THE INTERNATIONAL MAGAZINE OF THE GEA GROUP ISSUE 11 AUGUST 2010
THE INTERNATIONAL MAGAZINE OF THE GEA GROUP ISSUE 11 AUGUST 2010
FOR THE LOVE OF COOL FRENCH FRIES ELECTRIC CARS
FOR THE LOVE
OF COOL
ELECTRIC CARS
FRENCH FRIES
GENERATE is published by the GEA Group
Aktiengesellschaft, one of the largest system
providers for food and energy processes with
about EUR 4.4 billion revenue in 2009.
Listed on MDAX stock index, the company
focuses on process technology and
components for demanding production
processes in various end markets. The group
generates about 70 per cent of its revenue
from the food and energy industries, both of
which have long-term growth prospects.
As of December 31, 2009, the internationally
operating technology group had a workforce
of over 20,000 employees serving customers
in 50 countries. GEA Group is a market and
technology leader in 90 per cent of its
business areas.
GENERATE is the external
magazine of the GEA Group.
Published three times a year, it
is distributed across the world.
Welcome to the eleventh issue of
GENERATE, published by the
GEA Group Aktiengesellschaft.
GEA FARM TECHNOLOGIES
Dear Readers,
GEA HEAT EXCHANGERS
For thousands of years mankind has
been finding different ways of keeping
cool. But the advent of refrigeration
and air conditioning in the 20th century
irrevocably changed the way we live,
where we live, how we buy food and
which countries we can buy it from. Our
main feature looks at this wide-ranging
area and GEA’s role in developing the
most energy efficient ways of keeping
food, people and environments cool.
GEA MECHANICAL EQUIPMENT
GEA PROCESS ENGINEERING
GEA REFRIGERATION TECHNOLOGIES
Contact
GEA Group Aktiengesellschaft
Dorstener Straße 484
44809 Bochum
Tel: +49-(0)234-980-0
Fax: +49-(0)234-980-1087
www.geagroup.com
Dairy will always be a big part of GEA’s
business – since 1926 we’ve been
helping farmers to manage their dairy
business sustainably and profitability.
In this issue we look at milk’s journey
from the cow’s udder to the consumer.
For many people around the world,
extended shelf life (ESL) milk is more
convenient and you can read how GEA
technology is helping to lengthen milk’s
shelf life while keeping its nutritional
value and taste.
We are one of the world’s biggest
engineering companies and, as you
might expect, we play a role in the
production of many items that are an
everyday part of life. For example, one
of GEA’s group companies is involved
in the manufacture of tomato ketchup,
a favorite the world over. And GEA
Refrigeration Technologies is helping to
reduce the amount of energy needed to
freeze French fries.
But at the same time, we have a
presence in industries where you might
not expect to find us, for example
algae and nanotechnology. To many
people algae are just plants that grow
everywhere – but energy companies
are investigating the possibilities of
using algae to produce the biofuels
of the future. GEA technology is used
to separate algae from the water it is
grown in. Meanwhile, GEA’s Process
Engineering segment is involved in
the development of nanotechnology.
Our team in Denmark has developed
a method of spray drying nano
particles to make them safe to use in
industrial applications. In the future,
nanotechnology could produce car
windows that don’t steam up and fabrics
that won’t stain.
Finally, our Question and Answer
feature looks at Nissan’s plans to build
the world’s first affordable electric
car. Again we have a role to play in this
sector as one of our group companies’
spray drying technology is used to
produce the lithium batteries that power
the next generation of electric vehicles.
GEA continues to makes its presence
felt in traditional and new industries
the world over.
Jürg Oleas
Chairman of the Executive Board
GEA Group Aktiengesellschaft
IMPRINT
PUBLISHER
GEA Group Aktiengesellschaft
Dorstener Straße 484
44809 Bochum
Germany
EDITOR IN CHIEF
Donat von Mueller
(responsible for editorial content)
EDITORIAL STAFF GEA
Gaby Fildhaut
Maren Schneider
PHOTOGRAPHY
Cover, feature: Gareth Sambidge
Page 20-21: Chris Moyse
Page 22-25: Gareth Sambidge
Page 28-29: Nick Dawe
Page 30-31: Frank Freihofer
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COPYRIGHT
© 2010 by GEA Group Aktiengesellschaft,
Dorstener Straße 484, 44809, Bochum,
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permission of the publisher. The contents
do not necessarily reflect the opinion of
the publisher.
