可以根据不同产品精确地定义和控制干燥温度和在输送带上的停留时间。对于粘性、吸湿性、热塑性、短碳水化合物分子含量高或结晶缓慢的产品，也可达到极佳的干燥效果。
精确控制
FILTERMAT® 可独立控制干燥器不同位置的空气温度，因此可根据不同客户的需求精确控制粉末特性。细粒保留在粉末层内，可最大限度地减少产品浪费。
GEA 分散器整流器
FILTERMAT® 分散器整流器（DFS）是 GEA 的一项全新创新型产品。DFS 与集成式气动剃刀一起使用时，可在更高的入口温度和干燥能力下运行，而不会增加干燥器或气体分散器中燃烧或变色沉积物的风险。
它结构精巧，带有侧面安装的斜角喷嘴喷枪入口，可减少喷枪长度，使其易于调整，方便取放。侧装式设计可降低建筑物的高度，易于取放和拆卸，便于检查和清洗。双饲喂喷嘴系统允许在干燥器运行时更换喷嘴或清洗饲喂管路（CIP）。
与前几代 FILTERMAT® 气体分散器不同，全新 DFS 分散器只使用主气流，稳流系统(专利申请中)极大提高了气流均匀性。单一主气供给可使加热器系统更简化并且进气管更紧凑。
GEA FILTERMAT® 的优势
- 可干燥粘性、吸湿性和热塑性产品
- 平缓处理
- 精确控制粉末温度和停留时间，可确保所需的含水量、产品结构和感官特性
- 无需回收粉末细料即可生产团聚粉末（旋风分离机或袋式除尘器中收集的粉末很少）
- 易于检查和清洁，将停机时间降至最低水平
- 操作时可同时进行 CIP
- 符合所有相关卫生设计标准
GEA 分散器整流器的优势
- 喷嘴喷枪更短且可调节
- 双饲喂喷嘴系统提供全天侯运行
- 建筑物高度更低
- 便于对所有工艺接触面进行可视检查
- 单一主气供给，二次空气需求量小
- 加热器系统更加简化，进气管更紧凑
- 加装了气动剃刀，可用于高温操作并提高干燥能力
- 改装项目有可能大幅提高产能
FILTERMAT® 用于中试设备/小规模生产
FILTERMAT® 中试设备干燥机专用于为过程确认、市售样品和小型生产。其精确模拟了商用 FILTERMAT® 喷雾干燥过程，可确保扩大生产规模的可靠性。交付后可随时使用的中试设备：空气加热器、给水泵、喷嘴、配备集成可移动滤网的干燥区段、旋风分离机、排气过滤器和控制器。
Key applications for the FILTERMAT®
Whey UF-permeate consists primarily of lactose, which in its amorphous state attracts water from its surroundings. By retaining the product on the band, the FILTERMAT® prevents lumping and supports uniform lactose crystallization into a stable, non-hygroscopic state.
The FILTERMAT® can reproducibly process high fat dairy products into free-flowing, agglomerated powders with the desired properties, for many different applications.
The FILTERMAT® allows you to reliably and efficiently spray dry non-dairy products that have a fat content of more than 60%.
The FILTERMAT® can be an ideal solution for drying a wide range of fruits and vegetables, and can process products such as orange powders with less carrier, or tomato powder with no filler, to give you higher value products with a higher concentration of product relative to filler/carrier, and commonly a more natural color.
GEA FILTERMAT® systems are used to reliably and efficiently spray dry hydrolyzed proteins and flavors, including fish and meat products, palatants and other pet food ingredients. In many cases you can use less carrier and better control Maillard reaction, to generate flavor products with a higher fat content than you could achieve using a traditional spray dryer.
Conventional hot air spray dryers may not be the best option for sensitive biomolecules such as fat-soluble vitamins, or lysed algae and yeast cells. The FILTERMAT® spray drying process can help to maintain product integrity and properties, and reduce the need for carriers, to give you a more concentrated, uniform and higher value product.
Key applications
Benefits of the FILTERMAT®
- Reproducible spray drying of sticky and thermoplactic products
- Gentle processing, with reduced heat impact
- Precise control of powder temperature and residence time
- Production of agglomerated powders without the need for powder fines recycling
- Easy equipment inspection and cleaning
- Longer production runs and less risk of unexpected stoppage
- Less product waste
GEA gas disperser flow straightener
The FILTERMAT® features some great GEA engineering, including our compact disperser flow straightener (DFS). The DFS is designed with side-mounted, angled nozzle lance inlets to reduce lance length and improve ergonomics, and accommodates a double-feed nozzle system, so you can change nozzles and carry out feedline CIP without having to stop production.
24/7 production, and optimized CIP
While the basic FILTERMAT® design is founded on decades of GEA engineering and process expertise, we also offer equipment and configuration options that will give you a FILTERMAT® solution to best match your products and processes. Options include a double-feed system that allows continuous, 24/7 production, as well as clean-in-place (CIP) systems either for the entire plant, or to enable belt cleaning without disrupting the production run.
Energy saving, and safety systems
The FILTERMAT® can also be configured with the GEA COTECTOR® safety system, which detects and alerts operators to potential fire or explosion risks, and with GEA AddCool high temperature heat pump technology, which recycles and amplifies waste heat from the plant to preheat the spray dryer air up to 120°C. AddCool heat pump technology can halve a spray drying plant’s overall energy demand, while cutting fossil fuel consumption by up to 70%.
Testing with the FILTERMAT®
You can find out more about these systems at the GEA Center of Competence in Soeborg, Denmark, where our GEA experts will work with you to configure and test out FILTERMAT® equipment for spray drying your existing and new products, at pilot scale. And if you would rather evaluate the FILTERMAT® at your own site, we also offer pilot plant equipment that can be used for process confirmation and scale-up evaluation, to generate market samples, or just for smaller production runs of up to about 70 kg/h. The FILTERMAT® pilot plant is user friendly and delivered fully featured, and ready to use, so it’s fast to install.
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服务产品
GEA SAFEXPERT®
食品安全和产品质量是企业发展的根本。借助 GEA 的 SAFEXPERT®，助您应对挑战，保护品牌。
GEA Health Check Spray Dryer
Inadequate maintenance can lead to safety risks, lower product quality, costly repairs, and reduced equipment life. GEA Health Check Spray Dryer offers a thorough inspection and tailored service report to help you proactively maintain uptime, quality, and longevity.
