, obvious in the shape of higherproductivity, consistent quality andbetter food safety.

Process automationProcess automation is another key-word. Concurrently with the devel-opment of suitable components forautomation especially with regard toinstrumentation, automation andcollection of process data have be-come important parameters for aneffective control of the manufactur-ing of food stuffs while ensuring ahigh quality level and a high degreeof food security.

At the Arla Foods production fa-cility in Linköping, an advanced pro-cess automation package has beeninstalled. Consequently, only twooperators per shift are required tocontrol and carry out the entire pro-duction process. Apart from au-tomating the process, the processautomation package also includes adata collection part, which ensuresproduct traceability from the finishedproduct and backwards through eachsingle production step all the wayback to the raw milk and other in-gredients. Therefore, it is possible totrace the history of a product back-wards through the entire productionprocess. The unique marking of eachpackaging indicates in which part ofthe plant the content in the packag-ing has been produced, the heattreatment it has been exposed to, theculture used to produce it or, in oth-er words, how the various ingredi-ents of the end product have beentreated all the way through the pro-duction process. The overall result isa high degree of product traceability,which contributes to Arla Foodsquality assurance and can have apositive effect on product optimisa-tion. The high traceability level ben-

efits the consumers by ensuring ahigh quality level and not least ahigh degree of food safety.

GEA Liquid ProcessingScandinaviaGEA Liquid Processing ScandinaviaA/S, located in Skanderborg, Den-mark, is part of the GEA AG ProcessTechnology Division. In Skander-borg, 110 people are employed in 2divisions: Dairy & Food and Biotech,Pharma, Personal Care, Brewery &Beverage.

Apart from having Scandinavia asits primary market, GEA Liquid Pro-cessing Scandinavia A/S is also an ac-tive player in the Middle East with asales office in Dubai as well as marketsin South America and the Far East.

GEA Liquid Processing Scandi-navia A/S in Skanderborg is the Cen-tre of Excellence in the field ofBioTech in the entire GEA PT Divi-sion.

GEA Liquid Processing Scandina-via A/S designs and supplies processplants with focus on hygienic designbased on more than 70 years of ex-perience within the process indus-try. ■■

Processing


GEA TU valve block using the R valvetechnology.


TraceabilityHas the food industry control overhygiene and bacteriology after CIPcleaning, surface cleaning and thewashing of cleaning equipment andplant? In general, the food industryhas a good reputation for cleanli-ness. Otherwise, we would hearabout it. In addition, of course, foodmanufacturers check their end prod-ucts and equipment during and afterproduction, while the authoritiescheck the companies' self-control re-sults. Therefore, as a whole, the in-dustry has a good reputation.

Individual companies within theindustry have a great responsibilityto maintain this reputation and

must put considerable effort intonot only ensuring but also docu-menting that the company is in con-trol of hygiene in its food produc-tion and of the quality of its hygiene.Traceability tools are therefore re-quired to answer questions of thefollowing type: Are there problems?Has the company experienced suchdifficulties before? How often havethey occurred? What corrective ac-tion has the company taken to en-sure food safety and maintain focuson consumer health and companyreputation?

Methods and toolsThe industry must continuously fol-low up on hygiene and bacteriology.To this end, various tools and meth-ods are available which give a goodpicture of the success achieved. Onecommonly used method is contactplates containing agar on which bac-teria colonies are counted after 1-5days. In such cases, however, theproducts may have been delivered tocustomers - or even consumed (withthe problems that may cause) - longbefore this time has elapsed. On theother hand, the main advantage ofthe method is that companies canuse it to screen for specific bacteria(e.g. coli, listeria, yeast, mould andsalmonella) and are thus able to takeappropriate steps to combat specificbacteria should they be found.

How can companies in futurebest avoid having to recall productsor destroy large batches of productsand raw materials? How can they en-sure that hygiene and cleaning stan-dards are always tip-top?

The best answer is on-the-spot ac-tion, so that raw materials or endproducts can be re-routed or, if nec-essary, reprocessed, equipment canbe additionally cleaned, and the

company can save worry and costs -while maintaining its positive im-age.

For on-the-spot solutions, No-vadan utilises ATP (adenosine tri-phosphate) measurements. ATP par-ticipates in energy transport mecha-nisms in all living cells. NASA, whoused the system in their endeavoursto find life in outer space, developedthe method of using ATP to detectliving organisms. Today, the tech-nique has been optimised andadapted, allowing it to be used tocontrol hygiene and cleanliness inthe food industry.

As ATP is formed in all living cells,it can be measured anywhere: in rawmaterials and end products, onequipment, work surfaces and pack-aging, and in water. Therefore, ATPmeasurement always gives a veryprecise picture of hygiene levels. It isalso important to point out thattrained staff can generally performthe test within 5 minutes, allowingproducts to be recalled before lea-ving company premises should pro-blems be revealed.

In comparison with convention-al swabbing and culture methods,the ATP technique measures thepresence of both product residuesand bacteria. The method thereforeprovides companies with documen-tation on whether product residuesand/or bacteria are present, thusproviding accurate information onwhether processing equipment isclean before production is commen-ced.

The measurement itself consistsof swabbing a given surface area.Swabbing is performed with a cottonapplicator to which the enzyme lu-ciferin-luciferase has been applied.When ATP reacts with this enzyme,light is generated. The light is mea-

NR. 15

Food Safety and

By Torben Jensen,ProjectManager, ITWNOVADANApS

28 Danish Dairy & Food Industry... worldwide 2005


Documentation

sured using a luminometer and re-sults recorded in relative light units(RLU). The higher the concentrationof ATP the more light will be gener-ated and the higher the RLU readingwill be.

Typical values: - Fruit juice and raw meat = 8000-

9999 RLU.- Pasteurised milk = 100-200 RLU.- Stainless steel surfaces > 6 RLU.- General clean/unclean levels = 10/

20 or 15/30 RLU.- High Care ranges = 6/8 or 10/11

RLU.

These RLU values have been de-termined empirically via countlessATP measurements in food manu-facturing companies, and are cur-rently used as general standards forhygiene and cleanliness.

The supplier's roleOverall, ATP is a fantastic tool for on-the-spot documentation of hygienelevels in the food industry. As a sidebenefit, costs are reduced thanks tomore efficient cleaning and fewerproblems with unsafe products.

For Novadan, it is only naturalthat we urge our customers to use

tools like ATP. As a total supplier ofcleaning agents and systems for op-timising hygiene, it is natural for usto look forwards to the next link inthe chain: How can we ensure thatour customers are able to documenttheir level of hygiene at all times?The answer is ATP. In addition, withcustomers in all segments of thefood industry, it is only natural thatNovadan staffs are specialists withinthe various segments. The tool, how-ever, is always the same: ATP. ■■


From ingredient production to

bacterial removal – GEA Filtration

brings know-how and industry

understanding to any partnership.

GEA Filtration is a world leader in

crossflow membrane filtration,

with reverse osmosis and nano-,

ultra-, and microfiltration as

core technologies.

op

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IL-D

-01

Industry Know-How– Process Expertise

GEA Filtration • Noerskovvej 1b • DK-8660 Skanderborg • DenmarkTel: +45 70 15 22 00 • Fax: +45 70 15 22 44 • [email protected] • www.geafiltration.com

A company of mg technologies group

GEA Filtration

G E A M E M B R A N E F I L T R A T I O N


Traditional dryingprocessesIn the traditional permeate dryingprocesses, the permeate is evaporat-ed, flash-cooled and pre-crystallisedprior to spray drying (Fig. 1).

The drying processes applied areeither the Straight-through processor the ‘Wet Process’.

Straight-through processConventional spray drying of pre-crystallized permeate concentrate can

be carried out in f. inst. a CompactDryerTM as shown in Fig. 2.

Drying of crystallized permeate ismuch more difficult than drying ofwhey concentrate, i.e. a given con-ventional spray dryer has to be oper-ated at considerably lower capacityon permeate, resulting in increasedenergy consumption and dryingcosts. The reason for the complica-tions is the absence of the whey pro-teins as a carrier for the low molecu-lar weight components, resulting inpronounced hygroscopic and ther-moplastic properties of the product.There are considerable differences inthe chemical composition of perme-ates, depending on types of cheesefrom which the whey derives (typeof starter cultures, cheese processtechnology etc) resulting in differ-ent levels of true lactic acid and pos-sible accumulation of galactose asmay occur especially in whey, wherethermophilic starter cultures havebeen applied. Lactic acid in particu-lar, but also monosaccharides, suchas galactose, is known to contributesignificantly to the thermoplasticbehaviour.

Only 70–85% of the lactose willcrystallize in the above process, theactual degree of crystallization de-pending on the concentrate tempe-

rature profile during crystallization,concentrate solids content and crys-tallization time. The 15-30% non-crystallized lactose will appear asamorphous lactose in the final pow-der, rendering the product hygro-scopic and potentially caking.

‘Wet Process’The other permeate drying process,which produces a non-hygroscopicproduct, is the so-called ‘Wet Pro-cess’ (Fig. 3).

