GEA VARI-DOS-ASEPT is a sterile dosing system that allows you to add precise volumes of micro-ingredients or macro-ingredients and functional components directly into an aseptic product stream, without compromising product sterility.
The GEA VARI-DOS-ASEPT system can be an ideal solution when you need to add sensitive components, for example enzymes, vitamins, minerals, flavors or colors into your aseptic food or beverage process, after the sterilization stage.
Constituents to be added are delivered via sterile, barcoded pouches, and then injected using our patented transfer port and automatically sterilized needle.
Producing lactose‑free milk after the heating step offers several advantages compared to enzymatic hydrolysis beforehand. For instance, lactose can be split during the time the product spends in its packaging, and this process occurs more quickly at room temperature than in refrigerated conditions prior to UHT treatment. Additionally, the product’s visual quality improves because fewer browning reactions occur during heating, resulting in a lighter, more appealing milk. The compact, user-friendly GEA VARI-DOS-ASEPT system can be integrated seamlessly into existing or new aseptic lines, keeping you in control and giving you confidence in accurate dosing, reliability and hygiene. Integrated process control software is easy to navigate and reduces the need for manual oversight.
GEA VARI-DOS-ASEPT can be ideal for:
- Dosing enzymes, stabilizers and other functional ingredients
- Vitamin and mineral enrichment of beverages and liquid foods
- Addition of flavors, colors and natural extracts
- Tailoring sweetness, mouthfeel or nutritional profile
Typical applications may include:
- Dairy and plant-based beverage formulations
- Nutritional and infant formulas
- Products requiring mineral fortification, or the addition of colors, flavors or extracts
- Late-stage product customization for premium or limited-edition varieties
Dosing directly into the aseptic stream
GEA VARI-DOS-ASEPT is engineered for high dosing accuracy across a wide range of volumes. It can handle very small micro-ingredient additions in the milliliter volume range, as well as larger macro-additions in the liter range per batch or production run. This allows you to dose anything from trace levels of vitamins and aromas up to larger volumes of liquid additives with precise control, whatever the additive type.
Flexible integration into your aseptic process line
The space saving GEA VARI-DOS-ASEPT unit may typically be installed between the UHT system and sterile tank, although it can also be integrated into the line before the filling station. Our experts can work with you to find the best solution for your needs.
Meeting industry standards
We've design the GEA VARI-DOS-ASEPT to support your need to meet stringent industry standards and secure consistent product quality. Our technology is equipped with advanced features that we believe set it apart from other aseptic dosing system designs.
Procise dosing control
GEA VARI-DOS-ASEPT uses highly accurate flow meter and weighing devices to ensure precise, consistent dosing, whatever the additive, and at any supported volume. The built-in software monitors the consumption of the dispensed material, thereby ensuring accurate dosing. The components to be dosed are delivered via sterile, barcoded bags and are scanned and data logged so you can keep every batch fully traceable. Up to two bags of additives can be hung in the weighing unit Keeping precise control of dosing helps to reduce the potential for product and ingredient waste, and so ultimately can reduce costs and increase productivity and efficiency.
Hygienic design
Hygienic by design, the GEA VARI-DOS-ASEPT has been developed to maintain process sterility and support top product quality that meets all regulatory requirements. The dosing needle is sterilized automatically in the patented port valve, and the lamina airflow system in the chamber in which the dosing material bags are stored includes a HEPA filter to further reduce contamination risk. The GEA VARI-DOS-ASEPT unit requires no separate CIP. The system is cleaned as a component of the process line into which it is integrated, which reduces downtime and complexity.
Versatility for different applications
The GEA VARI-DOS-ASEPT aseptic dosing system can handle a wide range of product viscosities, allowing you to dose different liquids – from milk to desserts (e.g. pudding) – with ease, and with precision and consistency.
Seamless integration and small footprint
The GEA VARI-DOS-ASEPT can be integrated seamlessly into existing aseptic production lines, so you can continue your process without undue disruption. The compact unit has a relatively small footprint to save space, so you can retrofit the system into an established facility, as well as configure the technology into a new aseptic line.
Advanced process control
Our GEA VARI-DOS-ASEPT aseptic dosing system is supplied with advanced process control features This includes barcode-based monitoring to ensure every bag is properly processed, feedback mechanisms, and precise dosing algorithms. The process control system helps to ensure the highest level of dosing accuracy, even in demanding production environments.
Compliance and safety
GEA VARI-DOS-ASEPT adheres to the strictest food safety and regulatory standards and meets HACCP (hazard analysis and critical control points) compliance, to help ensure the safety and integrity of your products.
Your local GEA representative can point you in the right direction to find out more, so get in contact, and let’s get talking.
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