Trendsetting and sustainable: The DNA in every GEA centrifuge

From ugly duckling to beautiful swan – whey

In recent decades, whey in particular has transformed itself from an unpopular by-product into a much-appreciated value-added product in the production of cheese and casein. It has enormous potential. For the production of 1 kg of cheese, for example, 12 liters of milk are consumed – leaving about 11 liters of whey, which can be used in various forms in products such as bars, beverages, baked goods, snacks and cereals. These are packed with proteins, lipids, carbohydrates, vitamins and minerals. In other words, whey holds enormous potential for meeting the protein needs of the world’s growing population.

Producers need appropriate cost-effective and flexible technologies to keep whey at the highest quality from the farm to the final formulation. The solutions from GEA that have been on show at Anuga FoodTec appeal particularly to small and medium-sized productions that want to maximize their yield and minimize their process waste through optimum pre-treatment.

GEA milk Pasteurizer Skid with new control system

The GEA milk Pasteurizer Skid is a compact, pre-assembled milk pasteurizer with skimming separator and state-of-the-art automation as a plug-and-play solution that also comes as a unit optionally for whey processing. The skid can be designed for processing capacities from 3,000l/h up to 10,000l/h.

GEA makes the stick-slip effect in decanters a thing of the past

The unwelcome stick-slip effect is a familiar problem in decanter applications in dairies. As well as impairing the efficiency of the system and making it less profitable, it also damages the inside of the decanter, leading to repair costs and downtime. Users can prevent this with GEA’s automatic active torque control (ATC) system. It enables precise, automatic correction of the differential speed using active torque control to continuously maintain the optimum operating point while preventing stick-slip. This maximizes solids yield and minimizes energy costs for thermal drying. These cost savings also go hand in hand with ecological benefits: Less drying saves energy resources, substantially reducing the carbon footprint of the production equipment. GEA now offers new machines in the CF decanter series with ATC equipment as well as the option to retrofit existing CF decanters.

GEA CIPClean Separator for clarifying detergents

Plant operators looking to reduce their need for CIP media, fresh water and wastewater can achieve this with GEA’s new CIPClean Separator, which will also be launched at Anuga FoodTec. The unit is delivered as a plug-and-play skid and is available in five variants for capacities from 1,000 to 10,000 l/h. The skids can be used to properly clarify CIP fluids for subsequent reuse. Recycling with CIPClean skids also gives operators a better and more stable cleaning process, with enhanced efficiency of process components such as separators, evaporators and heat exchangers. The extended utility of the hot detergent also saves energy.

Digital whey processing with GEA IDEAL whey separation

The GEA IDEAL whey separation concept exemplifies how technology providers can exploit digitalization as a key lever in taking industrial production processes to the next level of resource efficiency, plant availability and product quality. Dairies can deploy the smart IDEAL whey separation system to optimize their plant at the touch of a button, boosting productivity and safety. Separators in cheese production separate the by-product whey from cheese dust and cream before it becomes a protein-rich high-value ingredient in downstream products. IDEAL whey separation uses a series of digital components to detect and regulate this process. The combination of sensor technology, mechanical design and smart control strategies generates key centrifuge performance data such as feed volume, bowl speed and discharge intervals. These are all intelligently linked in the tool, intuitively displayed, and adapted to the process conditions in real time.

In minimizing product losses and energy and water consumption, IDEAL whey separation takes the pressure off dairies, so that they can process whey more efficiently and economically, in a way that optimizes resources. GEA’s system, which received the DLG International FoodTec Award in silver, is an innovative step forward in the development of centrifuges that can optimize themselves.