In the ‘Wet Process’ the dryingconditions are chosen to give a mois-ture content of 7 - 9% in the perme-ate powder leaving the drying cham-ber. The moist powder falls onto aslowly moving crystallisation beltand resides there for about 15 min.Due to the high moisture content(read: water activity) the crystallisa-tion will proceed further, renderingthe final powder non-hygroscopicand non-caking. Final drying andcooling is carried out in a VIBRO-FLUIDIZER®.

Although permeate powder withabove mentioned desirable proper-ties can be produced, the ‘Wet Pro-cess’ has some less desirable features.The high moisture content of the

NR. 15

The Niro A/S A Novel Whey- and


By Ejnar Refstrup, Niro A/S, Soeborg, Denmark

The increasing cheese productionand utilization of the resultingwhey for whey protein concen-trate (WPC) production togetherwith increasing milk protein con-centrate (MPC) production has leftthe dairy industry with increasingamounts of whey permeate andmilk permeate to be processed.Some permeate is used for lactosemanufacture, but a considerableamount is being evaporated, pre-crystallized and spray dried.

Fig. 1: Evaporator, Flash-Cooler and Crystallization Tanks.

Fig. 2: Straight-through drying in a COM-PACT DRYERTM.

Evaporation Crystallization

Flashcooling

to spraydrying

Compact DryerTM

from crystal-lization

tanks


S TIXOTHERMTM Process d Milk- Permeate Drying Process

powder inside the drying chamberinevitably results in deposit forma-tions, which may result in productbrowning, and also increases the CIPfrequency and BOD load on effluentsystems.

The TIXOTHERMTM ProcessThe new, patented TIXOTHERMTM

process was developed with the pur-pose of offering the dairy industry acost-effective process with signifi-cantly improved plant performance.It consists essentially of the follow-ing five process stages:1. Evaporation to 60% TS or prefer-

ably higher in a conventional fal-ling film evaporator. This is iden-tical to the previously describedprocesses, only without flash-cool-ing. Tests have actually shown that pre-crystallization prior tohigh-concentration is decidedly un-wanted.

2. High-concentration to 86 – 89%TS takes place in the Barr-RosinROSINAIRETM paddle processor(Fig. 4), operating at atmosphericpressure. The high shear rate inthe paddle processor keeps the vis-cosity of the thixotropic productlow, even at the high solids con-tent. The product exit tempera-ture from the ROSINAIRETM isabout 40-50 °C. This combinationof solids and temperature resultsin rapid initial crystal nuclei for-mation and mutarotation of lac-tose during the passage throughthe ROSINAIRETM, and the result-ing final crystals are extremelysmall.Crystallization inside an evapora-tor is a special feature, which is incontrast to most other whey andpermeate evaporation processes,where lactose crystallization mustbe avoided as it may cause pipe

and/or pump blockages. The eva-porated water is carried out of theROSINAIRETM by means of a flowof sweep air, which eventually iscleaned in a wet scrubber.

3. Cooling and curing of the con-centrate in an auger further en-hances crystallization and resultsin transformation of the productthrough a high-viscous paste to asemi-solid, friable product suit-able for fluid bed drying. Finescollected in the bag filter are ide-ally returned to the inlet end ofthe cooling auger to act as condi-

tioner or a flowing and dispersionagent.

4. Fluid bed drying and cooling ofthe product. The drying takes placein a non-vibrating fluid bed, simi-lar to the standard fluid bed sy-stem offered by Niro for drying oflactose, i.e. proven technology.The fluid bed consists of an agitat-ed back-mix fluid bed, where theinitial drying takes place, followedby final drying and cooling inplug-flow fluid bed sections.

5. Milling to the required particle size.


Fig. 3: ‘Wet Process’with TALL FORMDRYERTM with Crystal-lization Belts andVIBRO-FLUIDIZER®

for After-Drying andCooling.

Fig. 4: ROSINAIRETM Paddle Processor.

from crystallization

tanks

➔


The entire TIXOTHERM™ pro-cess is shown in Fig. 5.

Extensive test work has been car-ried out on a pilot plant installed ina permeate processing facility in Ab-botsford, Wisconsin, USA.

The pilot plant is available for testand /or demonstration trials for in-terested clients.

Provisional test work on otherproducts than milk and whey per-meate has indicated the potential ofthe drying process for other crystal-lizable products.

Energy consumptionTable 1 shows a comparison of theestimated energy consumptions of

the different process stages and asummary comparing the total ener-gy consumption and the energyconsumption of the drying process-es only.

ConclusionThe unique features of the TIXO-THERMTM process are:● No flash-cooling required. ● No crystallization tanks,

hence little cooling water consumption (for cooling auger only).

● High-concentration to 87-89% so-lids at atmospheric pressure.

● No pumping of high-solids con-centrate.

● No spray drying process – only flu-id bed drying.

● Non-hygroscopic and non-cakingpermeate powder produced.

● Robust with respect to raw materi-al properties.

● Low running costs.● Low building volume requirement,

hence lower investment costs.

References:● US patent 6,790,288. ● International patent application WO

03/086091. ■■


Fig. 5: The Niro TIXOTHERMTM Process for Drying of Permeate.

Process Traditional ‘Wet Process’ TIXOTHERMTM

kW kW per kW kW perProcess step kg product kg productEvaporation 1,915 0.766 1,915 0.766Flash cooling 45 0.018 - -Pre-crystallization 125 0.050 - -Rosinaire - - 1,110 0.444Pre-heating of concentrate 80 0.032 - -Spray drying 1,715 0.686 - -Curing/After-crystallization 20 0.008 40 0.016After-drying / Cooling 375 0.150 690 0.276Total energy consumption 4,275 1.710 3,755 1.502Total energy consumption:

% of ‘Wet Process’ 100 87.8Energy consumption of drying process excl. evaporation: 2,360 1,840

% of ‘Wet Process’ 100 78.0

Table 1: Comparison of Energy Consumption of the Different Process Stages. 2500 kg/h final product.

Fig. 6:TIXOTHERMTM

pilot plant.

Exhaust Fan

ExhaustFan

SANICIPTM

Bag Filter

CombinedBack-MixPlug-FlowFluid Bed

MVREvaporator

WetScrubber

Sweep Air

Mill

Product Out

DehumidifierSupplyFans

Pre Air Filter

Air Heaters

Fine Air Filters

CodingMedia

Twin ScrewAuger

ROSINAIRETM

Paddle Processor


Niro A/S • Gladsaxevej 305 • PO Box 45 • DK-2860 Soeborg • DenmarkTel: +45 39 54 54 54 • Fax: +45 39 54 58 00 • [email protected] • www.niro.com

op

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-Gen

1

N I R O P O W D E R T E C H N O L O G Y

Niro A/SA company of mg technologies group

Why risk working with

several suppliers, when

you can entrust your

dairy factory to just one?

Niro unites innovation

with proven industry

experience in dairy

processing, including milk, whey, and

formulated products. We bring superior

and reliable quality to every part of a

successful processing line, from reception

and storage over pasteurisation,

evaporation, and spray drying, to

powder handling, storage, and bag filling

systems. So stay away from unnecessary

risks – choose one process supplier.

Choose Niro.

Niro is a world leader in industrial drying,

with spray drying, freeze drying, and fluid bed

processing as core technologies. The Niro

companies are part of the Process Engineering

Division of the GEA Group.

Complete Milk PowderFactories

A company of GEA Group


Scan-Vibro A/SGlobal Leader in Vibra

Complex food productsThe food industry has become moresophisticated and complex by usingmany kinds of different food ingre-dients in the production of finishedgoods. Various producers of high pro-file food products, for example use anincreasing amount of traditional aswell as new milk powder ingredients.- This is a perceptible trend also atScan-Vibro, tells Steen Brogaard Lar-sen, Managing Director of the compa-ny. During recent years, experts atScan-Vibro has designed and built anincreasing number of especially sif-

ters, conveyors and feeders for Danishas well as global milk powder plants.

Vibration equipment from Scan-Vibro is also well known and usedwithin other food industries, such ascereal production, instant coffee, andpotato chips production.

Experts in vibration technologyScan-Vibro manufactures a wide ran-ge of spiral elevators, sifters, convey-ors and feeders. Especially the lastthree mentioned are in operationwithin the dairy industry. Each ma-chine does not only do its own job,but can also execute a range of otherprocesses, such as spreading, cool-ing, heating, draining, distributing,aligning, dusting, sorting and dry-ing.

Before designing a solution, theexperts at Scan-Vibro perform a tho-

rough test on the new product, i.e.milk powder, cereal, potato chipsetc. The test is performed either atScan-Vibros testing facility or on thecustomer’s premises to make surethat the vibration solution is opera-tional and as required.

High sanitary equipmentWithin the food and dairy indus-tries, sanitary demands are veryhigh. To meet the demands from thecustomers Scan-Vibro has for severalyears been approved according tothe strict sanitary standards of theUSDA-3A and the NZCP6.

In general, the vibration equip-ment is built in stainless steel, AISI304 or AISI 316(L). On request, theequipment can be supplied with dif-ferent types of cleaning systems in-cluding CIP.