CONTACT
Questions or suggestions on the contents of
the magazine: [email protected]
FEATURE STORY
KEEPING COOL
HOW REFRIGERATION AND AIR
CONDITIONING HAVE CHANGED
THE WAY WE LIVE
NANOTECHNOLOGY
LIFESTYLE
HOW TO DO IT
ALGAE
Q&A
RECIPE FOR SUCCESS
FRENCH FRIES
CHILLVENTA 2010
A DAY IN THE LIFE
ART IN ENGINEERING
LAST WORD
Where small is big
Biofuel of the future?
GEA technology aids energy
saving freezing process
Processing technologies extend fresh
milk's shelf life
Nissan plans to built the world's first
affordable electric car
GEA gets ready for world's
premier refrigeration and air
conditioning exhibition
Cooling milk
Tomato ketchup: a favorite
the world over
GEA Refrigeration
Technologies' David Bostock's
passion is his profession
GENERATE MAGAZINE ISSUE 11
1
THE NEXT BIG ADVANCES IN TECHNOLOGY HAVE VERY
SMALL BEGINNINGS – ON A NANO SCALE. ALTHOUGH
NANO PARTICLES PROMISE UNLIMITED POTENTIAL
FOR EXCITING NEW MATERIALS AND APPLICATIONS,
MAKING THEM SAFE TO USE HAS BEEN A MAJOR
CHALLENGE. A TEAM FROM GEA NIRO IN
DENMARK HAS FOUND THE SOLUTION.
2
Copenhagen-based GEA Process
Engineering company GEA Niro, which
has been involved in the project from the
outset, channelled its proven expertise in
spray drying into tackling the problem. The
solution was to bind the nano particles
into granules.
ou don’t need a crystal ball to see the
future: just a very powerful microscope.
That’s because nano particles, which
could trigger the next industrial revolution,
are impossible to see with the naked eye.
Nano derives from ‘nanos’, the Greek
word for ‘dwarf’. But this term seems an
understatement for something that is so
mind-bogglingly tiny. A nanometer is one
billionth of a meter – equivalent to one
thousandth of the width of a human hair.
A sheet of paper is 100,000 nanometers thick.
Yet these tiny particles are beginning to
make a massive impact. The unusual
physical, chemical and biological properties
of materials at the nano scale could be
harnessed to develop a wide range of novel
products: car windows that don’t steam
up, paints and dyes that won’t fade, fabrics
that reject dirt and stains and super highstrength yet lightweight components.
According to the UK’s Institute of
Nanotechnology research at the nano scale
is multidisciplinary. On its website it states:
“The contribution of nanotechnology to
new products requires a team effort,
which may include life scientists working
with physicists, chemists and information
technology experts.”
Such an approach is behind SAPHIR (Safe
and Controlled Integrated Production of
High-tech Multifunctional Materials and their
Recycling). Backed by the EU, this EUR 15.7
million project involves 22 partners from
13 countries who, together and separately,
are developing products that exploit the
unique properties of nano particles. The aim
of SAPHIR is to ensure that nano particles
are used safely, from synthesis to the final
products, without exposing people to health
risks or damaging the environment.
“Nano particles are so small that they
stay in the air, stick to surfaces and can
be sucked into the lungs,” explains Jesper
Sæderup Lindeløv, Research Scientist Test
& Development at GEA Niro. “There’s a lot
of debate about the possible effects of nano
particles in humans. Tests on animals have
shown them to be potentially harmful.
“Because nano particles are difficult to
handle they are placed in a suspension of
solvent when they are synthesized. But,
for subsequent use, they need to be in a
dry form.”
Spray drying
Lindeløv and his team received nano particle
suspensions of hard metals and ceramics
synthesized by SAPHIR partner organizations
and tested them with different spray drying
configurations to produce granules. “The
experimental phase took us two years
because we had a limited amount of
materials to play with,” he says.
Early tests showed that if the granules were
too small they retained the ‘dusty’ properties
that made nano particles problematic.
Eventually the GEA Niro team came up with
a method of processing the particles into
granules of more than ten micrometers.
Another challenge was finding a spray drying
concept which avoided too many of the
particles escaping. The answer was a spray
dryer with an integrated filter within a closed
circuit. A HEPA filter, originally developed to
prevent the emission of radioactive materials
in the nuclear power industry, collects
any particles that escape from the drying
chamber. Also a Buck Hicoflex® containment
system avoids the release of product when
the container is changed. The solvent in
which the nano particles are suspended is
evaporated in the drying chamber and the
atomized gas is cooled in a condenser and
turned back into a liquid, which is
then recycled.
difficult to achieve a high solid content.
You need 90 per cent solvent to ten per cent
nano particles, which considerably adds to
the weight of the shipment.”
