GEA Powder Handling, Packing and Components Technology - Process Engineering
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GEA Powder Handling, Packing and Components Technology
Process Engineering
GEA Powder Handling, Packing and Components Technology
6 Powder Handling
Powder Ingredient Unloading Systems. . . . . . . . . . . . . . . . . . . . . . . . . . 7
Pneumatic Conveying. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Powder Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Sifting & Blending Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Batching and Weighing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CIP Cleanable Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Powder Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
10 25kg Bag Filling
Two Brands – one source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Avapac™. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Li Range - Limited Intervention Range . . . . . . . . . . . . . . . . . . . . . . . . . . 12
RBF Range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
IBF Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SmartFil™. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Line Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
16 Bulk Container filling
Automated Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Manual Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
18 Retail Container Filling
Accuracy is the Key. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Integrated Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Vacuum Filling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Auger Filling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Specialist Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Sanitation & Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Controls & Integration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
24 Packaging Formats
Rigid Containers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Multi-wall Kraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Big Bags. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Boxes & Drums. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Boss Pak™. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
26 Modified Atmosphere Packing (M.A.P.) for Powders
Pre-gassing of Powders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Pre-gassing for Retail Containers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Continuous Gassing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Post Gassing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
30 Components
Manufacturing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Rotary Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Central Vacuum Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Blower Packages for Powder Conveying. . . . . . . . . . . . . . . . . . . . . . . . . . 31
Dust Collection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Product Range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
34 Aftermarket
Global Service Organisation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Spares Packages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Training. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Product Quality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Plant Optimisation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Upgrades. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2
Introduction
Introduction
GEA Systems Capabilities Integrated Systems
You might recognize our company and our brand names A system is more than just the sum of
already. We are GEA Avapac and GEA Nu-Con, and we
represent the brands of: the parts
• Avapac™ Successful design involves the translation of good ideas into
• Colby™ practical solutions. GEA approaches a solution by looking at
• Albro™ the entire process. We work with our customers to ensure
• Nu-Con™ that the solution we provide is properly integrated within
• SmartFil™ their plant. We look for synergy in our solutions and this is
where our customers will see the real value that GEA offers.
Collectively, we come together as GEA Powder Systems.
• Batch & Plant Control
GEA Powder Systems is dedicated to the world-class design • Automated Control
and manufacture of Powder Handling including: • Smallest Plant Footprint
• Dry Blending Systems • Lowest Energy Consumption
• Ingredient Unloading Systems • In-built Safety
• 25-kg Bag Filling and Powder Packaging Systems
• Retail Container Filling Systems
• Inert Gas and Modified Atmosphere Powder Packaging
Systems
Components
• Bulk Bag (Supersack or FIBC) Powder Filling Systems The difference is in the detail
• Integrated Automation Systems
The team at GEA knows that the quality of every component
The service we provide is unique. In fact, as our clients in is vital to the overall performance of the system. Our
the Americas, Europe, Africa, the Arabian Gulf, South and purpose built manufacturing facility is set up to produce
East Asia and Australasia will attest, there is nothing like it high quality components which are not only offered as part
in the world. of our turnkey systems but which can also be provided as
GEA is the only supplier capable of meeting the full discreet, stand-alone products that can be integrated into an
spectrum of powder filling and packing requirements saving existing plant.
the need to search the world for specialised machinery. Our aftermarket support for spares and service ensures that
Whether purchasing an individual machine or a fully our customers receive expert attention throughout the life of
integrated system, all clients benefit from our understanding our products.
of the exacting requirements of the powdered food industry.
We know that our chosen industries can demand very
high quality, reliability and sanitary standards, so we do
everything with these requirements in mind.
3
Meeting Customers’ Needs
Introduction
Corporate Social Responsibility
Our customers are an integral part of
our business
The solutions that GEA provides, whilst designed to meet specific
business objectives, also enable our customers to maintain a
sustainable and reliable plant operation with minimal downtime.
Our leading edge engineering is helping our customers,
throughout the world, to reduce waste and power consumption
and to increase the overall yield of their plants thereby
contributing to a sustainable industry.
Safety and Hygiene
Safety and hygiene are at the forefront of our design philosophy.
GEA solutions are helping our customers to feed the world and
as a world leader in the manufacture of systems for the food and
dairy industry we do not cut corners when it comes to safety and
hygiene.
It is our goal to not only ensure that our customers have a safe
plant but that the products they manufacture are also of the
highest quality for the consumer.
Standards Compliance
Delivering high quality systems and components to the global
powdered products industry demands a strong focus on
international standards and directives. Our team of experienced
engineers has automated real time access to the latest directives
to enable them to carry out detailed risk assessments and thereby
ensure compliance with the applicable standards in each of our
key markets.
Reliability
Reliability is not just a word – it’s a philosophy.
Our customers need to have a trouble free plant for the lifetime of
the equipment and it is our goal to ensure that they do!
This is why our teams of engineers painstakingly select
components which have a high service life to give trouble free
operation for many years with minimal downtime.
4
Integrated Powder Systems Solutions
Introduction
GEA has the experience, resources and
components required to deliver state-of-the-art
powder handling systems anywhere in the world.
