GEA Announces New Line for Flavor Manufacturers
The goal is to create a flavor that mimics, as closely as possible, the real thing, GEA explains. It’s not just the combination of raw materials that contributes to the taste result; the manufacturing process is equally crucial. Any variation in method can cause unacceptable variations in a product.
The new GEA integrated line controls all the individual unit operations precisely and, by doing so, controls the output. “Achieving a consistent product requires very precise engineering, to allow the component parts of the line to work together in harmony. For example, feed systems must be calibrated specifically to match the capabilities of the mixer and the size of the mixer must be scaled precisely with the size of the dryer to ensure compatibility,” explains GEA.
In order to comply with the hygiene regulations, every production plant must be cleaned effectively. But, flavors and aromas can linger in equipment even after they have been cleaned to the most scrupulous hygiene standards. Any residue of the previous flavor can easily taint the next product, destroying the all-important consistency. To prevent this, GEA developed on a rotating-ball cleaning system.
With the overall concept, GEA has eliminated sharp edges or dead zones in the machines, pipework and valve systems, which even the smallest quantity of product could become trapped. Special materials have been carefully chosen to provide smooth internal surfaces to which product cannot adhere. The size of cleaning fluid tanks has been calculated to ensure that they hold precisely the right volume of medium to clean the whole system efficiently in less than four hours. Even gasket materials have been chosen to ensure that they do not harbor traces of product. These elements combine to ensure the efficiency of the CIP (Cleaning In Place) system making it efficient and enabling fast product changeover, reduced downtime, minimal waste and low use of water and detergents.
There is also another key factor in maintaining repeatability when using this line, according to GEA. When producing multiple products on the same line, it is critical that products are processed in the correct sequence to help prevent any tainting from one to the next. Purer flavors such as melon or strawberry, that are instantly recognized by consumers and are often consumed on their own, take precedence. Stronger flavors such as orange, garlic, chili, curry, etc., that are usually mixed with dishes, come later. The control system on the GEA line is capable of sequencing the production for maximum efficiency ensuring that after each operation the line is cleaned sufficiently.
Under the motto “Discover the World of Food”, GEA will promote its key themes of innovation, food safety, top quality and maximum flexibility for food, beverage and dairy processing at Anuga FoodTec this year.