The GEA Niro team has presented its
successful spray drying method at
conferences and companies have expressed
an interest in using it as part of the
subsequent processing of nano materials.
So far the SAPHIR partners have targeted
their nanotechnology research on five
industry sectors – automotive, aeronautics,
energy, construction and health – with
one project for each. For example, in
the aeronautics sector, nano-structured
materials can be use to make helicopter
rotor components stronger but lighter. In
the case of construction, nanotechnology is
being applied to coatings that can destroy
organisms that pollute and erode surfaces.
“The idea is to concentrate on the big stuff
first, where cost is an issue,” explains
Michael Wahlberg, Manager of GEA
Niro’s Test and Development Center.
“Then, if it’s successful it can be used for
lower cost applications.
“Nanotechnology has been identified as the
next industrial revolution and I expect it will
be an interesting market for us. There is
a great opportunity in the pharmaceutical
sector because it is possible to produce
nano-sized active ingredients that can
pass through the digestive system
quickly and target the source of disease
more effectively.”
Wahlberg is keen to avoid nanotechnology
suffering the same fate as genetically
modified crops. “GM organisms failed
because people were afraid,” he
believes. “And if people don’t understand
nanotechnology, they may become frightened
which could then result in legislation to
prevent it being used.
“It’s important that we are open about
nanotechnology and the huge potential
that it has for all of us.”
Lindeløv says: “The resulting granules are
non-dusty, free flowing and have a high
purity. And they are cheaper to transport
– with suspensions of nano particles it is
GENERATE MAGAZINE ISSUE 11
3
HOW GROUNDBREAKING PROCESSING
TECHNOLOGIES ARE
EXTENDING THE SHELF
LIFE OF FRESH MILK.
4
This process destroys a large percentage
of the bacillus cereus spores that survive
pasteurization, extending the shelf life to at least
21 days. Significantly, this is achieved without
losing the fresh milk taste or the nutritional
value. It’s worth noting that many vitamins are
light sensitive so the amount of light to which
milk is exposed affects the end product more
than the ESL process.
GEA TDS offers four different methods for
reducing the micro-organisms in milk – direct
heating, indirect heating, microfiltration and
deep-bed filtration. Direct heating involves
preheating the milk to between 70°C and 85°C
and then heating it to a maximum of 127°C by
direct steam injection for three seconds before
This unusual manifestation of east meets
bringing the temperature back to 70°-85°C in
west took place in January 2010 at the Muak
a flash cooler. For the indirect heating method,
Lek Dairy Festival in Saraburi province, 145
heat exchangers are used to heat the milk in
kilometers north of Bangkok. The highlight was
three stages, to temperatures ranging from
the cowboy night which attracted hundreds of
70°C to 124°C, then cooling it to 5°C.
people from around the country.
Microfiltration
But perhaps such a display of cowboy culture
Microfiltration involves preheating the raw
doesn’t seem so out of place when you consider
milk then skimming it in a separator. The
that Muak Lek has been a major dairy farming
skimmed product is filtered through ceramic
area since local farmers began importing cattle
membranes. The retentate, which does not
in the 1950s. It now supplies most of the milk
pass the membrane, together with the cream,
products sold in Thailand’s supermarkets.
is then heated to 105°-125°C for between four
The Muak Lek Dairy Festival is just one of
and six seconds. The skimmed milk and cream
countless events organized throughout the
are homogenized and pasteurized in a milk heat
world every year to celebrate milk and dairy
exchanger, then cooled down to 5°-6°C. The
products. In 2001 the United Nations’ Food
deep-bed filtration process, developed by GEA
and Agriculture Organization (FAO) added
TDS and E. Begerow GmbH & Co, in cooperation
another when it declared June 1 World Milk
with the University of Applied Sciences and Arts
Day. The date was chosen to avoid conflicting
in Hanover, was originally used in the beverage
with national milk days held in many countries
industry. It is similar to microfiltration except the
around this time. Promoting the importance
particles are not deposited on the membrane
of milk globally is part of the FAO’s mission to
surface but are retained in the filter.
make sure that people have regular access to
GEA Westfalia Separator has adapted a tried and
good quality food.
tested method used in cheese manufacturing to
Complete food
produce ESL milk. Called Westfalia Separator®
Milk is often regarded as a complete food as it’s
prolong, it involves using two bacteria removal
packed full of essential protein, vitamins and
separators in front of the skimming separator.
minerals. Also, it has year-round availability.