By Anna Marie Thøgersen, M.A., Sub-Editor, Danish Dairy & FoodIndustry

Sifters, conveyors, feeders and spi-ral elevators. Scan-Vibro is an ex-pert within vibration technologyfor a broad range of dairy and food industries. Customer designed sif-ters, conveyors and feeders arebuild and in operation at manymilk powder plants … worldwide.

Steen Brogaard Larsen, Managing Direc-tor of Scan-Vibro A/S.

This Scan-Vibro sifter is part of a huge milk powder plant designed by GEA Niro, andin operation at Arla Foods.


a tion TechnologyLong lasting relationshipsThe technological superiority ofScan-Vibros solutions rest on know-ledge and years of high tech experi-ence among the employees. - Thestaffs count highly skilled engineers,smiths, CAD draughtsmen and oth-er technicians. Several have beenemployed for 15-20 years and evenlonger, and thus gained comprehen-sive knowledge within vibrationtechnology, underlines Steen Bro-gaard Larsen.

Scan-Vibro is also engaged in longlasting relationships with large plantand engineering companies. Whenit comes to collaboration with theselarge companies, Scan-Vibro con-tributes as a subcontractor withinthe field of vibration technology ex-pertise. Consequently, Scan-Vibro´svibration equipment is at work allover the world.

However, Scan-Vibro also worksalone, when customers worldwidelearn about the company’s expertiseand want to either replace or expandtheir powder plants with new types ofvibration equipment. Furthermore,

Scan-Vibro is internationally recog-nized for its long lasting equipment.In addition, it is even possible for cus-tomers who have equipment dated30-40 years back to call Scan-Vibro forthe original draft of the machine andthus obtain spare parts.

Scan-Vibro - VÅV Scan-Vibro was founded in 1949 inthe small Danish town Vester Åby.Right from the beginning, the foun-der produced vibrators, and thus thecompany name became Vester ÅbyVibrator shortened into VÅV - or inEnglish VAV. This short form is stillpart of the company name while thelogo VÅV was designed as a sinuscurve, characteristic for vibrationfrequency. Moreover, VAV is regard-ed as a worldwide synonymous trade-mark, as for instance the US dairy in-dustry consequently calls milk pow-der sifters for VAV sifters.

Scan-Vibro has been the name ofthe company since 1992. Scan-Vibrohas two production facilities, 53 em-ployees and is a private owned com-pany. ■■


This is one of the largest sifters ever constructed at Scan-Vibro. The sifter was shippedof in Mid-June 2005 and the customer is a dairy company in Brazil.

Processing and Handling Vibration Equipment

For Dairies all over the World

Based on our experience and broad range of products

we develop tailor-made solutions together with

our customers.Pictured below are

examples of our equipment – for a general view

please visit our website.

Sifters

Conveyors

Feeders

We view new projectsas a welcome challenge

SCAN-VIBRO A/SSørup Kirkevej 745700 Svendborg

DenmarkTlf.: +45 62 21 16 20Fax: +45 62 22 37 [email protected]


New consumer demandsToday, research and development ofhealthier food products and ingredi-ents are extensive and very compet-itive. The numbers of flavours andingredients where saturated fatty acidsare substituted with polyunsaturat-ed fatty acids and/or vegetable fibresare constantly increasing.

During the nineties and continu-ing into the new millennium therehas been and will be an increasingfocus on ingredients and composi-tion of food. Research results on theinfluence of various forms of fat on

general health conditions have ledto demands from consumer organi-sations for healthier food productsfrom the dairy industry.

These demands have led to thedevelopment of low fat productswhere butter fat in various amountshave been substituted with productsof vegetable origin, together withthe new trends in fortified drinks,now also with various cultures.

The dairy industry will continueto develop these new products. Allyou need in order to take advantageof the opportunities today and inthe future is a compact and effectiveprocess mixing plant.

EquipmentScanima A/S is manufacturing oneof the most effective and multipur-pose turbo mixers on the market to-day.

The programme of mixers rangefrom a PLC controlled process turbomixing plant, direct steam injectionand dimple jacket to a self-circulat-ing in-line mixer.

The plant is built around the spe-

cial designed turbo unit. When mix-ing, it is possible to add ingredientsdirectly into the turbo unit by meansof vacuum - all in closed systems,which improves safe manufacturingagainst contamination of foreign mat-ters.

The availability of highly devel-oped turbo mixers which at the sametime can heat, emulsify, homoge-nize and mix under vacuum, meansthat producers with a single piece ofequipment have a unique flexibilityin capacity as well as products.

ApplicationsThe Scanima Process Turbo mixerhas successfully been applied for: Pro-cessed cheese, Imitation cheese, Icecream mix, Sweetened condensed milk,Labneh, Cream dessert, Sour cream,Mayonnaise, Salad cream, Sauces,Dressings, Baby-food, Purée of fruits,Pharmaceutical creams/pastes, Che-mical blends, etc.

With our new patented dynamicstator - only your imagination is thelimit. Please contact us www.scani-ma.com for further information. ■■

Turbo Mixing in the Food and Dairy Industry

By Erik Petersen, Sales Manager,Scanima A/S


At the top Scanima Turbo Mixer withstator down, high shear. At the bottomScanima Turbo Mixer with stator liftet,no shear.

Shear control mixer



Scanima A/S · Gugvej 152 · DK-9210 Aalborg SØTlf.: +45 96 33 10 00 · Fax +45 96 33 10 11

[email protected] · www.scanima.com

Please help us to keep upa complete mailing list!We continuously update our mailing list. In order to receive the journal on aregular basis, we kindly ask you to inform us if you have changed your addressor it is incomplete.

Identification No.

Title and Name

Company

Street

Postal code

City

Country

Danish Dairy & Food Industry ... worldwideThe old Dairy • Landbrugsvej 65 • 5260 Odense S • Denmark

Fax: +45 66 14 40 26 • E-mail: [email protected]


Hygiene and food safety regulationshave placed a sharp focus on pro-duct safety and traceability. In addi-tion, the industry is striving to opti-mise yield and minimise costs, aswell as launch innovative productsinto the marketplace faster than everbefore.

Intelligent processingThe Intelligent Process Unit (IPU) isa new process surveillance conceptfrom APV that promises to revolu-tionise operations on the dairy floor.IPU employs computerised processmanagement to monitor, manageand control every single process stepin real time. Some of the major ben-efits include:● recording of every single event af-

fecting any process batch ● warnings when critical thresholds

are reached, guidance and an in-

formed decision making capabilityfor operators

● distribution of process informa-tion at any level of detail in realtime or in automated report form.

The first step is to have equip-ment that is optimised for a particu-lar process and lends itself to intelli-gent processing. APV has developeda number of sizing tools for opti-mum engineering and design ofeach plant and unit, including pumpand heat exchanger sizing, mixer op-timisation, and membrane plant con-figuration.

Intelligent processing is depen-dent on being able to collect theright data at critical points through-out the process. APV has developeda number of tools designed to im-prove product quality and safety in-cluding methods for recording on-

NR. 15

Are Computers Poised Dairyman’s J


By Jørgen Østergaard Iversen, Product Group Manager, APV UHT & Aseptic Group

Process innovation in the dairyindustry is as much about optimi-sing operations in terms of qua-lity, traceability, safety and cost-effectiveness as it is about design-ing new filtration, mixing and heattreatment plants. Computers andintelligent software from APV arepoised to help dairy customersproduce safe, high-quality pro-ducts whilst improving profitabi-lity.

APV Infusion Plant.


d to Take over the s Job?

line Fo value, B* and C* values inheat treatment plants (mainly UHTplants), and yield readings in mem-brane and butter plants.

Proactive process surveillanceThe IPU enables correct remedial ac-tion in real time, for example to in-crease yield from a batch with high-er cream ratio, or in the event of athreshold alarm. It employs instru-ments that not only measure, butalso report process parameters suchas temperature, pressure, heating andholding times to a computerisedprocess management system. Proac-tive surveillance enables the opera-tor not only to react to a given event,but also to pre-empt events by tak-ing action based on projections.

These could be approaching clean-ing times when he can opt to presson if the shift is nearly over, or CIPimmediately if this will result in alonger production period afterwards.The computerised management sys-tem can even enable the plant itselfto take remedial action in the eventof an alarm.

Setting new standardsIntelligent Processing also offers va-luable opportunities for innovationin the process itself. An example ofthis is APV’s instant infusion systemused for the production of ExtendedShelf Life (ESL) products.

Traditionally the infusion processheated the product from 70° to 140°C in 0.2 seconds, with an accurate

holding time of 3 - 4 seconds andrapid cooling to 70 °C. The Intelli-gent Process Unit enabled APV toshorten the holding time to lessthan 0.1 second in order to preserveoriginal taste as much as possibleand reduce destruction of thiamine(vitamin B). The IPU enables docu-mentation of a reduction of ther-mophilic spores by log 7.7 in everysingle batch.

From the cow to the cupThe IPU is based on a core system withvarious flexible module options, de-pending on the individual needs ofthe dairy. It enables compliance withtraceability requirements by makingit easy to record and report every pro-cess phase. As the process plant is a


InTouch Screen picture.

➔


Contact: Mælkeri tidende- the only professionaljournal about the Danish dairyindustry!