By coupling our Core Technology Centres in New
Zealand with GEA’s strong local market focus, we
can deliver local market support and service on a
global scale.
All GEA systems are distinguished by their
unrivalled engineering and manufacturing
quality, sanitary design, efficient installation and
commissioning complete with a comprehensive
maintenance and service support to ensure a
long and trouble free life.
5
Powder Handling
Powder Handling
Our understanding of our
customers’ needs to control
the flow of materials in their
plants has resulted in some
ground-breaking innovations.
6
Our experience, resources and high quality components coupled with our
extensive knowledge of powder packing equipment enables us to provide
genuine ‘turnkey’ solutions to meet and even exceed our customers’
requirements.
Powder Handling in a Hygienic Food Processing Environment covers a
Powder Handling
broad range of expertise. GEA delivers that expertise to your doorstep in one
complete package of
• Process Engineering
• Project Management
• Equipment Supply and Installation
• Control System Integration
• On site Commissioning
• After Sale Service and Support
Powder Ingredient Unloading
Systems
Unloading Systems are used to empty materials from bags, bins and other
containers into a production process. GEA has a wide range of solutions that
can be easily integrated to provide a complete tipping system suitable for the
customers’ requirements.
GEA systems frequently include additional features for the safety and
comfort of operators and to eliminate labour requirements such as lifting
devices, dust extraction systems, empty bag compactors, and automated
cutters, shakers and sifters.
Pneumatic Conveying
GEA has the know-how and broad range of components required to configure
clean, efficient and cost effective powder conveying systems for many
applications.
Because the product is transported pneumatically in stainless steel tubes and
vessels, the systems supplied by GEA meet all sanitary standards. Where
necessary, the entire system can be atmospherically sealed, evacuated and
filled with an inert gas, ready for final packaging.
From non-friable and non-sanitary powders to high-value, fragile
pharmaceuticals, we can supply all the components and systems required.
Both standard products and fragile powders can be transported under lean-
phase or dense-phase, using pressure or vacuum.
Our method for conveying agglomerated (fragile) products uses proven
technology to provide the most gentle and reliable means yet developed for
conveying a broad range of powdered products, most notably dairy powders.
Low product velocity means minimal damage for fragile powder particles.
Because only small quantities of air or gas are used, filters are small and easy
to service. The systems we offer are easy to install and simple to use, clean
and maintain.
7
Powder Storage
GEA offers a wide range of bulk storage solutions for both raw
materials and finished goods. We understand ”Bulk“ in every
sense of the word – our experience includes a high level of design
Powder Handling
competence in powder storage silos and hoppers.
Our proven understanding of our customers’ needs to control
the flow of materials in their plants has resulted in some ground-
breaking innovations.
Every storage solution we recommend demonstrates our awareness
and knowledge of bulk storage issues, including loading and
feeding, internal and external silos, hoppers and day-use bins,
flexible intermediate bulk containers (FIBCs) and rigid intermediate
bulk containers (RIBCs).
GEA can design the most practical solution to all your bulk powder
storage requirements.
Sifting & Blending Systems
GEA can engineer and supply a wide range of sieving and blending
techniques to suit many industries.
We offer cost-effective means of fine screening dry powders
and granular products such as milk powders, food additives,
pharmaceuticals, chemicals and other high value products.
The sanitary sieves that GEA offers are manufactured from a range
of stainless steel and food-grade materials to ensure the most
suitable contact surface for each product. Sieves can be supplied
with a wide variety of throughput rates and aperture sizes.
Sieves can be operated as stand-alone units, or can be integrated
into complete GEA powder processing systems.
GEA has extensive experience with all types of blender units,
ranging from simple batch units to multiple units providing
continuous output. Our experienced system integration engineers
can advise the correct solution for your application, whether it be
a simple ‘tumble’ blender, high-efficiency ribbon blender, paddle
mixer or vertical ribbon blenders.
Our close ties with blender OEM’s also allow for cost effective
special blender configurations to suit the most demanding
requirements. We can provide the technology required for high
throughputs, high levels of accuracy and high sanitation standards.
Batching and Weighing
Many powder handling systems require bulk weighing of large
volumes of materials for the preparation of product batches for
ingredient formulations. Typical applications are for food mixes,
soups and flavourings, pre-mixed baking recipes, infant formulas,
drinks, sauces, health and nutritional supplements, breakfast
cereals, confectionery, pharmaceuticals and many others.
GEA has a wide range of equipment suitable for systems from 100
tonne silo weighing to micro ingredient systems dosing a
few grams.
8
Typical Features include:
• High accuracy load-cells and weight control electronics
• Major, minor and micro ingredient dosing
• Safe, sanitary and dust free
• Multiple ingredient
Powder Handling
• Gain-in-weight, loss-in-weight and continuous weighing
• Fast/bulk fill and slow/trickle filling with self-tuning pre-act
• Automatic top-up
• Maximised flexibility for variable recipes
• State of the art control systems and recipe management using
SCADA/HMI software for process visualization, inventory
control and reporting functions for management information
systems.
CIP Cleanable Systems
GEA is a world leader in the design of
completely CIP Cleanable Powder Systems for
the most stringent hygiene requirements.