Large-scale trials at a German dairy proved
But, as with all fresh foods, it has a short shelf
that with this new method more than 20 days of
life. The temperature of raw milk as it comes
extended shelf life can be achieved. It reduces
out of the cow is approximately 37-38°C and the
the total bacteria count by up to 90 per cent
bacteria count doubles every 20 minutes that
before pasteurization and bacillus cereus in
it remains at body temperature. It’s therefore
particular to less than one spore in 10 ml. The
crucial to chill the milk as fast as possible and
additional advantage of Westfalia Separator®
keep it cool – below 4°C – during transportation
prolong is that it requires less energy than for
and storage.
the heating or filtration methods.
airy farming festivals featuring cowboys,
whip-cracking and roping displays, country
and western music and cattle contests are
events you would expect to find in the United
States – but in Thailand?
The most common methods of processing
For consumers, ESL milk means fewer trips to
milk to make it safe to drink are pasteurization
the shops. The advantages for producers are
and ultra heat treated (UHT). Pasteurized milk
that they can distribute their products further
goes off after a week whereas UHT milk can be
and also, because of the longer shelf life, valuestored for several months and doesn’t need to
added products can be produced in longer runs
be kept in the refrigerator until it’s opened. But
and therefore more efficiently. As the upward
the high temperature used in processing UHT
trend for convenience continues, the demand for
impairs the flavor. However, there is now a third
ESL milk looks set to grow.
way – extended shelf life (ESL).
GENERATE MAGAZINE ISSUE 11
5
Milk cooling
Raw milk is approximately
37-38°C when it exits a cow’s
udder. If it remains at body
temperature the potentially
harmful bacteria it contains
will double every 20 minutes.
Pasteurization and other
processing methods will destroy
much of the bacteria but, for
optimal preservation time and
a fresh taste, milk needs to be
kept cold from the cow to the
consumer. Here are the key
links in the milk cold chain.
FROM THE COW
From the milking parlor the raw milk is
filtered and then cooled to around 14°C
using a heat exchanger which has cold
water circulating through it. Some systems
additionally have a chilled glycol solution
circulating in the heat exchanger. This
reduces the temperature even further, to
as low as 1°C. The milk is then pumped
into the farm’s storage tanks.
LEAVING THE FARM
Large tankers, insulated to keep their
contents at or below 4°C, collect the milk
from the farm storage tanks and transport
it to the dairy processing plant.
6
PACKAGING
From the storage tanks the milk is packaged
into cartons or bottles of varying sizes, stamped
with a sell-by date, then placed in a cold
storage warehouse.
DISTRIBUTION
The packaged milk is transported
in refrigerated trucks to depots and
distribution warehouses and from
there to supermarkets and shops.
IN THE DAIRY PLANT
The milk is pumped into large refrigeration
storage vats ready for processing. Pasteurization
is the most common process and involves
heating the milk to 72°C for 15 seconds, to kill
off harmful bacteria, and then cooling it rapidly
to 4°C. Again heat exchangers are central to the
heating and cooling process. Once the milk has
been pasteurized and homogenized, it is held in
insulated storage tanks ready for packaging.
TO THE CONSUMER
On arrival at the shop, the milk is
placed in a cold storage room or
refrigerated display shelf ready
for purchase.
GEA AND THE MILK COLD CHAIN
Approximately 25 per cent of all milk produced worldwide involves technology from GEA Group
companies. They provide comprehensive, market-leading equipment and know-how for all stages
of the dairy chain – including cooling.
For farms, GEA Farm Technologies offers a wide range of trend-setting milk collection equipment, filters, plate
coolers and cooling tanks. GEA Process Engineering company GEA TDS builds and supplies complete lines for
processing milk, including the VARITHERM® and VARITUBE® heat exchangers for heating and cooling. GEA Heat
Exchangers companies also provide heat exchange systems for the dairy industry. GEA Küba, part of the GEA Heat
Exchangers segment, supplies air coolers for use in refrigerated cabinets, dairies and other applications. And the
necessary process components, including separators, homogenizers, valves and pumps are manufactured by
GEA Mechanical Equipment companies.
GEA Refrigeration Technologies is a leading supplier for industrial refrigeration plants and also of innovative
heat pump systems, which can be used from the delivery of the fresh milk to the factory through all stages of
production and storage.
GENERATE MAGAZINE ISSUE 11
7
LAST SUMMER, OIL GIANT EXXON
AND A LEADING CALIFORNIAN
BIOTECH COMPANY ANNOUNCED
A USD 600 MILLION INVESTMENT
IN PRODUCING BIOFUEL FROM
ALGAE. THIS COULD BE A SIGN
OF THINGS TO COME.
o. What is the economic importance
of slime? The answer is: huge,
and growing!