New markets or employees?Are you looking for new markets to introduceyour products, such as new dairy plants, ingredi-ents, packaging, analysis or sanitary equipment?Or are you looking for highly skilled dairy employ-ees with international experience such as dairy-men, dairy technicians or M.Sc. in Dairy Techno-logy? No matter what, you can always advertisein Mælkeritidende!

Mælkeritidende"Mælkeritidende" as well as "Danish Dairy & FoodIndustry ... worldwide" is published by the DanishDairy Managers Association and the Danish DairyEngineers Association. The scope of Mælkeritidende is scientific and tech-nical issues within the dairy and related areas. Fur-thermore, subjects of dairy Research & Develop-ment, dairy product information’s, company pro-files and exhibition information’s are accepted forthe journal.

Subscribers of MælkeritidendeThe subscribers of Mælkeritidende are managersat Danish dairies and several Nordic dairies,employees at the Danish dairies, members of thetwo Associations in Denmark and other coun-tries, dairy researchers, dairy advisers, personnelat dairy organisations and managers at other foodcompanies.

Contact MælkeritidendeIf you want further information about the Danishdairy industry, please contact the editorial staff:Chief Editor, M.Sc. in Dairy Technology, K. MarkChristensen, sub-editor M.Sc. in Dairy Technolo-gy, Per Nielsen, sub-editor M.A., Anna MarieThøgersen.

Mælkeritidende · The old Dairy · Landbrugsvej 655260 Odense S . Denmark · Tel.: +45 66 12 40 25Fax: +45 66 14 40 26 · [email protected]

critical element in the supply chain,APV has developed interfacing tech-nologies that enable the IPU to com-municate seamlessly with the in-stalled IT base at the dairy, providingan individual batch trace right backto the farm.

Where does all this leave thedairyman?The computer will never be able toreplace the skills and experience ofthe dairyman. However, what it cando is provide him with the right dataat the right time to help him to make

decisions that will optimise plantyield and minimise costs while com-plying with food regulation, hy-giene and traceability requirements.■■


Step in trace Responsible Critical parameters

Milk in the shop Shop Temperature

Shop storage Shop Temperature in storage, hours in storage

Distribution lorry Driver Temperature

Storage in dairy Dairy Temperature, hours in storage

Filling machine Dairy Temperature, last CIP

Buffer tank, pasteurised milk Dairy Temperature recording, hours in tank

Pasteurisation line Dairy Temperature recording, time, last CIP

Raw milk storage Dairy Temperature recording, hours in tank

Reception line Dairy Temperature recording, time

Milk collection truck Driver Temperature, hours in truck, last CIP

Farmer Farmer Number, name, cows

The table shows typical steps that milk passes through on its way from the farmer to the customer, and critical parameters thatmust be recorded. The dairy is responsible for a major part of traceability in the supply chain.

Are you looking for new Markets for your Products?- or Highly Skilled Dairy Employees?



Bourdon-Haenni A/SJacob Knudsens Vej 14, DK-8230 Aabyhoej, DenmarkTel: +45 - 8931 7611, Fax: +45 - 8625 6577E-mail: [email protected] Web: www.bourdon-haenni.com

Level

Product RangesTemperature Transmitters

Pressure Transmitters

Conductivity Sensors

Temperature Sensors

Thermometers

Level Sensors

Calibrators

Displays

Gauges

TemperaturePressure

Conductivity

A Strong Partnerin Hygienic Processing


Quality is defined as: "The character-istics of a product or service - viewedas a whole - and its ability to fulfilspecified or underlying needs and re-quirements" by the InternationalOrganization for Standardization.This definition reveals that the tra-ditional perception of the term qual-ity, which alone was linked to theproduct - and according to manyonly the physical product - no lon-ger is adequate. The needs and ex-pectations of the customers and theconsumers are equally linked to theservices, which surround or accom-pany the product and not only tothe product itself. Products shouldbe seen as results of human actions.

The attention towards pollutionof foodstuffs is growing. The numberof consumers with foodstuff allergiesis increasing. Stricter demands aremade on traceability and controlwith the content of dama-ging sub-

stances in foodstuffs. Consequently,quality management and documen-tation are necessary and importantcompetencies in order to maintainfoodstuff security and preserve cred-ibility and professionalism.

Quality management Orana A/S develops, produces andsells fruit based raw materials fordairy products and beverages of highquality, which are exported to morethan 30 markets in the Middle East,Asia, Africa and Europe. The prod-ucts are developed in our own labo-ratory in close co-operation witheach customer, to fulfil his needsand expectations to quality. In addi-tion, safety is highlighted at OranaA/S, as a link in a foodstuff chain thesafety of our products is of great im-portance for the customer’s end pro-duct.

The quality management systemat Orana A/S is based on DS/EN ISO9001:2000 and HACCP principlescomprising all links from develop-ment, raw material and productionto thoroughly analysed finishedproducts. The quality managementsystem makes it possible for OranaA/S to be in conformity with all de-mands on traceability of products, atraceability, which in practice quick-ly and precisely states when, whereand how, from raw material to fin-

ished product. Moreover, reactiontime upon possible quality problemsis reduced, providing a more satis-factory customer service.

Quality under productdevelopmentQuality management at Orana A/S isinitiated already in connection withthe development of a product. Thisphase in a product’s creation is char-acterised by creative work, repeatedchoices between several different so-lutions and a high level of abstrac-tion. Additionally, this is the phase,where errors and future problems li-terally may be built into a futureproduct.

The level of risk is minimised bythorough planning, creating a largerand better overview, a detailedknowledge of the techniques, whichmay prevent these problems, as wellas qualified knowledge on the rawmaterials selected to be used in aproduct.

Continuous control of rawmaterials When receiving raw materials atOrana A/S, demands are made con-cerning high quality and to obser-ving legal requirements. These de-mands include full documentationand traceability in terms of certifi-cates for raw materials. Orana A/Sonly deals with bonafide and ap-proved suppliers, which are able tosupply the qualities requested byOrana A/S. Additionally, all raw ma-terials must undergo quality testingand subsequent approval.

Documentation and traceabilityis maintained when raw materialsare received, e.g. by registration ofsupplier, batch number and shelflife. Samples from all batches are alsoacquired and controlled at our own

By Joan Karlsen,Quality ControlManager,Orana A/S

NR. 15

Quality Management- A Way to



Healthy Dairy and Food Productsquality laboratory and finally, stor-age management is carried out in ac-cordance with GMP rules, whereFIFO is a natural component.

Management of the productionDuring the production process, Ora-na A/S has great emphasis in manag-ing quality and safety. The manage-ment is primarily based on tho-roughly educated production per-sonnel, who possess technical skillsand a constructive and positive atti-tude to production with quality as amain focus. Moreover, it is based onwell-documented procedures andwork instructions.

Orana A/S has experienced, thatpaying attention to the persons andthe processes responsible for manu-facturing as well as to the product inquestion has positive effects. Thephilosophy of the company is sim-ple and logical: if the qualificationsof the employees are satisfactory, ifthe necessary information is readilyavailable, and if all processes aremanaged safely and qualified, thiswill in itself result in products ofhigher quality.

Products of high qualityThe effect of the resources, which sofar have been and in the future will

be used at Orana A/S for implemen-tation and maintenance of the qual-ity management system, is reflectedin the fact that Orana A/S throughthe past 6 years has been the fastestgrowing Danish producer of fruitbased raw materials.

Until now, Orana A/S has had nodifficulty in conforming to tight-ened demands from the authoritiesin regard to traceability, etc. The suc-cess of Orana A/S is among otherthings coming from the customers’satisfaction with the high qualityproducts delivered by Orana A/S. ■■


Dairy ProductsStirred Yoghurt

Set Yoghurt

Layered Yoghurt

Fromage Frais

Drinking Yoghurt

Cultured Milk

Milk Drinks

Whey Drinks

Ice Cream

Ice Lollies

Orana supplies tailor made fruit based raw materials forthe beverage industry, dairies and other food producers

Fruit Based Raw Materials for

ORANA A/S · DK-5350 Rynkeby Phone +45 6362 3575 · Fax +45 6539 1574e-mail: [email protected] · www.orana.dk

BeveragesJuices

Nectars

Juice Drinks

Ice Tea

Carbonated Drinks

Cordials

Bakery productsBaking Jam

Pie Fillings


"Making the most of what you’vegot" is a principle that most moderndairies will agree with and it’s cer-tainly one that the Process systemsgroup at FOSS Analytical A/S havetaken to heart.

"We want dairies to get maximumvalue from their production," saysSune Christensen, head of ProcessGroup at FOSS Analytical. "We helpthem to do this by giving them an

online system that allows specifica-tions to be followed precisely, hourafter hour and day after day. And notjust for a single parameter, but for arange of key control parameters suchas fat, protein, moisture and so on.In this way, we help dairy producersto ‘standardise’ production and makeoptimal use of valuable raw materi-al. Online standardisation systemsalso open up new opportunities toimprove the overall process opera-tion, for example, by reducing theneed for storage tanks."

"The savings involved in using anonline standardisation system soonstart to repay the initial investment.Not to mention that product qualityis made more consistent," Sune adds.

But why do dairy producers needa standardisation control system whenmost already have a number of con-trol systems in place?

