Accurate dosing, material traceability and parallel operation all combine to deliver flexible, high quality and efficient production
The GEA DIBATCH mixing system is designed to accurately and reproducibly process complex formulations - which can include liquid and dry ingredients - to a premix, final syrup, or final beverage. Here at GEA we think our system represents a flexible, efficient option that will be gentle on your valuable ingredients, and provide an ideal solution for creating premixes for energy drinks, isotonic sport drinks, soft drinks, flavored drinks, and other final beverage products.
We recognize that our customers need great versatility, so the GEA DIBATCH technology can be configured for a wide range of custom products and processes, powder and liquid ingredients. Dissolution parameters can be adapted for each type of raw material, and accurate dosing means you don’t waste expensive raw materials. The system can be used for unitized or non-unitized products, and where parallel operation is possible, the batch time can be further shortened.
The modular GEA DIBATCH technology incorporates a system for handling and emptying powder-carrying bags, big bags, sack, drum and IBC containers, as well as liquid-transported containers (bottles, cans, canisters, drums and barrels) into the dissolving tank.
A control system provides a cross checking function to ensure accurate ingredients dosing, and also generates reports and trend information that can be integrated into an overall process plant control system.
Scalable plant process control solutions
The GEA DIBATCH system can be linked to and controlled using our GEA Codex® software, which comprises an engineering portal, a high-performance HMI, standardized and structured software. GEA Codex® is the easy way to compile master recipes, and has been designed as a user friendly system for incorporating ingredients, access points and operating instructions into the process workflow.
Offering human readable material identification codes and RFID technology, the GEA DIBATCH system can be fully automated for batch execution. The double-check validation option for recipe changes and previous versions ensures compliance with current legislation and transparent version logging.
Features
- Thorough clean-in-place (CIP) system ensures efficient and thorough cleaning
- Traceability by barcode readers
- Recipe-defined flush water helps to prevent carryover and maintain product quality. As all flush water is recipe controlled, manual flush functions will not effect the product quality.
- System function monitoring to avoid production failures
- Optional pre-weighing system
Benefits
- Designed to help you achieve consistently high product quality
- Accurate dosing to help avoid wasting raw materials
- Easy product changeover
- Complete traceability
- Reduced labor in the batch-preparing area
- Modular, versatile technology
- Proven recipe system for batches with 20 or more ingredients
- Partly emptying functionality for great flexibility in purchasing raw materials (big non-unitized packages, multiple supplier for one ingredient)
- Short batch production times where parallel operation is feasible
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GEA Insights
The breakthrough that changed spray drying
In 1976, NIRO engineers responded to a competitive challenge by rethinking what spray drying could do. Their idea became the multi-stage dryer MSD. Fifty years later, the same fundamental principle helps turn liquids into the powders used in essential nutrition products and important medicines around the world. Refined through decades of engineering expertise, customer insight and continuous development, MSD is a story of innovation with lasting impact.
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An efficient machine does not automatically make an efficient factory. Real improvement often starts by looking beyond individual equipment and understanding how processes, energy systems and operating decisions affect one another. It’s a holistic approach designed to uncover opportunities that might otherwise be missed.
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