In Powder

Processing Plants
for the Food and
Dairy Industry
N I R O P O W D E R T E C H N O L O G Y
Hygiene
by Design
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rammen
Hygienic Design 2
Hygienic Installations 4
Liquid Processing 6
Raw Product Reception and Storage
Pasteurization
Mixing of Liquid and Powder
Liquid Concentration 8
Efficient Vaporizing Process
No Recirculation of Product
Minimized Non-evaporative Product Contact Surface
Low Hydraulic Operating Volume
Feed Treatment and Installations 10
Designed to Meet Hygienic and Sanitary Demands
No Product Contamination
Minimum 20 Hours of Operating Time
Easy Cleaning of Atomizer Units
SANICIP

bag filter
and VIBRO-FLUIDIZER

12
Pneumatic Conveying
Compatible with 3A Requirements
No Condensation or Powder Deposits
Powder Handling and Silo Storage
Filling and Bag Packing Systems 14
Fully Welded Connections
Modified Atmosphere Packing Systems
Removable Filling Heads
Large surface Area Vacuum Probes
Quick-release Components for Tool-Free
Disassembly
Powder Handling
and Packing
Drying
Evaporation
Raw Material Reception
and Pre-treatment
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page 2
page 3
Increasing Hygienic Standards
To fulfill today's increasing demand
for dairy-products to meet physical,
chemical and bacteriological require-
ments, there is an increasing focus on
designing processing lines that meets
the strictest hygienic standards.
And for the suppliers of processing
equipment, the challenge is not only
to stay on top of current requirements,
but also to take into consideration
tomorrow's hygienic standards.
Constant Improvements
During the last decades each unit
operation, including milk reception
and pre-treatment, evaporation and
spray drying, powder handling and
storage and packing, has undergone
major changes in order to improve
all aspects of hygienic design.
Enhancing Performance
The GEAcompanies all constantly
seeks to improve technologies and
equipment to enhance efficiency of
our unit operations and complete
processing lines and make sure they
comply with even the strictest inter-
national requirements valid today -
and tomorrow.
We are proud of setting the standard
for hygienic design of powder plants
for food and dairy products.
Hygienic Design
For maximum plant hygiene
Evaporation Drying Powder
Raw Material
Reception
Every components of a Niro
powder processing line is
designed with strict focus on
hygiene and safe operation.
page 4
Hygienic
Considerations
More than just state-of the-art-technology
In each link of the production chain it must be possible to trace from where the
product is coming and to where it is sent
Pre-treatment
Track and Trace
Handling Powder Packing
Focus on Safety
Today, there is an increased focus
on food safety, pollution control,
and health and safety requirements.
Directives such as Hygiene of
Foodstuff (incl. HACCP), Integrated
Pollution Prevention Control (IPPC),
ATEX, and other local regulations
all require careful analysis and
interpretation when designing a
complete processing line.
At Niro, we can assist you in finding
the most cost-effective design to meet
all relevant directives. Our engineers
are specialists - they know the direc-
tives and how they are implemented.
Factory Layouts
Acomplete powder processing line
designed in compliance with current
hygienic standards has to have a clear
separation of dry and wet processing
areas, of pasteurized and non-pas-
teurized products and a clear zoning
of non-hygienic and hygienic areas.
Clear separation helps avoid any
cross contamination between the
products and the environment.
At Niro, we implement these consid-
erations in our arrangement drawings
in close co-operation with our clients.
Track and Trace
Track and trace enables the producer
to follow the product through the
processing and identify all
ingredients - and their origin - at
any step from reception until final