What’s wrong with traditionalsystems?"Most control systems involve batchproduction," says Sune. "These sys-tems rely heavily on manual sam-pling to determine the mix ratio ofraw materials. Manual sampling isalso performed for the monitoring oftank composition during produc-tion and again for final quality con-trol. This can be a time-consumingoperation, especially in cases wherefinal adjustments to a batch are nee-ded to get it within specifications.

"Another factor is that traditionalsystems do not include the instru-

mentation and control systems thatallow for real-time optimisation ofvaluable components such as pro-tein and total solids."

Achieving optimisationProcess Solutions from FOSS offerdairies the possibility to improve ontraditional control systems, as SuneChristensen explains.

"With on-line standardisation youcan optimise the production processand achieve accuracies that have notbeen possible with the traditionalstandardisation of production batch-es. For instance, real-time informa-tion about compositional values intanks allows for swift release of evensmall batches for further processing- overcoming a traditional bottle-neck in the capacity of storagetanks."

"Another example is the stan-dardisation of milk for cheese pro-duction," says Sune. "This can be ba-sed on complicated recipe specifica-tions that require both fat and pro-tein standardisation and the use ofwhey cream and multiple proteinsources.

"Traditionally, batches are prepa-red before the milk is sent to thecheese vats for the actual cheesemaking. Using the FOSS ProcesScan TM

By Richard Mills, Writer, FOSS Analytical A/S


How process control solutions arehelping dairies to get more outwithout having to put more in.

FOSS process control solutions combineanalysis hardware with advanced soft-ware. Specifications for a range of keycontrol parameters can be followed pre-cisely, hour after hour and day after day.

The Big Squeeze


FT on-line instrument and the Pro-cessTouchTM software for standardisa-tion control, many cheese plantshave eliminated the need for inter-mediate batches. Instead, they canaccurately standardise the flow.

"Process control solutions also al-low accurate standardisation controlof milk for powder production. Milkis standardised ‘on-the-fly’ using on-ly a balance tank before the evapora-tor. The variations in raw milk com-position and process conditions thatcause fluctuations in compositionalvalues are automatically compensat-ed for and optimal performance ismaintained."

One of the obvious benefits of us-ing process control solutions is thereduced need for storage tanks. Butthere are many other indirect sav-ings when reducing the number oftanks as Sune explains. "Savings canbe found in the reduced use of CIPliquids, less pollution through re-duced waste and reduced loss of milkduring flush outs and cleaning of the

tanks. Then there are the other ben-efits associated with standardisationtoo, such as the ability to make pro-duct quality more consistent. Thishelps dairies to build their repu-tation with others in the supplychain."

Process control to fit So much for the benefits of usingprocess control solutions, a finalquestion that remains is how to ob-tain and implement a process con-trol solution?

"It is important to find right solu-tion from the right supplier, saysSune Christensen. "And, of course,we believe we can offer somethingunique here, especially in terms ofour decades of experience in deliver-ing analytical solutions to the dairyindustry. We understand the pro-cesses involved and can thereforedeliver the right solution. Dairiesemploying the right control systemcan face future challenges with con-fidence." ■■


About FOSS

FOSS provides dedicated analytical solu-tions that ensure optimal produc-tionof food, agricultural, pharmaceutical andchemical products. FOSS solutions ana-lyse products during pro-duction - hel-ping to optimise both quality and pro-fit.

FOSS is unique in offering a range ofdedicated solutions based on both in-direct and reference methods. Solutionsprovide analysis and control throughoutthe production process, from raw mate-rial to finished product and from la-boratory analysis to at-line and in-lineprocess control.

An established leader in the field ofdedicated analytical solutions, FOSS isa privately-owned company employingover 1100 worldwide. Solutions are soldand supported through FOSS sales andservice companies in 21 countries andby more than 75 dedicated distributors.


Respect for Raw Ensures High

Who is Dairy Fruit?Dairy Fruit produces fruit preps andliquid spice mix for the dairy indus-try. The company has supplied theNorth-European market since 1976.During recent years, the firm haswitnessed a very positive develop-ment and expanded several times.Today, 85 people are employed indifferent positions, which togethermake it possible for Dairy Fruit to sellquality products in the amount ofDKK +200 million per year, domesti-cally as well as abroad. More thanhalf of Dairy Fruit’s products are ex-ported - primarily to Sweden, Fin-land, Iceland, Germany, Ireland, Hol-land, Belgium, Italy and the Balticstates. Our latest initiative is the es-tablishment of production facilities

for liquid spice mix, which is used inthe fast growing segment of con-venience products and mixed withcottage cheese, sour cream, creamcheese etc.

Development towards healthierproductsIn a line of business where the life ofthe products often is short, DairyFruits needs always to be ready withnew ideas and fruit variants for thedairy and ice cream industry. In2003, Dairy Fruit established a TasteLab to uphold optimal conditionsfor this creative part of our job. TheTaste Lab works with developmentof new as well as existing products tomake sure that Dairy Fruit stays infront. Product development requiresmany resources. Today, 10% of thefirm’s employees work with develop-ment related activities.

Increased focus on health in oursociety is also reflected in the DairyFruit products. The first step towards"healthier products" was an increa-sed interest in fat-reduced products,which however only relates to milkproducts. Since then, products withfunctional qualities like fibres, ad-ded vitamins or vitamin rich fruit,calcium and Omega 3 have enteredthe market. The most recent devel-opment is the rising demand forproducts with low sugar content.

Focus on increased productsafetyProduct quality and security is a verysignificant parameter, when cus-tomers experience our products andin this connection, the completetraceability in the Dairy Fruit pro-duction is imperative. All produc-tions can be traced through all stagesfrom the ready-to-eat product andback to the supplier of raw materials.

Allergens and GMO are two im-portant concepts for the quality-minded consumer and as a naturalpart of our daily routine, Dairy Fruitmakes product statements coveringboth areas. For each individual fin-ished product we specify whetherthe product contains allergens and ifthey do, we clarify which allergenswe are talking about. Furthermore,our customers can always ask for aGMO statement. It is very importantfor Dairy Fruit to stand as a seriousand open-minded supplier, who isproud of the way GMO and allergensare being handled and as a part ofthis development the firm has cho-sen not to handle nuts in any shapeor form, they are simply bannedfrom the production.

Raw materials - an importantelementA very central element in DairyFruit’s quality control is the inten-sive raw material control. All rawmaterials are being analysed and in-spected according to standardisedroutines and no raw materials are be-ing released for production untilthey have undergone a thoroughraw material control in our opera-tion lab.

Having access to high quality rawmaterials is imperative to good qual-ity in the finished products. The qua-lity of individual raw materials hasbeen build up through decades of ex-perience in purchasing of raw mate-rials all over the world. The quality isensured through communicationand contact with our suppliers aswell as numerous control visits.Dairy Fruit has several reliable sup-pliers, which all live up to writtenagreements and contracts, which de-fine requirements and expectationsof Dairy Fruit.


By BetinaHansen,LaboratoryManager,Dairy FruitA/S

The employees know the functions theyperform and any deviation from normalis corrected instantly.


MaterialsQuality

Respect and understanding Production takes place in closed sys-tems, where the raw materials areprocessed, heat treated, cooled andtapped aseptically onto stainless steelcontainers. Steel containers is DairyFruit’s most used packaging, but thecustomers can also choose to havethe product delivered in smallerunits, e.g. buckets or bag-in-box.

Dairy Fruit employs well-educa-ted people to ensure the quality ofthe products. It is important that ev-eryone understands the process andthe products and respect the workthey do. The employees are DairyFruit’s finest security that the prod-

ucts are perfect. The staff is trained ex-tensively in the functions they per-form and any deviation from normalis instantly being attended to.

All batches of finished productsare subject to a thorough control be-fore being released, just like the rawmaterials. In addition to a number ofphysical and chemical analyses, theyare also subject to a sensory test andbacteriological analyses. All infor-mation is stored electronically at DairyFruit’s premises, which means thatwe are capable of tracing all finishedproducts and analysis results, ingre-dients and process parameters canbe traced for all batches.

New initiativesSince June 2003, Dairy Fruit hasbeen approved according to HACCPDS 3027, a proof that foodstuffs se-curity is under full control. Some ofthe most important parameters inDairy Fruit’s HACCP system are con-trol of pasteurization, metal detec-tion and hygiene. Today, the HACCPsystem is a well-implemented ele-ment of our daily routine. Our nextinitiative is certification of the firmaccording to strict British BRC regu-lations. This certification is expectedto take place at the beginning of2006. ■■


Dairy Fruit is a competent player. Longexperience and modern production facilities makes Dairy Fruit a flexibleand responsible business partner.

Dairy Fruit have more than 25 years ofexperience in blending fruits from thewhole world into fruit preparation thatstimulate and excite your customers.

Dairy Fruit is the place where we uniteknowledge, ingredients and people, into exciting products for dairy, ice cream,desserts and confectionery.

Dairy Fruit employs well-educated people to ensure the

quality of the products.


