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Carbonation Systems for Beverage Applications DICAR™ Carbonation Systems

DICAR-B™

Special features and advantages of the GEA carbonating systems type DICAR™

Single-stage carbonation up to 10 g CO2/l of product Measurement of the CO2 content in the product (only DICAR-C™)

  • Direct control of the CO2 content (-> DICAR-E™ with pressure)
  • CO2-dissolution by means of a special jet nozzle
  • Easy operation
  • Compact factory-tested unit
  • Possible combination with the in-line blending system type DICON-C™ for a compact mixer type DIMIX-C™

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Function of the carbonation

By the aid of a booster pump the ready-mixed beverage is conveyed to the saturator which is working according to the Venturi principle. An optimizing control keeps the flow velocity through the saturator within a constant working range. The partial vacuum generated in the area of the smallest cross-section of the saturator causes a reduction of the pressure level and, thus, involves the desired suction effect for CO2. Apart from that, the short-time increase of the flow velocity guarantees a fine distribution of the CO2 gas and its homogeneous mixing with the product. CO2 is supplied from the pressure tank to the saturator. The constant overpressure of the pressure tank permits an equal carbonation of the beverage. This procedure also ensures a loss free CO2 supply.
Consequently, the carbonation of the beverage is essentially dependent on the tank pressure that is adjusted according to the desired CO2 setpoint of the specific beverage and that is only slightly higher than the saturating pressure of the product. Moreover, the temperature compensation adapts the pressure in the tank to the saturating curve. The system is dimensioned subject to the required flow rate of the whole system. 

The GEA carbonating system type DICAR-C/E™ has been designed for continuous high-accuracy carbonation of soft drinks.

The carbonating system DICAR-C/E™ mainly consists of the following components:

  • Carbonating tank 
  • Saturator 
  • Booster pump 
  • Analyzer (CO2-meter, conductivity meter (acid content and brix metering)) 
  • Operating unit

By the aid of a booster pump the ready-mixed beverage is conveyed to the saturator which is working according to the Venturi principle. An optimizing control keeps the flow velocity through the saturator within a constant working range. The partial vacuum generated in the area of the smallest cross-section of the saturator causes a reduction of the pressure level and, thus, involves the desired suction effect for CO2. Apart from that, the short-time increase of the flow velocity guarantees a fine distribution of the CO2 gas and its homogeneous mixing with the product. CO2 is supplied from the pressure tank to the saturator. The constant overpressure of the pressure tank permits an equal carbonation of the beverage. This procedure also ensures a loss free CO2 supply.

Consequently, the carbonation of the beverage is essentially dependent on the tank pressure that is adjusted according to the desired CO2 setpoint of the specific beverage and that is only slightly higher than the saturating pressure of the product. Moreover, the temperature compensation adapts the pressure in the tank to the saturating curve.

The system is dimensioned subject to the required flow rate of the whole system. For that purpose, the following nominal widths are available: DN 50, DN 65, DN 80, and DN 100.

The essential product data such as

  • CO2-content 
  • Conductivity for the acid content 
  • Brix value
are acquired and monitored within the predetermined limits. The CO2 content is controlled within parameterizable limits by changing the pressure in the mixing tank.

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Special Features

  • Single-stage carbonation up to 10 g CO2/l of product 
  • Measurement of the CO2 content in the product 
  • Direct control of the CO2 content 
  • CO2-dissolution by means of a special jet nozzle 
  • Easy operation 
  • Compact factory-tested unit 
  • Possible combination with the continuous in-line blending system type DICON-C™ for a compact mixer type DIMIX-C™

For carbonation of beverages GEA has the DICAR-C™ in its product range, designed for highly precise, continuous carbonation of beverages. It is suited for both alcohol-free beverages as well as for alcopops, champagne and sparkling wines.

Optionally, DICAR-C™ can also be designed as an "aseptic" version with the properties described above. The focus is on the design and choice of components, which have to fulfil the requirements for aseptic facilities, as well as the sterilization capability of the complete system, including the CO2 supply.

In the aseptic version, sterile valves are used in the production process. The CO2 supply then occurs via a sterile filter, so that the system can be steamed. In addition, a thermo siphon system (TS system), is installed on the base frame of the system. In this TS system, sterile steam, which has to be fed from outside the system, is cooled down in a controlled manner. The condensate which is created is used to rinse the double-acting mechanical seals of the pump. In this way, the TS system fulfils all the tasks of a locking system, such as leakage compensation, circulation of the lock fluid through a thermo siphon effect, cooling the seal, pressure build-up in the lock room and prevention of dry running. 

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Advantages of Aseptic Carbonation

In case of aseptic filling, the customer saves investment and energy costs by using an aseptic carbonation process. This is because of the fact that the pasteurization can occur at a lower pressure level. In addition, this means that, during production, a lower energy input of the pumps is required.