packing of the powder.
Niro offers track and trace as
an integrated part of our
control systems.
The Lock where people entering
the hygienic area must change clothes
and footwear to avoid contamination
of the process area
page 5
Our plants meet the strictest
requirements to food safety,
pollution control, and to
health and safety precautions
Liquid
Processing
Milk reception, cooling, storage, separation and pasteurization
To ensure a first-class quality of the
products, it is important to cool the
raw milk before storage and further
processing. This is done in the raw
milk coolers
Pasteurization plant with pressure
differential control ensures that
pasteurized milk is not contaminated
with unpasteurized milk in the
regeneration section
Hygienic design is an
integrated part of
everything from milk
reception and onwards.
The Heart of Engineering
To GEALiquid Processing
Scandinavia hygienic process design
is the heart of engineering and it
requires a basic understanding of
food microbiology. Hygienic design
simply must be taken into account
early on in the design phases of the
project and carefully followed
throughout project execution and
installation.
Milk reception. Flexible food-grade
hoses are used to ensure fast emptying
of the tankers by gravity into large
silos in the basement. From here
various tests of the milk for quality
and batch tracking can be made
page 6
Raw Material Reception
and Pre-treatment
Today, CIP systems in milk powder
plants are divided into separate
zones, one for the milk tanker,
another for the unpasteurized
process section, and a third for the
pasteurization process and dryer
section. This design eliminates the
risk of cross contamination.
The heating of the CIP solution is
achieved using external indirect
heaters
page 7
The Liquid Process
In a dairy and food powder plant, the
liquid processing typically includes:
Every part of the processing line is
designed to minimize product deposits
and contamination, and to support
CIP systems.
Raw milk reception
Raw milk storage
Milk/cream pasteurization
Other liquid ingredients
reception, egg, oil, glucose
Mixing of liquid and
powder ingredients
Pasteurized milk/cream
Storage
CIP plants
Integration of CIP Systems for
Hygienic Design
Automated cleaning-in-place systems
(CIP systems) are an important part
of hygienic design. Automated
CIP system - true CIP- ensures a
repeatable, efficient, thorough and
documented cleaning of the
processing line.
Today, CIP systems are designed so
the CIP-forward flow and temperature
are regulated to meet specific
requirements. And to ensure
optimum cleaning of all pipelines
a turbulent flow is used.
When the CIP cycle is completed,
production can be resumed. If the
CIP is not completed according to the
programme, an interlock will hinder
production-start.
Double Seat Valve matrix
secures minimum dead space
and prevents mixing of product
and CIP liquid
Wrap-around separator with rounded corners improves
efficiency. The products' contact to the evaporator's surface
is reduced and CIP is done easily
An evaporator calandria
with 16-18m tubes. Coverage
of each tube is improved and
fouling/deposits are
reduced. CIP is fast and
effective
page 8
Flash regenerative vessels with no
heat transfer surface reduces steam
consumption. When the same principle
is used instead of traditional tubular
pre-heaters, 20 hours continuous
production is possible with low
mesophile and thermophile growth
Hydro-cyclone. Aself-cleaning in-line
filter removes sludge during CIP and
gives full protection against blockage of
the distribution system
Evaporation
Heating media chest
can be equipped with
CIP spray balls
Liquid Distributor and
heat surface pipes
No sharp corners
Concentration of dairy
products requires efficient
falling film evaporators,
designed to meet both
product- and energy
specifications.
Hygienic Design is Essential