Rapid Test Kit - Delivers Accurate

Keeping milk safeNever before has there been so muchfocus on the quality and safety of foodproducts. And the dairy industry is noexception. Antibiotic residues in milkcan create major problems for dairyproducers. According to the WorldHealth Organization, more than halfthe world’s production of antibioticsis used on farm animals, and dairycows are typical candidates for antibi-otic treatments. It is common practiceto use antibiotics to treat infectiousdiseases in cows, such as mastitis.Normally, treated cows must be iso-lated for a certain period before beingmilked. If this quarantine period isnot obeyed, farmers run the risk of theantibiotic residue passing into themilk thereby inhibiting starter cul-tures in yoghurt and cheese making.

For a dairy producer, this can re-sult in production delays, unhappycustomers and loss of revenue. Buteven more important are the grow-ing health concerns associated withantibiotic residues in milk - residuescan cause antibiotic resistance, aller-gy and hypersensitivity in humans.Therefore, dairy producers must findnew, cost-efficient ways to improveprocess quality without compromis-ing productivity.

Chr. Hansen, leading natural in-gredients supplier, quickly recogniz-ing the challenges their customersface responded with an integratedantibiotic testing system that givesdairy producers a fast and reliableway to ensure milk quality from farmto factory.

An integrated system ensuresqualityChr. Hansen studied the needs oftheir customers and found that bothspeed and accuracy were importantrequirements when testing for an-tibiotic residues. The integrated milktesting system consists of both rapidand microbial tests - giving dairyproducers a flexible and reliable wayto test for antibiotic residues at vari-ous points during the milk produc-tion process.

Beta Star rapid test - fast, easy, reliableThe Beta Star rapid test kit is an ef-fective way of screening milk for an-tibiotic residues. The test kit detectsb-lactams and cephalosporins, whichare responsible for the majority of

the cases where milk is contaminat-ed. Testing can be done either at thefarm or during unloading of thetanker at the factory. And it’s fast,too.

"It’s the fastest rapid kit on themarket," says Alan Abolencia, Inter-national Product Manager for Chr.Hansen. "With Beta Star, it takesonly 5 minutes to detect if milk hasbeen contaminated. Generally, ourcustomers use the test to quicklyscreen the milk when unloadingmilk tankers but the test is versatileand reliable enough so it can also beused on the tanker or at the farm lev-el."

For busy dairy producers, ease-of-use is also important. All kits containvials with lyophilised receptor, testtrips, syringes and tips. Interpreta-tion of test results on the sticks canbe performed visually without ex-pensive electronic equipment. Butan electronic reader is available, ifneeded. Results from the reader canbe easily downloaded onto a com-puter for safe storage.

According to Alan Abolencia, theBeta Star, as a visual test, has beenthe best selling rapid test in Europeand its reliability has been docu-mented in a number of independentstudies by AFNOR and the SwedishUniversity of Agriculture (SLU).

Copan Test - complete screening at the plantIn addition to rapid tests, dairy pro-ducers are often required by law touse a microbial screening test to de-tect a broader spectrum of antibi-


By Karen S. Frost, Journalist,Communication & PR, Chr. Hansen A/S A new integrated milk screening system from Chr. Hansen gives dairy

producers a fast and dependable way to test for antibiotic residues inmilk – on the farm, at the tanker, and in the factory.

Testing can be done either at the farm orduring unloading of the tanker at thefactory. And it is fast, too.


Readings in Only Five Minutesotics including b-lactams, tetracy-clines, sulfonamides and aminogly-cosides. This type of testing is usu-ally performed before the milk ispumped from the silos into the pro-duction plant and is an effective wayto verify and confirm positive resultsobtained by rapid test kit screening.

To complement the Beta Star ra-pid test kit, Chr. Hansen provides itscustomers with the Copan Test - abroad spectrum microbial test that issensitive to b-lactams, tetracyclinesand sulphonomides. The Copan Testutilizes bacillus stearothermophilusspores with the nutrients alreadypresent in the agar medium. Unlike

other microbial tests, no tablet mustbe added prior to testing. This givesa clear, consistent color develop-ment in the vials and reduces the po-tential for false results and contami-nation.

The reliability of the Copan Testhas been validated by independentstudies in many countries through-out the world.

Industry knowledge and supportBecause Chr. Hansen is a food ingre-dients producer, they are able to of-fer their customers specialized know-ledge of the dairy industry and tech-nical support. "Chr. Hansen takes

great pride in offering our customersnot only the state of the art in testkits, but in technical support aswell," says Alan Abolencia. "We areunique because we know the indus-try. Our technical support teams areexperienced professionals - dairy en-gineers and scientists - with industryexperience who can relate and com-municate effectively with custo-mers." ■■


The Beta Star rapid test kit is an effectiveway of screening milk for antibiotic resi-dues.

GEA Liquid Processing Scandinavia A/S • Nørskovvej 1B • DK-8660 Skanderborg • DenmarkTel: +45 70 15 22 00 • Fax: +45 70 15 22 44 • [email protected] • www.gea-liquid.dk

GEA Liquid Processing Scandinavia A/S

The performance of your process

plant is essential to your business.

Plant reliability, bacteriological

safety, product safety, minimum

product waste and maximum

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GEA Liquid Processing Scandinavia

supplies expert process solutions.

Let us optimize your process.

Discover the benefi tsof process optimization


Gam Bling or Sam Pling?

Confronting the human error insamplingSampling is easy to understand: yousimply take a small quantity from apipe or tank and analyse it in the la-boratory for qualities such as itschemical and biological content. If itis within the established guidelinesthe processing is being correctly per-formed. Because of the very narrowand easily understood function ofthe sampling device, it is often givenlittle consideration. However, sam-pling requires a device that is prop-erly designed and manufactured be-cause the information the sampleholds is relied on to generalise thecondition of the greater quantity itwas taken from. A poor sampling de-vice can force expensive decisions tobe made, such as discarding or re-working product, or, worse, releas-ing product that does not meet thequality standards established. Yetthere are many processors relying onsampling devices that cannot, by thevery nature of their design, take a

sample that represents, as accurate-ly as possible, the greater quantityfrom which it came.

Why is that? No processor woulduse a pasteurizer that cannot pas-teurize or a filter that cannot filter.So why accept a sterilizable samplerthat cannot be sterilized betweensamples?

Two explanationsFirst part of the reason could well bethe absence of product and valida-tion standards for this particular pro-duct group. There is no 3-A categoryfor sterilizable sampling devices. Inaddition, there are no EHEDG (Euro-pean Hygienic Equipment DesignGroup) sterilizability test proceduresto actually validate whether a sam-pling device can be sterilized be-tween samples. Instead, manufac-turers, 3-A and EHEDG test laborato-ries are forced to evaluate equipmentaccording to processing equipmentstandards. Unnecessary to say, pro-cessing valves are tested in their nor-mal open position. But this is not thenormal position for a samplingvalve. Unique to any process system,this is only valve that must providein situ sterilizability repeatedly atany time in its closed position, inde-pendent of the processing stage. Butthe sampling valve is such a smallvalve, so why bother?

Second part of the reason couldwell be the attribution and divisionof function responsibilities withinthe processor’s organization. Pro-cessing is one function and respon-sibility while quality control andlaboratory functions are another.Sampling typically falls betweenthese two areas for one trivial reasononly: The sampling device is physi-cally located in the processing area,whilst the user usually has his or her

functions in the laboratory. Whilethe analytical equipment in the lab-oratory remains the natural respon-sibility of the laboratory manager, itis less obvious that the sampling de-vice welded to the process line is ac-tually not (or should not be) the re-sponsibility of the process manager.But clearing up the responsibility is-sue is going take some effort andtime involving people from differ-ent departments, so why bother.

So what do these two tentativeexplanations have in common? Thehuman factor versus our scrupulousattention to details. With everythingcarefully planned and thought out,including the critical control points,the analytical procedure, the sam-pling frequency and volume, we stilljeopardize it all in the end. This fac-tor gives way to (in-)famous acci-dents in this and in other contexts,too. Even funny ones… ■■

NR. 15

By Henrik Lysgaard Salomon,Managing Director, Keofitt A/S


Or areyou SamPling?

Are you Gam Bling?


is distributed in the following countries:Algeria, Belize, Benin, Botswana, Burkina Faso, Cameroon, Congo, Ethiopia, Gabon,Gambia, Ghana, Guinea, Kenya, Lesotho, Liberia, Libya, Madagascar, Malawi, Mali,Morocco, Mauritius, Mozambique, Niger, Nigeria, Senegal, Sierra Leone, Somalia, Sudan,Swaziland, South Africa, Togo, Tunisia, Tanzania, Uganda, Zambia and Zanzibar.

Bangladesh, Bhutan, Burma, China, Fiji, Hong Kong, India, Indonesia, Japan, Laos,Malaysia, Mongolia, Nepal, North Korea, Philippines, Singapore, South Korea, Sri Lanka,Taiwan, Thailand and Vietnam.

Australia, Fiji and New Zealand.

Austria, Belarus, Belgium, Bosnia, Bulgaria, Croatia, Cyprus, Denmark, Eire, Estonia,Faeroe Islands, Finland, France, Germany, Greece, Greenland, Holland, Hungary, Ice-land, Italy, Latvia, Lithuania, Luxembourg, Malta, Macedonia, Norway, Poland, Portugal,Rumania, Russia, Serbia, Slovakia, Slovenia, Spain, States of CIS, Sweden, Switzerland,The Czech Republic, Ukraine and United Kingdom.

