GEA DISUGAR Sugar Dissolving Systems for Beverages

The DISUGAR-H is a continuous dissolving unit for producing pasteurized sugar solutions from granulated sugar and water. The unit uses a cold sugar dissolving method. 

The process starts with the delivery of preheated water into the dissolving tank. When the preset water quantity is reached, the granulated sugar is added into the system. The speed of the conveyor (e.g., screw conveyor or rotary valve) is adjusted by a variable frequency drive.

At the same time as the sugar is delivered to the system, a predetermined volume of water is pumped through the unit’s water heater into the dissolving tank. The pump and special mixing nozzle in combination generate high turbulence in the dissolving tank, which helps to speed dissolution of the sugar crystals in the water.

Part of the circulating solution flows through the separation chambers into the regenerative section. The system adjusts the Brix value by fine water dosing, before the solution is transferred into the bag filters. The standardized sugar solution then flows to the heater where it is heated up to the pasteurizing temperature. Brix and flow rate are monitored and controlled via mass flow meters. 

After pasteurization the sugar solution is cooled down in the regenerative section (where heat is recovered) and then in the cooler, where flow is counter-current to the dissolving water. Passage through an additional cooler ensures that the liquid sugar is at the correct outlet temperature before storage. 

If at any point the Brix value or temperature are not maintained within acceptable boundaries of deviation from their setpoints the unit will be automatically switch to continued circulation until the setpoints are reached again. This ensures that no unpasteurized solution can contaminate the sterile parts of the system, and only sugar solution with a correct Brix will be transferred to the storage area.

The pumps and control valves also safeguard a positive pressure difference between pasteurized and non-pasteurized sugar, so that even in the event of a micro-crack or leaking gasket, no unpasteurized sugar can reach the sterile parts of the unit.

GEA DISUGAR-C is a continuous dissolving unit for producing sugar solutions from granulated sugar and water, using the cold method. 

After the start of the process, preheated water is dosed into the dissolving tank. As soon as the preset water quantity is reached, granulated sugar is then added into the system. 

At the same time, the correct volume of water is pumped through the water heater into the dissolving tank and circulation of the sugar solution is started. The speed of the conveyor (e.g., screw conveyor or rotary valve) is adjusted by a variable frequency drive. 

The pump and special mixing nozzle in combination generate high turbulence in the dissolving tank, which helps to speed dissolution of the sugar crystals in the water. 

The amount of water is measured and controlled by a flow meter, and the amount of sugar is monitored and adjusted according to the required Brix value. 

Part of the circulating solution flows through the separation chambers into the regenerative section. Brix value is measured using an in-line measuring device, at the exit point, and if the target value is not reached the system automatically switches to continuous circulation and the Brix value is corrected by fine water dosing into the system. This ensures that only sugar solution with the correct specification leaves the system.

GEA DISUGAR-T is a batch operating sugar dissolving unit for producing sugar solutions from  granulated sugar - delivered out of bags, big bags, or trucks - and water using the cold dissolving process. 

The preset volume of water, controlled by a flow meter, is dosed into the dissolving unit, and heated using a small water heater. The sugar is then fed into the dissolving tank or into the recirculation loop, depending on the customer requirements and the existing site setup and conditions. 

The water dissolution temperature will be set dependent on the available sugar quality and the required brix value. The pump and special mixing nozzle in combination generate high turbulence in the dissolving tank, which helps to speed dissolution of the sugar crystals in the water. 

The resulting sugar solution exits the dissolving unit through a bag filter and is transferred to the next stage in the production process. The dissolving tank can also be used as a storage tank if there is no immediate demand for liquid sugar. If necessary, additional liquid sugar storage tanks can be installed downstream of the sugar dissolver. 

The entire sugar dissolving process runs automatically. Temperature and Brix value are monitored as an integral part of the dissolving system, to help ensure constant, reproducible product quality. Fully automated CIP can be activated by the operator after each batch, or at desired time points.