Hygienic design of falling film evapo-
rators is not only about surfaces and
component details. The design of the
Niro evaporators takes hygienic
design a step further. All components
are mounted for optimum functionality
and drainage, and for a minimum of
surface exposure to the product.
CIP Systems
CIP is an essential part of Niro's
hygienic evaporator-design - both in
the mechanical execution as well as
in the design of control software and
logging of operating data. To eliminate
the need for opening and inspection
afterwards, CIP is performed while
the evaporator is under vacuum.
Tangential swirl heater
for controllable direct
steam injection to final
heating temperature
makes 20 h continuous
operation possible
Vertical holding
tubes makes CIP
and inspection easy
page 9
Liquid Concentration
In falling film evaporators
Design Features:
Low mesophile and low thermophile concepts for product pre- heating
Regenerative direct contact product heating
Tangential swirl heater unit, for controllable direct steam injection to final heating temperature
Culinary steam re-boiler concept available as partial or total steam supply
No recirculation of product
Low hydraulic operating volume
Minimized non-evaporative product contact surface
Shell & tube execution of condenser
No sharp corners, dead legs etc.
GEA Process Engineering, France is the technology centre for Niro dairy-evaporators
page 10
Feed Treatment
Spray Dryer
Cleaning of nozzle lances
and/or rotary atomizer is
performed in a specially
designed CIP stand,
which is included in the
CIP circuit for the feed
line. Disassembly of
nozzle lances and the
high-pressure feed
line/flexible high-
pressure hose is
therefore unnecessary
Functionality and flexibility
are important factors when
designing a feed system for a
spray drying plant.
Two feed tanks fully enclosed with CIP
spray balls and automatic changeover
from one to the other. One is in use
while the other is being cleaned
Continuous Operation
Our hygienic design is developed to allow
for 20 hours or more continuous operation
without adverse effect on the product
quality. In addition, the feed system is
designed for fully automatic CIP.
The feed pump is often a
combined homogenizer and
high-pressure pump. The
Niro Soavi high-pressure
pumps comply with the 3A
standards. They have a
smooth and polished surface
and rounded edges on all
parts that are in contact with
the product. Cleaning
requires no disassembly
Drying
Concentrate heat treatment in a tubular heat exchanger
with no moving parts and a corrugated heat transfer
surface. The heating is achieved using hot water in a
counter-current flow. This results in a low t and mini-
mum 20 hours of operation even at high temperatures
Feed tank system, concentrate pre-heating
and high pressure pumps
page 11
Design Details
Process air filtration, fan room,
chamber design and insulation
Spray Dryer
In all details, the
plant is designed not
to compromise the
hygienic conditions
Aplant layout with separate
fan rooms isolated from the
production areas helps avoid
contamination from the
outside. Process air is filtered
after passing fans and heaters
Focus on Details
Production of sensitive food and dairy
powders requires the spray dryer and
all other associated equipment to be
carefully designed in accordance to
strict hygiene requirements.
Every part of the plant is designed to
avoid product deposits and contami-
nation. All materials are carefully
selected focusing on the surfaces'
ability to improve the performance,
and design includes automated CIP.
The removable insulation
is an air-filled sandwich
panel mounted close to
the drying chamber's
surface. No insulation
material is needed
Removable insulation
allows regular inspections
of thechamber's outer
surface at any time. Cracks in
the chamber wall can be
discovered in time so prompt
actions can be taken. Product
contamination is
therefore avoided
SANICIP