Bermuda, Canada, Mexico, Panama and USA.

Argentina, Barbados, Bermuda, Bolivia, Brazil, Chile, Columbia, Costa Rica, Cuba,Ecuador, El Salvador, Guatemala, Guyana, Haiti, Honduras, Jamaica, Montserrat,Nicaragua, Paraguay, Peru, Puerto Rico, Tobago, Trinidad, Uruguay and Venezuela.

Afghanistan, Bahrain, Cyprus, Egypt, Iran, Iraq, Israel, Jordan, Kuwait, Lebanon, Oman,Pakistan, Qatar, Saudi Arabia, Syria, Turkey and Yemen.


Africa:

Asia:

Australasia:

Europe:

North America:

South America:

The Middle East:


Packaging – A Guarantor of Product Quality

To constantly meet the markets in-creasing demands for food safety Su-perfos places great importance ondeveloping systems for traceability,product safety etc. However, Super-fos does not stop at present legisla-tive demands. Built-in qualities in apack are an increasingly importantcompetitive parameter.

Barcode label system"The demands and possibilities tooptimize product safety are accele-rating and we need to be at the fore-front of the development. On onehand, Superfos of course meets allformal demands for product safety,traceability etc. For instance, in thearea of traceability we have chosento implement a new barcode label-system so we can now offer our cus-tomers, additional labels with SerialShipping Container Codes in bar-code format EAN 128. This corre-sponds to the future European stan-dard that is first expected to bemandatory for packaging in 2007,"says Product Manager Michael Stens-boel from Superfos and continues:"But more than that, we seek to de-velop solutions with value addingbuilt-in qualities such as unique clo-sure systems and outstanding barri-er properties that further optimiseproduct safety. Legislation is oftenbased on demands from consumersand consumer protection organisa-tions and the clear signal is thatproduct safety is of increasing im-portance for consumers who at thesame time desire convenient prod-ucts that stay fresh longer and areeasy to use."

Built-in qualitiesTherefore, apart from using trackingand strict hygiene-control systemssuch as the BRC/IOP, Superfos focus-es on solutions that offer built-inproduct safety. An example is thesealing solution SuperSeal® suitablefor i.a. spreadables.

The SuperSeal® solution combi-nes a unique closure system with de-mands for high quality and productsafety. The key is a combined PP lidand PP seal that eliminates the needfor aluminium seal, optimizing pro-duction efficiency and hygiene. Anultra thin lid seal area allows forshort sealing time, which means

minimum exposure of the content.Furthermore, the lock mechanismoffers end-users an effective re-closefunction with small hooks under theskirt that hitch onto the lid when re-closing, making storage easy andsafe long after the seal is broken.

Altogether, the new SuperSeal®

meets the increasing demand forfood packaging solutions that up-hold high product hygiene through-out production and offer tight anduser-friendly closure systems that se-cure the freshness of the products inproduction, in storage, at the storeand at home. ■■

By Annette Gottsche,Communication Manager, Superfos


As a major supplier of packaging solutions to the European foodindustry Superfos believes that new technologies and built-inqualities will set new standards for food safety.

The SuperSeal® solution combines a unique closure system with demands for highquality and product safety.



Everything you need –Whenever you need it

Alfa Laval manufactures sanitary solutions for a wide variety of industries: the dairy, food, beverage, bio-pharm and personal care industries. Our equipment not only solve problems – they also prevent them from occurring.

Our engineering excellence, innovative equipment and decades of experience are some of the reasons why we’re the world leader in our industry. To be able to offer our customers the best possible service, we have chosen to market and sell our equipment through a global network of cooperation partners.

We are also easy to do business with. So contact us at Alfa Laval Nordic A/S and get everything you need - before you need it.

www.alfalaval.com/nordicAlfa Laval Nordic A/S • Krondalvej 7 • DK-2610 Rødovre • Tel: +45 44 57 62 00


Future Solution for the Analysis Field

OptimisationsThe development of new dairy prod-ucts is currently proceeding at a rateand creativity never previously ex-perienced. At the same time, thepower of the distribution sector isbeing strengthened by globalisationand consolidation across nationalboundaries. The struggle for custo-mers' favours is intensifying, alter-nating between new and interestingproducts, low margins and combi-nations of the two.

This means there is an extremeneed to be able to generate new andcreative concepts if one is to differ-entiate one's products, minimise costsand secure results in the black.

For the dairies to be able to re-main competitive, it is imperativefor them to focus on their core com-petences within their specific fieldsof business.

In future, maximum focus will beon rapid product development si-multaneous with trimming and op-timisation of production.

The market placeThe range of products we see in to-day's market place stretch from veri-fiably health-promoting concepts toembellished fashion-based products.The future development process ofmore sophisticated and complexproducts will certainly involve the

use of everything from modified pri-mary produce, new strains of bacte-ria, added vitamins and proteins tosubstances, which, although they havepurely cosmetic effects, will boost salesall the same.

The future of analysisIf we compare this with ever-in-creasing demands on food security,demands for the documentation ofthe effects of functional food andthe fact that end users impose muchmore stringent demands on exter-nal, impartial documentation, it isobvious that this enhanced focuswill also make greater demands onthe way we regard analysis, qualityassurance and documentation. Inthis regard, demands such as speedof analysis and efficient communi-cation of results constitute weightykey parameters.

The demands analyses and labo-ratories will face in future will there-fore include much greater concrete,specific knowledge of specific prod-ucts and substances, quick and effi-cient analysis integrated into theproduction process, reliable, rapidreporting, direct information pro-cessing, advice and integration ofnew learning and knowledge.

Steins Laboratorium is already ina position to deliver a number of fu-ture solutions, and it is no secret thatSteins focuses strongly on strategiccollaboration with a number of re-search institutions as well as a num-ber of suppliers of advanced tech-nology.

All types of assignmentIn close collaboration with its cus-tomers, Steins Laboratorium per-forms all types of task from the mostadvanced analyses on even thesmallest components to large series

of systematic analyses involving moreuniversal parameters.

For analyses most often perfor-med as at-line and on-line measure-ments, it is vital to calibrate equip-ment for reliable, credible results. Atthe same time, considerable savingscan be achieved by running as closeas possible to critical product para-meters in order to facilitate rapid in-tervention in the production pro-cess.

To this end, Steins Laboratoriumsupplies a wide range of calibrationsamples, which can ensure that mea-surements are always precise and ac-curate. Since this field is developingso rapidly and the demands imposedon reference materials are perpetual-ly changing, Steins Laboratorium re-mains in constant dialogue with itscustomers to adapt and optimiseanalysis processes and equipment toensure that they are suited as well aspossible to the job in hand.

Similarly, Steins Laboratorium par-ticipates in the testing and imple-mentation of new analysis equip-ment so as constantly to be in a po-sition to offer customers new, morerapid analyses of considerable relia-bility.

Increased focus on corebusinessesEver increasing competition in allmarkets demands an increased focuson a company's core business. In theanalysis and quality assurance field,the solution to these demands willbe wholly or partly to outsource lab-oratory analyses.

A combination of rapid in situanalyses and outsourcing remaininganalyses ensures cost-effective solu-tions, in which analyses can alsoquickly be adapted to account forcurrent limitations in the laborato-


By Jesper BaggePedersen,BusinessManager, SteinsLaboratoriumA/S


ry. Standby-capacity costs can thusbe reduced and it will not be neces-sary to consider staffing during ho-liday periods and at weekends. Fur-thermore, customers will have ac-cess to accumulated knowledge ofproblem issues and efficient soluti-ons in the field.

At the same time, end users' needfor accredited reference analyses canbe fulfilled, in that documentationcan be provided to show that thequality of the end product alwayslives up to expectations.

Steins Laboratorium is preparedto act as a partner in this process, thepurpose of which is to find the mostcost-effective solution. We are alsoprepared to carry out an evaluationof the necessary proportions of theanalysis together with the customer,in which an HACCP evaluation andan own-check also appear.

All in all, Steins Laboratorium isready – together with our customers– to tackle the solutions of the futurein the fields of analysis and qualityassurance. ■■


A combination of rapid in situ analyses and outsourcing remaining analyses ensures cost-effective solutions.

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Safety and qualityThe Danish food sector is knownworldwide for its high level of safetyand quality. In addition, the level ofexpenses in food production hasbeen kept low by a high degree of au-tomation. This position has beenreached through priority to food re-search and research-based educationin a joint initiative from the Danishpolitical system and the public andprivate food sectors.

Challenges like the mounting com-petition from low-cost countries dueto globalisation, increasing elderlypopulations in Western Europe andgrowth in lifestyle diseases and obe-sity can only be met successfully byknowledge-based innovation, edu-cation and targeted science.

Some of the more remarkable re-sults of knowledge-based innova-tion in the Danish food sector arethe extremely low level of Salmonel-la in Danish animal production.Other results are elimination of driploss in pork meat, optimisation ofcheese and milk powder processingtechnologies, development of meth-ods for enzymatic esterification ofanimal and vegetable fats and oils,and development of sensor tech-nologies and advanced statisticalcomputing in integrated food pro-cessing control.