When your hygienic requirements demand that batch separation
is absolutely assured, GEA can provide completely CIP cleanable
powder handling systems for particularly critical applications
such as pharmaceutical and infant formula manufacture.
Conveying, storage and mixing systems can all be CIP cleaned for
minimum downtime with approved designs and components.
System features include:
• Proven CIP resistant valves, diverters, mixers, vessels and other
components, CIP cleanable filtration and isolation systems
• Hot air drying and reticulation equipment
• USDA / 3A accepted CIP nozzles and spray balls – hydraulic,
pneumatic or removable
• Water/acid/caustic supply systems and controls
• Waste liquid drain / recovery systems
• Automated and semi-automatic PLC
Powder Testing
Powder handling and packaging is an increasingly complex
business. Customers are demanding ever higher levels of
performance and service. GEA is meeting their demands by using
advanced tools and systems to deliver products of superior design
and performance.
GEA understands the advantages of powder testing. Prior to
designing mechanical or pneumatic handling systems, GEA
typically tests for a wide range of powder properties including
sieve analysis for particle size distribution, bulk density, flow-
ability, mechanical stability and fluidisation index. Each of these
parameters is carefully taken into account in the development of
the design and the execution of the project.
With the results of powder tests we can utilise our extensive
in-house knowledge base and experience to design a system with
guaranteed performance.
9
25kg Bag Filling
25kg Bag Filling
GEA can now proudly offer
two brands of filling system
to offer even greater choice
to our customers.
10GEA Filling Lines - the heart of the operation
Two Brands – one source
“Our success is often limited by the choices
available to us”
GEA now proudly offers two brands of filling system to
provide an even greater choice to our customers.
The two ranges of filler have been carefully selected from our
original Avapac™ and SmartFil™ machine brands to ensure
that GEA has a system to meet most of our customers’ needs
and preferences.
25kg Bag Filling
From a basic but elegant manual system to high output
and high accuracy systems and even an almost completely
unmanned solution, GEA has a solution to fit the most
demanding powder packing requirements.
Avapac™
The Avapac brand of fillers is well known throughout the
world and is synonymous with high quality and reliability.
Our experience with many and varied powdered products
means that we have a solution to fit most packing needs.
11Li Range - Limited Intervention Range
The flagship of the GEA Avapac range is the all new Li (Limited Intervention)
bag filling system. This technology sets a new benchmark in automated powder
packing and bag handling.
Reliable bag filling and closing, combined with an automated bag de-stacking
system has resulted in the world’s first truly automatic packing system which
eliminates the need for an operator inside the packing room.
Starting at the optional fully automated bag de-stacking system, bags are
delivered to the filling system and loaded onto the filling head ready for filling
and closing.
25kg Bag Filling
Multiple independently controlled bag stations are combined into a carousel to
perform bag filling, preparation and closing whilst the bag is fully held ensuring
fault free operation and thereby maximising throughput of the bag packing plant.
Well proven GEA Avapac bag sealing and closing technology has been integrated
into the filling system to provide a very compact operation which significantly
reduces the space required for production.
An optional wireless operator panel can be used to monitor the packing process
from a central location - which was previously only possible for large automated
processing plants.
Ethernet connectivity enables both local and remote monitoring and data analysis
using the customer SCADA system.
RBF Range
The GEA Avapac RBF (Rotary Bag Filler) range is designed to pack a wide variety
of products at high filling rates.
The RBF range features a bottom-up filling system which maintains a constant
distance between the outlet of the filler tube and the top of the powder in the bag.
By doing this, the displacement of air is kept to a minimum and the resulting dust
emissions are dramatically reduced over more conventional systems.
This makes the GEA Avapac range of fillers very clean and safe in operation
and the reduction of product losses, through better dust control, means greater
product yield for our customers.
PLC with touch-panel operation allows complete control of the packing line
from the filler, whilst multiple product configurations held as recipe’s take care
of a wide variety of packing parameters for multiple products. All RBF product
contact parts are constructed of stainless steel, making them ideal for both dairy
and food ingredient products.
IBF Range
The GEA Avapac IBF (lnline Bag Filler) range is designed to pack a wide variety of
products at low to medium filling rates.
Featuring the same bottom-up filling system as the larger models, the IBF range
offers great value and flexibility for medium packing rates.
All IBF fillers are constructed of stainless steel which makes them ideal for both
high hygiene and corrosive products. Change parts are available for customers
wishing to pack a variety of products on the same machine, and options include
CIP cleaning.
12RBF1200Li RBF800Li
25kg Bag Filling
RBF1800 RBF1200
IBF800 IBF600 IBF450
13SmartFil™
The SmartFil™ brand of fillers has been developed to provide
customers with a flexible and cost effective filling solution for lower
throughputs or where there is a requirement for frequent cleaning.
25-200D
The SmartFil™ model 25-200D bag filler is designed to fill 25kg bags
with powdered products.
The easy-clean horizontal auger feed filling system is ideally suited to
food and dairy applications where there is a requirement for accurate
25kg Bag Filling
and hygienic filling.