bag filter
page 12
The SANICIP

CIP-able
bag filter complies with the
strictest legal requirements.
Today, the SANICIP

bag
filter sets the standard in the
industry
Drying
Improving Product Recovery
Niro's SANICIP

bag filter is
designed in accordance with the
strictest standards. Emissions from
a spray drying plant of less than
10mg/Nm
3
can be achieved by
replacing traditional cyclones with
a SANICIP

bag filter.
Reliable Cleaning Technology
With SANICIP

CIP-able bag filters

a complete plant CIP can be done
automatically. This reduces
downtime, and ensures a repeatable,
thorough, and documented cleaning.
Reverse jet nozzles are used
during operation to keep the
bags clean. During CIP they
act as two fluid nozzles
During wet cleaning all reverse jet
nozzles are supplied with CIP liquid.
The fluid is atomized by compressed
air and forced through the bags from
inside out (the opposite direction of
the process air stream). The patented
cleaning principle is unique for the
SANICIP

bag filter
VIBRO-FLUIDIZER

page 13
The VIBRO-FLUIDIZER

vibrating fluid bed and

sieve are equipped with CIP nozzles in the clean air
plenum and above to make it completely CIP-able
30 Years of
Hygienic Performance
The Niro VIBRO-FLUIDIZER

was
introduced more than 30 years ago.
Since then, it has undergone many
changes, and today, the
VIBRO-FLUIDIZER

is state-of-the-art
in hygienic vibrating fluid bed design.
The VIBRO-FLUIDIZER

designed with open

profiles for stiffening.
There are no hollow
spaces in this unit
The VIBRO-FLUIDIZER

is equipped with Niro's patented

BUBBLE PLATE

for superior air

distribution and powder transport.
The fabrication technique means the
BUBBLE PLATE

conform to the
3Arequirements, as there are no
crevices
page 14
Powder Handling
And silo storage
Top of the powder silos
and the air filters for
the conveying air. The
silos can be CIP cleaned
Powder transport by HEPA
filtered air to avoid
contamination of the powder
Powder diverter valve
enabling remote control of the
powder flow
For conveying of powder to the
bagging off line or retail packing,
the bottom of the powder silos
are equipped with pipework
Powder Handling
and Packing
Colby Powder Systems
There is an increasing concern about
contamination of powders during
handling and storage. This includes
contamination by bacteria. Colby
Powder Systems are designed to
avoid any contamination, and to
meet strict standards worldwide.
The systems are developed for tool-
free disassembly and easy access.
Individual items are manufactured
to high tolerances and standards of
finish ensuring a long life with
reduced cleaning costs.
Colby Powder Systems makes
extensive use of demountable unions,
clean designs and modern materials
such as food grade and engineering
plastics to achieve lightweight
construction. This allows for easy
inspection and cleaning of individual
components and complete machines.
Hygienic plant
design includes
focus on powder
handling and
storage.
page 15
The palletizer and
shrink-foil wrapper
present the bags in
the best possible
way on the pallet
A Clean Step for Hygiene
Avalon Engineering takes hygienic
design a step further in bag filling
and handling by providing smart
methods that enables producers to
keep bag filling and handling systems
clean and properly serviced:
AVAPAC

bag filling machines are

easy to disassemble and CIP clean
Bagging-off
Plant for 25 kg bags
Metal detector and
check weight
ensures rejection of
the bag if any metal
is detected
Quick-release auger spouts
Removable filling heads
Sliding joints on dust extraction
system
Large surface area vacuum probes
Full CIP design for wet cleaning
Quick-release components for
tool-free disassembly
Open chain type conveyor belts
and flat bed conveyors
Food grade lubricants
AVAPAC

The AVAPAC

range of bag fillers

are designed to meet the stringent
requirements of hygienic standards
compliance worldwide. All
AVAPAC

fillers are designed

to meet the requirements:
Avalon Engineering supplies hygienic
packing systems for a wide range of
food and dairy powders.
USDAand 3-ASanitary
Standards (3A)
Ministry of Agriculture &
Fisheries (MAF)
European Hygienic Design
Group (EHEDG)
And many more.
The AVAPAC

Inline-800
bag filler offers a flexible
and reliable straight line
packing process
N I R O P O W D E R T E C H N O L O G Y
Hygiene by Design
Niro is a world leader in industrial processing
with evaporation, spray drying, freeze drying,
and fuid bed processing as core technologies.
GEA Liquid Processing Scandinavia, Avalon
Engineering and Colby Powder Systems holds
similar positions in liquid processing
technology, bag flling and handling, and
powder handling and storage.
The companies are all part of the Process
Engineering Division of GEA Group.
In Powder Processing Plants
GEA Process Engineering Inc. 9165 Rumsey Road Columbia, MD 21045
Tel: 410-997-8700 Fax: 410-997-5021 Email: [email protected]
GEA Process Engineering Inc. 1600 O'Keefe Road Hudson, WI 54016
Tel: 715-386-9371 Fax: 715-386-9376 Email: [email protected]
Web: www.niroinc.com