业务新闻

Newly developed GEA serum Separator significantly reduces product losses in Ghee production

07 Jul 2021

Continuing its tradition of customer-centric, innovative solutions, GEA has engineered a unique Ghee processing separator for its customer Amul Dairy, market leader in the Indian dairy sector and one of the largest milk unions in the state of Gujarat.

Amul products

Thanks to the customized GEA serum Separator, Amul Dairy has reduced fat losses by 85% and increased Ghee production by 30% with no additional investment in the already existing plant.

“GEA’s custom designed centrifuge has transformed our Ghee production,” says Amit Vyas, Managing Director of Amul Dairy. "After installing the GEA separator, we were able to dramatically reduce our fat losses – from 2% down to 0.3% in the serum part – while increasing Ghee production capacity by almost 30%. We achieved our ROI in less than a year, with the added benefit of improved safety, hygiene and energy efficiency.”

Holistic approach – targeted solution

The GEA team worked closely with Amul Dairy to develop a customized solution, taking time to thoroughly understand the nature of the entire process. “One precondition for a perfectly performing centrifuge is a detailed understanding of the overall process, the particular requirements at every single step and finally the seamless integration of the centrifuge into the line,” explains Thomas Veer, Product Manager Sales, Separation & Flow Technologies Division at GEA. “Amul’s previous Ghee production unit had a conventional pre-stratification setup which resulted in high-fat losses on the order of 2%. With thousands of liters of butter melted every day, the 2% fat loss was significantly impacting their bottom line. The traditional setup also posed operational challenges and was problematic with regard to safety, hygiene and energy consumption.”

GEA developed its groundbreaking serum Separator based on Amul Dairy’s requirements for the local market. With a capacity of 3,000 liters per hour, the separator allows Amul to bypass the conventional pre-stratification setup and scale up its production to generate an additional volume of 6 metric tons per day with no additional equipment or investment in the plant.

The groundbreaking GEA serum Separator was developed based on Amul Dairy’s requirements for the local market with a capacity of 3,000 liters per hour. (Image: GEA)

The groundbreaking GEA serum Separator was developed based on Amul Dairy’s requirements for the local market with a capacity of 3,000 liters per hour. (Image: GEA)

Success and sustainability into the future

Amul Dairy’s new installation has reduced the load on its effluent treatment plant (ETP), resulting in large savings in overall power and fuel consumption and benefiting Amul Dairy’s sustainability initiatives. The GEA serum Separator also helps reduce the turnaround time of the production process.

“GEA and Amul enjoy a longstanding partnership, with GEA supplying some of Amul’s largest capacity processing plants and equipment,” says Mr. Deepak Singh, Vice President Separation & Flow Technologies Business, GEA India. “The GEA serum Separator marks yet another step forward in our relationship. This machine is future-proof; the robust engineering allows the serum Separator to function as a standalone unit or be integrated with future automation solutions to serve a growing market. And the installation is more energy efficient overall.”

India produces around 5 million metric tons of Ghee every year; it is the second-largest milk-based product consumed in India after curd. Although Ghee is largely produced in the unorganized sector, the market penetration of the organized sector is increasing gradually. The Covid-19 pandemic has further boosted the demand for packaged food products, including packaged Ghee.

Contact

Lilian Schmalenstroer

Phone: 49 211 91362090

Media Relations

GEA Group Aktiengesellschaft

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Germany

+49 211 9136-0

About GEA

GEA 是食品加工行业及众多工业领域的领先供应商之一,2019 年的销售总额约达 49 亿欧元。

作为国际技术集团,我们专注于机械制造,生产运营,工艺技术及其设备组件。 GEA 为各种终端用户市场的复杂生产流程提供可持续的能源解决方案,并提供全面的服务组合。集团在长期持续增长的食品和饮料行业的收入约占其总收入的 70%。截至 2018 年 12 月 31 日,集团的全球员工已超过 18,500 人。GEA 在其业务领域中是市场和技术领导者。GEA 是德国 MDAX 上市公司(G1A,WKN 660 200),拥有 STOXX® Europe 600 指数和优选的 MSCI 全球可持续发展指数。
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