The removable auger is also well suited to plants where there is a need
to pack a wide variety of product and where frequent cleaning is a
key requirement. To further enhance the capability of the SmartFil™
system, an innovative fully CIP’able option is available.
The fully automatic operation of this filling system provides flexibility
for medium volume, high value packing operations.
25-100D
GEA recognises that customers have a broad spectrum of filling
requirements and we have developed the SmartFil™ 25-100D to fulfil
the need for low volume or pilot plants where customers wish to have
more manual control over their filling process.
This simple but elegant filling system has great flexibility to handle
a wide variety of filling methods. In its simplest form, the unit can
be placed beneath the customers’ existing powder feed system.
Alternatively, GEA can supply the 25-100D with a rotary valve,
vibratory-tube or screw feed system.
Line Equipment
GEA designed Line equipment includes solutions to meet the varied
needs of powder packing facilities.
Once the filled bag is closed, it is passed to the Line equipment
for processing and quality checks before being palletised. The
Line equipment can be specified and configured to meet customer
requirements, or to suit existing packing facilities.
A line control MCC can be connected to the filler to provide
distributed control for line equipment. This connectivity enables the
line to be monitored and controlled from a single interface thereby
providing a user friendly environment.
Optional connectivity of the check-weighing and bag coding
equipment enables both local and remote monitoring and data
analysis using the customers’ SCADA system.
14SmartFil™ 25-100D
SmartFil™ 25-200D
25kg Bag Filling
Line Equipment
15Bulk Container Filling
Bulk Container
Filling
Our team of experienced
engineers work closely with
our customers to develop
the right solution.
16GEA Filling Lines - the heart of the operation
GEA has a wide range of solutions for packing products into
bulk containers including FIBC’s, RIBC’s, Octobins, Tote bins
and even Boss Pak™
As nearly every solution is tailored to suit specific needs,
our team of experienced engineers work closely with our
customers to custom design the right solution.
Automated Systems
Our big bag filling customers are many and varied and with
particular requirements for safety and hygiene, GEA has
responded with several automated solutions.
The range includes safe and convenient systems for filling
high value products which can automatically palletise the
finished bags outside of the high hygiene area. With our own
Impulse sealing system, GEA offers a complete solution for
inert gas packing of oxygen sensitive powdered products.
Bulk Container
Filling
Manual Systems
For lower throughput or alternative packing format
requirements, GEA can offer very simple, low cost manual
solutions which can be easily installed directly below existing
powder feed installations.
17Retail Container Filling
Retail Containers
Powder Filling –
GEA retail powder filling lines
can fill the widest range of
powders including free flow
food powders.
18GEA Retail Filling Lines - the heart of the operation
When high hygiene, high accuracy, product safety and fully integrated
automation are your key requirements for filling high value powders into retail
containers, then…
GEA has a comprehensive range of world class fillers to cover throughputs up to
400 containers per minute and container sizes from 200 grams to 2.5 kilograms.
Our on-going development program means that you will always obtain state-of-
the art systems featuring the latest technology.
As all GEA retail powder filling lines are designed with the customer’s
requirements in mind, they combine the highest levels of productivity and
accuracy with the gentlest product handling, while ensuring that requirements,
such as correct spoon placement, are met.
GEA retail powder filling lines can successfully fill the widest range of powders
including free flow food powders such as:
• Milk Powder and Powdered Dairy Beverages
• Nutritional Powders
• Coffee and Coffee Creamer
Depending on the product to be filled, GEA filling technologies such as auger,
auger/vacuum or vacuum only can be offered.
Accuracy is the Key
‘Nothing Under’ Filling
Retail Containers
Powder Filling –
In many markets, local legislation states that the net content of each and every
container must never be less than the declared weight.
In these “nothing under” markets, GEA’s proven vacuum auger fillers or the more
gentle vacuum bulk fill and optional top-up system combines extreme accuracy
with high throughputs to produce average savings of up to 5 per cent compared
with other filling technologies. Dependable high fill accuracy is the key to
providing minimal product give away.
Rather than giving away large quantities of powder to reduce underweight rejects
to a manageable level, GEA has a solution for you.
We can provide either auger bulk fill machines with unparalleled accuracy or
vacuum bulk fill machines with a single station top-up if required.
When a top-up system is installed, the GEA control system instructs the bulk filler
to under fill all cans. Each can is then weighed again, and the amount required to
bring the can up to the specified weight is passed forward to the top-up system.
Average Weight Filling
In some markets, it is permissible to under fill a proportion of cans, provided that
the complete batch has an average weight which is greater than or equal to the
declared weight.
In these markets, GEA utilises a dynamic targeting feedback system that allows
clients that are filling to average weight legislation, to reduce give-away levels to
as low as 0.01 per cent.
Regardless of fluctuations in the bulk density of the supply powder, the filling
system calculates a running average of all containers filled, and adjusts the
dynamic target to maintain the average at (or slightly over) the declared weight at
all times.
19Integrated Systems
A truly integrated filling line is far more than a series
of machines running in sequence.
It is the product of a clear understanding of throughput, accuracy, shelf
life and quality standards. The types of powders to be handled, the
variety of container sizes and the frequency of product changeover must
also be taken into account.