Centre for Advanced FoodStudiesAll major Danish food science insti-tutions in Denmark (see box) nowcollaborate within the frame of Cen-tre for Advanced Food Studies (LMC).LMC coordinates the scientific activ-ities and higher educations withinthe food area and serves as a uniquepartner for the private and publicfood sector. LMC was established in1992, highly encouraged by the pri-vate Danish food sector.

LMC addresses the major issuesfor health, safety, quality and wel-fare by conducting innovative re-search across the food chain from

fork to farm, integrating the mostadvanced analytical techniques with-in “omics” and nano-science to eco-nomical and sociological sciences. Astrong record of investment in state-of-the-art research facilities and con-stellation of these facilities and theinterdisciplinary capabilities withinLMC combine to make the centreunique.

Owing to the national priority,Danish food science has reached ahigh scientific level within a numberof disciplines. Danish scientists takepart in more than 30 % of the pro-jects in the food priority of FP5 andFP6, and LMC is the only Europeanfood research collaboration, whichhas been awarded as a Major Re-search Infrastructure. These activi-ties open a fruitful network to thebenefit of the scientific level.

Research-based educationWithin the frame of LMC, The RoyalVeterinary and Agricultural Universi-ty (KVL) and The Technical Universi-ty of Denmark (DTU) offer a widerange of education ranging frombachelor and candidate programmes,PhD to continuing education.

To meet the demand for candi-dates from the dairy industry an in-


Successful Priority of Knowledge-Based

By LisbethMunksgaard,Director,Centre forAdvancedFood Studies,Denmark([email protected])

LMC LMC is an interdisciplinary collaboration of research and education within food science and technology. The following institutions take part in LMC:

The Royal Veterinary and Agricultural University (www.kvl.dk)Technical University of Denmark (www.dtu.dk)Danish Institute of Agricultural Sciences (www.agrsci.dk)MAPP-centre, Aarhus School of Business (www.asb.dk)Danish Institute for Food and Veterinary Research (www.dfvf.dk)Danish Institute for Fisheries Research (www.dfu.min.dk)

Please visit our website at www.lmc.dk for more information on LMC.


Food and Science

ternational MSc programme in DairyScience and Technology was set up in2004. It provides the students with ahigh-level, research-based teachingin dairy science and technologywithin an international environ-ment.

In order to recruit internationalstudents and to prepare Danishgraduates for an international careerthe language of LMC MSc pro-grammes is English. An internatio-nal MSc in Meat Science and Tech-nology will be added to the range ofspecializations within the food areain 2005, and in 2006 an internation-al MSc in Food Safety, Food Biotech-nology, and in Food Process, Inno-vation and Management. The teach-ing activities of all the programmesare based upon or related to the on-going research within food scienceand technology.

LMC focuses on continuing edu-cation and the universities’ offershort courses and a master’s degreein Food Quality and Safety. The mas-ter is a two-year qualifying and re-search-based education preparingemployees in the private and publicfood sectors to meet the flow of chal-lenges in relation to development,production and processing of food.

I 2003, LMC established the grad-uate school for LMC PhD students,FOOD. The objective of FOOD is toprovide research education at thehighest international standard inthe field of food science and tech-nology and to exploit opportunitiesfor a multidisciplinary approach.The short-term courses in FOODserve as continuing education forthe private food sector. ■■



The skilled dairyman educationDuring the past 20 years, the dairy-man education has seen a decreasein the number of applicants, but atthe same time, the number of dairieshas also decreased. If you look at theactual jobs in the dairy industry,many manual operations have dis-appeared and been replaced by me-chanical/automatic systems. Large


Dairy Educations at Education

By Paul SteinJensen, CourseManager & Jens A. Ullum,Lecturer,Dalum Collegeof Food andTechnology

Chemistry Processing Production Processing and Company matterstechnology and technology productionMicrobiology development

Chemistry Unit operations Production Processing Company economytechnology development

Microbiology Measuring, Companycontrolling and Production hygiene Product development organisationregulation

Quality control Management andSecondary cooperationequipment Logistics

Quality and environmental controlling

Figure 1: Disciplines at the technology education.

At the skilled dairymaneducation, the studentshave subjects such asprocess control andautomation.


dairies have become so automatic that it only takesvery few people to operate the production equip-ment. Therefore, the contents of the skilled dairymaneducation has had to change accordingly, and sub-jects like process control and automation take up astill larger part of the education, whilst a subject likeproduct manufacturing has become a minor part.

Figures for admission to the dairyman educationsince 2000 have been:

2000/01: 87 agreements2001/02: 84 agreements2002/03: 76 agreements2003/04: 97 agreements2004/05: 78 agreements.The basic elements in the skilled dairyman educa-

tion are: Dairy Technology & Product, manufactur-ing, Quality Control and Production Equipment.

Basic subjects are: English, Mathematics, Physicsand Chemistry. While the specialized subjects are: Lo-gistics, Packing and Quality control and Operationtechniques.

Normally, the education has a duration of threeyears, of which 50 weeks are theoretical training atDalum Education Centre.

After 11/2 years of the education, it is possible to fin-ish an education as dairy operator. Only a few ap-prentices make use of this possibility.

Previously, the skilled dairyman education con-sisted of written and oral examinations, but today thefinal test is a project on which the apprentices write areport. This report forms the basis for the final exam-ination. This kind of exam is more attractive to the ap-prentices and to the trade in general.

The subject quality control includes subjects likemicrobiology and quality control. It is very importantthat the apprentices obtain knowledge of hygieneconditions in order to avoid infections in the prod-ucts. The dairy industry is very proud to be a tradewhere there for years has been no bad publicity due topoor hygienic conditions.

Today almost all dairies are certified according to aquality system, for instance HACCP and/or the ISO9000 series. Therefore, these quality systems are in-cluded in the subject quality control.

The process technologist educationThe process technologist education was established in 2000 replacing three existing technologist educa-


Dalum Centre

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tions, namely the dairy technologisteducation, the food technologist ed-ucation and the laboratory technol-ogist education.

The new education was the con-sequences of a reform launched bythe Ministry of Education, where 75short-cycle higher educations werestandardised and cut down to 15new professional higher educations.

The process technologist educa-tion is a 2-year education. The firsttwo terms are common and consistof basic disciplines in chemistry, mi-crobiology, processing techniques,production and management stud-ies (see figure 1).

The second year will include oneof the specialities; dairy technology,processing technology or food tech-nology.

The speciality in dairy technolo-gy includes a number of subjects re-lated to the area, with emphasis onmilk and dairy products. The sub-jects include more advanced studiesof the subjects taught during the firstyear of the education and thosetaught during the dairyman educa-tion. As seen in figure 2, the subjectscover a wide spectrum of topics,which provide the students with com-petences that enable them to fill awide range of jobs within the dairy in-dustry and other related companies.

The speciality in food includesspecial subjects within the food area,see figure 3. The speciality in food isbased on the technology of the vari-ous kinds of foods. The first twoterms form the basic knowledge offood. The subjects during the secondyear include more advanced studiesof the subjects taught during for in-stance the butcher, the baker, thechef or the waiter education. Thespeciality in food includes a 6-weekin-service period.

The quality and the nutritionalvalue are very important factors inboth the food and in the dairy in-dustry. Therefore, functional food,ecology and control are part of therelevant subjects.

The weekly number of lessons is24-28, depending on the size of theclass.

At the examination, the studentsare evaluated according to theircourse assignments and their finalprojects, which are presented at anoral examination.

The process technologist educa-tion gives competence to assign-ments within production, analysis,planning, management, develop-ment, and processes. The processtechnologist specializing in dairytechnology is mainly employed inthe dairy industry. The process tech-nologist specializing in food tech-nology is mainly employed in the re-maining food industry. Both groupsare capable of operating with pro-jects, sales, control, developmentetc. and they have possibilities ofgood positions abroad. The medicaland the chemical industries also em-ploy process technologists. ■■


At the process technologist education, the students have subjects such as chemistrytechnology and microbiology, processing technology, production development andcompany matters.

● General subject (quality con-trol, chemical/physical pro-cesses, preservation, nutri-tion)

● Fruit/vegetables subject● Meat/fish subject● Cereal subject

Figure 3: Speciality subjects of the foodtechnology education.

Figure 2: Speciality subjects of the dairytechnology education.

● Dairy chemistry● Dairy bacteriology● Dairy products and ● Production technology

(cheese, consumer milk, fats,canned milk, frozen prod-ucts)

● Dairy processing equipment● Environment and building

techniques● Dairy economy● Marketing


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Phone + 45 59 43 14 79Primodan Food MachineryTelefax + 45 59 44 22 30Email [email protected] www.primodan.dkFood Machinery A/S

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Healthy Dairy & Food Products: Quality • Traceability • SafetyHygiene • Analysis • Processing • Ingredients • Packaging

Trepko A/S, Kuldyssen 15-17, P.O.Box 128, DK-2630 TaastrupTel: +45 43 99 22 44, Fax: +45 43 99 26 55, E-mail: [email protected], www.trepko.com

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