Successful filling line design also requires the careful selection of
complementary machines and components from all over the world, the
provision of buffers to ensure minimum disruption to operations and
specialised software which can integrate and control both machine and
system performance.
Each of these issues is critical and getting the line right is as much an art
as it is a science: an art based on specialist knowledge, experience and
expertise.
All GEA filling lines feature integrated control systems which
continuously monitor and adjust the performance of the filling line.
GEA can link our own machines with other O.E.M. supplied equipment
via a number of networked solutions. By carefully specifying such items,
we can ensure the supply of an integrated control system where overall
plant operation can be monitored on multiple SCADA displays.
Retail Containers
Powder Filling –
The GEA control system will facilitate running the filling line at high
efficiencies by balancing the flow at each station through the line. In
addition, the line operators are given complete visibility of the line
operation with graphical displays, allowing for maximum throughput
and line uptime.
Vacuum Filling
The GEA range of retail filling machines now includes all new vacuum
and free flow machines which have been fully redesigned from the
ground up. Taking the best of the well-proven Albro and Colby brands of
filling systems, GEA has created a new range of fillers for throughputs up
to 300 cans per minute!
Blending well proven vacuum filling technology with modern design
and manufacturing techniques has resulted in a cost effective retail
filling system for higher throughputs and higher accuracy. The new
RCF (Rotary Can Filler) and ICF (Incremental Can Filler) ranges are now
ready to be integrated into a complete retail filling system.
Auger Filling
For customers that require unparalleled accuracy with minimal plant
footprint then our range of high quality auger fillers, utilising proven
Colby technology, is the ideal solution.
Our technology ranges from our fully Integrated Filler and Seaming
system (IFC-1A) to the class leading 24-Head rotary auger filler which is
capable of high accuracy filling at up to 300 containers per minute.
20ICF-6F ICF-6V
RCF-10V/RCF20V RCF-10A/RCF-24A
Retail Containers
IFS-1A Powder Filling –
21Specialist Equipment
At GEA we recognised that the range of machinery designed specifically
for the needs of the food powder industry was limited. So we developed
a comprehensive range of spoon dispensers, container cleaners and
sterilisers, fillers, container gassers, conveyors and accumulators to suit
the exacting requirements of food powder packaging.
GEA can also integrate any of these single machines into an existing
filling line.
Those machines which are not specific to the requirements of the
powder industry such as palletisers, de-palletisers, check-weighers,
seamers, case-packers and ink-jet printers are carefully sourced from the
world’s best suppliers.
Scoop Dispensing
Infant formulae and other food powders often require the insertion of a
particular type of measuring scoop or spoon.
GEA’s flexible scoop dispensing system automatically handles virtually
all scoop types with speed and accuracy, eliminating the need for
unreliable and labour intensive manual insertion.
Can Handling & Accumulation
GEA conveyors link filling line machines, precisely matching supply
Retail Containers
to operating speed. Accumulation tables provide a buffer between
Powder Filling –
processes. Sophisticated, electronically controlled diverters and
channelisers reject underweight or overweight containers, enhancing
system performance.
Sanitation & Cleaning
The highest quality finished product is our goal
All GEA systems can be designed and manufactured to ensure world-
class sanitary standards will be met. We regularly supply equipment and
systems for use in USDA, MAF and other similarly regulated plants.
Tool-free disassembly allows for easy inspection and cleaning of
individual components and machines.
GEA’s main strength however, is the ability to engineer complete systems
for use on sanitary products. We understand the need for sanitary, clean
room design as well as HVAC systems rated for the highest filtration and
humidity control requirements.
GEA can help with your complete sanitary plant design.
22Controls & Integration
One of the most important aspects of any
modern manufacturing business is the human/
machine interface.
If the process is to work at maximum efficiency, the interface
must be optimised.
To offer the most up-to-date control solutions, GEA works
closely with established suppliers of industrial control
technology. Our close relationship with these companies gives
us a privileged window into the leading-edge advances they are
making. It also provides us with valuable access to reference
sites across a variety of industries.
As a result, GEA offers control systems with easy to use
operator interfaces requiring a minimum of operator training.
Automatic monitoring and sequence control ensure our systems
run with minimum staff and have high levels of reliability. GEA
has the experience to find the right balance between economy
and sophistication.
On the basis of this experience, we can provide control systems
which are tailored specifically to our customers’ needs.
Retail Containers
Powder Filling –
GEA also understands the importance of a formal approach to
software engineering.
We have developed an extensive library of standard software
solutions, which is continually being expanded and updated
as we provide new advanced control technology systems
worldwide. Disciplined use of this library enables us to continue
to provide customised solutions without having to “re-invent
the wheel” for each project.
23Packaging Formats
Packaging
Formats
GEA is at the forefront of this
industry and we work closely
with packaging companies to
ensure that we stay ahead.
24The safe and reliable packaging of food is our business. In
order to excel, GEA has had to develop innovative solutions Big Bags
in order to meet the ever changing needs of our customers. GEA has a vast
New packaging formats and construction techniques drive amount of experience
equipment manufacturers to develop reliable solutions. GEA with big bag formats,
is at the forefront of this industry and we work closely with including standard
packaging companies to ensure that we stay ahead. woven bags, Gambo
style bags and even
the latest Boss Pak™ system.
Rigid Containers No two bulk filling systems are the same. We at GEA
The GEA retail filler range is designed to enable our recognise this and we work closely with our customers to
customers to pack into a variety of retail format containers. deliver solutions which not only fulfil the functional and
performance requirements of the process but also ensure
Our systems offer customers the flexibility to handle that the solution fits within the customers’ existing building
container configurations, including three piece tin plate, constraints.
composite cans, moulded plastic and glass jars. Using quick-
release change parts our customers can modify our filling As a result, our products reflect world’s best practice for big
systems to adjust their packing plants to meet the ever bag filling and handling and we are proud to put the GEA
changing needs of the retail marketplace. name to all of our well proven systems.
Boxes & Drums
Customers that have very exacting
requirements for their packing plants look
to GEA to provide innovative solutions to
meet their needs.
Specialised package handling systems
combined with flexible line configurations
enable us to meet the needs of the
chemical, pharmaceutical and food ingredient industries.
GEA has developed Bag, Box and Drum filling extensions to
Multi-wall Kraft our existing range of IBF fillers.
Packaging
Formats
Packing into flexible multi-wall kraft These features extend the capability of the Avapac range of
packaging can be a challenging fillers to handle the widest range of packaging media in a
and unreliable process. This is why single machine. With quick-change parts, the filler can be
our team of packaging experts has quickly and easily set up to fill bags, boxes or drums.
developed unique technology to
ensure the most reliable bag handling
for its bag fillers.
Boss Pak™
Multi-wall kraft bags come in a large
Boss Pak™ is a high end big bag system that has been
variety of formats, shapes and sizes.
developed to meet the needs of product manufacturers.
Our team of packaging expert will guide our customers
Its patented system of filling using a spinning head
through a careful program of packaging and machine
arrangement ensures that the powder flows to every part of
selection to ensure that the delivered solution is the most
the bag during the filling process thereby maximising the
reliable it can be.
useable volume of the bag.
The filled bag is very stable and handling is done via belt
type conveyors. An integrated slip-sheet system provides
the means to take the bag from the conveyor and place it
onto a pallet outside of the high hygiene packing room. The
finished bag looks every bit as high quality as the product
contained within.
GEA has a number of well proven solutions to suit all needs
for customers wishing to pack into this flexible big bag
system.
25Modified Atmosphere Packing (M.A.P.) for Powders
GEA can provide a range of
M.A.P. systems for all your
needs; for both retail
and bulk products.
M.A.P. for
Powders
26Preservation of food products is one Pre-gassing of Powders
of mankind’s oldest challenges. GEA offers a proven method of removing oxygen from bulk
In modern manufacturing, high importance is attached quantities of powders and granules before they are packed.
to the processor‘s ability to provide extended shelf life for The system achieves extremely low levels of Residual
food products; including powdered or granular products. Oxygen (R.O.) at a higher speed and lower cost than other
Modified Atmosphere Processing (M.A.P.) Systems remove systems. It can be used to extend the shelf life of whole milk
oxygen and replace it with inert gases. powders, baby formulae, nutritional supplements and other
GEA can provide a range of M.A.P. systems for all your powders and granular products.
needs; for both retail and bulk products. We can apply our The highest product quality can be maintained by gassing
proven technology to our equipment or your existing plant. it immediately after it has been produced. This technique
If necessary, we can even produce specialised designs for is independent of the next process and can be applied to a
specific customer requirements. wide variety of packaging systems.
How do GEA do it? How our system works
GEA uses two main technologies to provide M.A.P. systems The extraction of oxygen and injection of an inert gas has
for their customers. long been recognised as the best way to improve the product
These are commonly know as ‘Post-gassing’ and ‘Pre-gassing’. shelf life.
In both methods, oxygen is removed from the product Our system uses a vacuum to evacuate the gassing chamber.
and inert gas introduced as a replacement. The inert gas is Nitrogen is then flushed through the powder.
typically nitrogen or a mixture of nitrogen and CO2. Oxygen removal is so effective that even after several days in
bulk storage, R.O. levels as low as 0.5% are achieved.
The Traditional Way - Post-Gassing
In a typical 250 kg (550 lb) batch, the entire gassing cycle
Post-gassing is the process of gas replacement ‘post’ filling;
takes less than two minutes.
in other words, after the product has been placed into it`s
packaging. GEA systems have sophisticated controls that are pre-
programmed and easy to use. The whole operation is
This is the most established methodology and GEA has many
automatic, so results are predictable and repeatable.
installations using this system.
The GEA pre-gassing system is a versatile gassing system
The Alternative - Pre-Gassing that offers a wide range of options for bulk storage and
packing.
As the name suggests, ‘pre-gassing’ is the process of
atmosphere replacement prior to packaging. This requires
the separate treatment of the product and the container prior
to filling.
Evacuation or Flushing?
Both methods have advantages and disadvantages;
M.A.P. for
Powders
depending on factors such as product type, processing speed
and cost of inert gases.
GEA has mastered both and can provide you with the right
solution for your needs.
27Pre-gassing for Retail Containers
By eliminating a number of steps from the inert gassing process
and reducing the number of mechanical elements, system
reliability and uptime are substantially improved, while the capital
cost is significantly lowered.
There are two distinct types of MAP systems, Nitrogen only and
Nitrogen plus Carbon Dioxide
Standard technology uses fully enclosed systems that can impede
access.
The GEA pre-gassing system for Nitrogen systems uses patented
gassing rail technology that removes the requirement for a sealed
system around the container conveyors, greatly improving access
and line uptime.
The GEA pre-gassing system is also very space efficient, reducing
the requirement for environmental control and air-conditioning
in new installations and freeing up additional space in existing
applications.
Pre-gassing involves treating bulk quantities of powder with
inert gas, prior to filling and seaming the container in an inert
environment.
To date, this approach has required all elements of the powder
packaging system, from the bulk supply to the seamer, to be
completely enclosed in an inert environment.
In addition to requiring large amounts of gas, this approach
is prone to delays. Production must stop any time the inert
environment is compromised, due to a stoppage or service
problem. There are also occupational health and safety concerns
associated with oxygen depleted environments.
The GEA system however, is based on a much simpler design,
with only the bulk storage hopper being enclosed. The inert
environment in the can is maintained by the use of patented
gassing rails.
As well as providing greater control over the gassing process and
simplifying maintenance and product changeovers, this approach
also enables continuous motion processing, resulting in high
M.A.P. for
Powders
productivity rates.
28Continuous Gassing
Modern filling and packing lines are frequently
high speed systems that require radical new MAP
technologies.
GEA can provide continuous or “on-line” gassing
which continually modifies the atmosphere of
empty containers and food products prior to filling
and closing.
The systems use state-of-the-art PLC and computer
control to achieve high efficiency gas exchange with
unequalled ease of use for the plant operators.
Post Gassing
The GEA Vacuumaster
The Vacuumaster cost-effectively extends product
shelf life by removing oxygen from retail
containers of oxygen sensitive powdered and
granular products.
Your product will remain fresher for longer because
the Vacuumaster achieves very low levels of
residual oxygen.
The system is economic to buy and run. It is simple
and compact. It can be tailored to suit virtually
any size range of rigid retail containers and can be
designed to suit the throughput rates of virtually
any powder packaging system.
Our technology is used by companies all over
the world to extend the shelf life of whole milk
powders, infant formulae, nutritional supplements
and other powdered and granular products.
M.A.P. for
Powders
29Components
GEA Nu-Con recognises that
our customers need peace
Components
of mind when it comes to
handling their valued products.
30Manufacturing Central Vacuum Systems
GEA proudly manufactures its extensive range of powder GEA central vacuum cleaning systems are designed to enable
handling components in its purpose built centre in the highest standards of cleanliness to be maintained in
New Zealand. Food, Dairy and Pharmaceutical plants.
Extensive R&D and pre-production testing has resulted in a Each system includes a centralised waste receiving hopper
range of the finest rotary valves, divert valves, magnets and and vacuum pump connected to a reticulated pipe network
other components which GEA is then able to integrate into throughout the plant area. Inlet isolation flap valves are
its powder handling systems. located at convenient plant locations for localised operation.
All components are carefully assembled and tested before A variety of hoses and nozzle fittings are available to enable
being packed for delivery to our customers throughout safe and effective cleaning of all floors, walls, crevices, pipes,
the world. ductwork and machinery.
GEA customers around the
world who have selected
Rotary Valves our central vacuum systems
benefit from its convenience
For over 40 years, GEA Nu-Con has been manufacturing
– something which is not
and installing its rotary valves for applications including
so achievable with portable
dairy, food, pharmaceutical, nutritional products and other
vacuum cleaners.
ingredients.
From this extensive experience, GEA Nu-Con has developed
an impressive range of both standard and customised
variants to meet our customers’ exacting requirements.
Blower Packages for Powder
Whether required for an isolation/air-lock or metering Conveying
application, there is a GEA Nu-Con rotary valve to suit most
GEA Nu-Con has sourced the
specifications.
most reliable and cost effective
GEA Nu-Con recognises that our customers need peace of blower packages from around
mind when it comes to handling their valued products. This the world. These systems are
is why the team at GEA Nu-Con has developed an innovative offered independently for existing
Rotor Detection System (RDS) which can detect and alert the applications or we can offer them as
plant operator of a potential metal to metal contact condition part of a turnkey plant installation.
within the valve.
The application of our technical expertise and experience
has resulted in an RDS system with superior performance Dust Collection
even during clean-in-place operation thereby giving
GEA Jet-pulse bag filters are designed for high performance
extended performance throughout the full spectrum of plant
and maximum efficiency, while reducing maintenance
operating conditions.
costs and downtime. Typical applications include process
air cleaning, silo venting, receiving vessels for pneumatic
conveying systems, dust extraction, bag tipping, air slide and
fluidiser venting.
Design features include modular component design jet
pulsed filter cleaning with fully adjustable control. Heavy
duty welded steel or stainless steel construction, easy access
Components
to filters for inspection and maintenance, with filter removal
from clean air side as standard.
Dust discharge can be provided via collection bin, airlocks,
screw conveyor, flap valves or even flange mounted onto
powder storage silos for maximum product retention.
31Product Range
The GEA Nu-Con brand of components builds on over 40 Typical applications include creating a flame prevention
years of experience in supplying high quality equipment path to act as a personnel protection device or to protect
to the food and dairy industries. Our extensive range of upstream and downstream processes.
components ensures that our customers do not need to
The internal components are certified for use in Zone 20
scour the globe to find a complete solution for their needs.
environments making them ideal for use in systems which
GEA offers rotary valves for ATEX applications. require intrinsic protection within the device.
Rotary Valves
Diverter Valves
Components
Gravity Divert Valves
32Rotary Sifters
Lump Breakers Rotary Magnets
Vibrators and Fluidisers Venturi Eductors
Components
Air Coolers and Preheaters Dehumidifiers
33Aftermarket
Our global service team can
deliver parts and service
directly where it is needed.
Aftermarket
34Global Service Organisation Product Quality
The global GEA organisation affords us the unique Product quality can mean the difference between poor
opportunity to service our customers locally. With GEA market image and increased sales. GEA has always placed
representatives in every continent, we have the ability to great emphasis on the quality of our goods and services.
provide assistance with all aspects of aftermarket care. We have the knowledge to assist our customers with their
quality problems. Our experience includes:
Spares Packages · Powder Breakdown Reduction
· Filling Accuracy Control
Having a global service organisation means that we can · Increased Yields
supply spare parts where they are needed in each market. · Container Damage Reduction
As part of our project cycle, our team of engineers work · Modified Atmosphere Control
closely with our customers to design a spares package to suit · Process Surveys
their needs. Based on many years of experience, we are able · Residual Oxygen Levels
to provide a recommended spares list with each system to
ensure that our customers have the necessary parts on hand
when they are needed. Plant Optimisation
Many plants can unknowingly run at reduced efficiency. The
Training causes can be ineffective systems, procedures and designs.
Improvement is often achieved by systematic analysis
GEA offers training courses for your plant operators and provided you have industry knowledge. We have that
plant maintenance personnel. We are able to prepare a knowledge and can help you achieve:
comprehensive training program to bring your staff up to · Production Line Output
date on how to get the best out of your machinery. · Instantaneous Filling Rates
GEA’s training can be tailor made for your equipment or · Powder Transport Systems Capacity
your system. We cover all GEA powder filling technologies · Utilisation Improvements
including Avapac, Colby, Albro, SmartFil and Sapac · Operational Strategies
machines. We also offer comprehensive training in the · Changeover procedures
operation and maintenance of all Nu-Con components and · Inert Gas Consumption
powder handling systems.
Instruction will be given on how to:
· operate the equipment correctly
Upgrades
· optimise output Improving existing plant and equipment performance is
· ensure quality of finished product every bit as important to GEA as providing new technology.
· maintain the equipment properly GEA recognise that our customers’ needs change with the
· troubleshoot and fault find life of their plant and it is therefore important to be able to
modify the plant to meet these changing needs.
Maintenance Our team of engineers and site service personnel can assist
with the evaluation of existing plant and then prepare a
Maintenance is essential. If this is not planned it can result comprehensive report to outline upgrade solutions to meet
in unexpected downtime and increased costs. GEA can help our customers’ requirements.
with a variety of programs and support services including:
· Service Contracts and Agreements
· Total Preventative Maintenance
· Reliability Centered Maintenance
· Breakdown Maintenance
· Shutdown/Startup Support
· Product Launch Support
· Maintenance Consultation
Aftermarket
35We live our values.
Excellence • Passion • Integrity • Responsibility • GEA-versity
GEA Group is a global engineering company with multi-billion euro sales and operations in more than
50 countries. Founded in 1881, the company is one of the largest providers of innovative equipment and
process technology. GEA Group is listed in the STOXX® Europe 600 Index.
GEA Avapac Ltd. GEA Process Engineering B.V.
12-18 Foreman Road, PO Box 10266, Te Rapa, Hamilton 3241, Munsterstraat 5, 7418 EV Deventer
© GEA Group AG. All rights reserved.
New Zealand Postbus 2064, 7420 AB Deventer, Netherlands
Tel: +64 7 849 3414, Fax: +64 7 849 3494 Tel: +31 570 663 366, Fax: +31 570 663 377
info.avapac.nz@gea.com info.gpnl.nl@gea.com
GEA Nu-Con Ltd. GEA Process Engineering Inc.
8 Fisher Crescent, Mt Wellington, PO Box 12-264, Penrose, 1600 O’Keefe Road, Hudson, Wisconsin 54016,
Auckland 1642, New Zealand United States of America
Tel: +64 9 276 2388, Fax: +64 9 259 0172 Tel: +1 715 386 9371, Fax: +1 715 386 9376
sales.nucon.nz@gea.com gea-pe.us@gea.comYou can also read