Slime on the surface of a pond might not be
attractive. But these are algae. And algae
are astonishing.
Though individually often no more than a few
micrometers long – similar in size to bacteria
– the prodigious volumes to which they can
grow mean that algal blooms in the world’s
oceans are visible from space.
They are among earth’s simplest life forms,
yet without them most other life on the planet
would be at risk, as micro-algae produce
approximately half of our atmospheric oxygen.
They are among the most robust forms of life,
being able to grow almost anywhere including
deserts and seawater. And they are among the
most enduring: fossilized algae discovered in
India have been dated back 1.7 billion years.
8
No-one knows how many varieties of
algae there are, but the American National
Museum of Natural History in Washington
DC has a collection of more than 320,000
varieties. And mankind uses them in an
enormous number of ways.
The Aztecs ate them. We still eat them
today – from sushi to food supplements.
Algae contain all the essential amino
acids, high amounts of simple and complex
carbohydrates, an abundance of vitamins,
minerals and trace elements. The health
benefits claimed for omega-3 fish oils are
in fact derived from algae as oily fish such
as salmon don't actually produce omega-3.
Instead they accumulate their omega-3
reserves by consuming micro-algae.
Different uses
Algae are used to reduce cholesterol. They
are used in ice cream and face cream, in
toothpaste and shoe polish. They have been
used as fertilizers and soil conditioners for
centuries. They can be used to bind
heavy metals.
But what are they? Algae are plants.
Seaweeds are types of algae, and kelp
seaweed varieties can grow up to 50
meters long. More often, though, algae
are microscopic single cell organisms
with no roots or stems or leaves. Like
other plants, however, they mostly grow
by photosynthesis. And the application of
biotechnology to micro-algae is where they
get really interesting.
Algae live on a diet of carbon dioxide and
sunshine, which they convert into oxygen
and biomass – a combination of fats,
carbohydrates and protein. They can be
farmed, and once they have been harvested
oil can be extracted from them.
Considerable research is currently taking
place into their use in the production of
biodiesel. Aircraft fuel is already being
produced from them by the US military,
and has been used by several
commercial airlines.
prime agricultural land from growing food
crops to growing fuel crops. But algaebased fuel is one of the second generation
of biofuels which show great potential. It
has been claimed that algae could produce
up to 300 times more oil per acre than
conventional crops such as rapeseed, palms
and soybeans; and harvesting cycles can be
between one and ten days.
Crucially, algae can be grown on land that is
not suitable for other crops, including arid
and excessively saline soils, and offer the
prospect of being able to convert a variety of
pollutants into valuable products. They can
be fed on waste water – including sewage
– and could use the CO2 produced by other
industrial processes, such as cement and
steel manufacture.
Algae-based fuels are essentially
carbon-neutral. While they do not reduce
atmospheric CO2 – because any CO2 taken
out of the atmosphere by the algae is
returned when the biofuels are burned – they
would eliminate the introduction of new CO2
by displacing conventional hydrocarbons.
Fuel production
Furthermore, once the oil has been extracted
from the algae, the remaining matter could
be used in the production of other fuels.
It can, for example, be digested to make
methane; or burned as a biomass fuel in its
own right for power generation; and it can be
fermented to produce ethanol.
In fact, the fermentation of algae to ethanol
releases CO2, which could be used to grow
more algae, and trials are taking place with
such closed-loop systems.
That might sound too good to be true, and
the commercialization of algae-fuel is
probably some way off. But slime is full
of surprises!
GEA AND ALGAE
Having grown the algae, it is only of any value if it
can be separated from the medium – water – that it
is growing in.
This process is called harvesting, and GEA Westfalia
Separator has been supplying centrifuges for
concentrating algae for almost half a century.
But the company has now designed a new generation
of separators specifically for algae biotechnology.
These separators can be used for processing small to
medium capacities of farmed algae suspension (up to
24,000 liters an hour), providing gentle treatment for
the sensitive cells and producing very high levels of dry
matter. With specially developed classification decanters,
GEA Westfalia Separator can now selectively separate
special high-quality dyestuffs from the algae or even
extrinsic algae from the original algae culture.
GEA Niro Soavi supplies homogenizers used in algae
processing, while both GEA Niro and GEA Barr-Rosin
supply varieties of equipment for drying algae. These
dryers are used in the manufacture of products such
as carrageenan, alginates and agar that in turn find
applications in medicine and the pharmaceutical
industry, and very widely in the food and cosmetics
industries where they are used as thickening agents.
The reputation of first generation biofuels
suffered as a result of the conversion of
GENERATE MAGAZINE ISSUE 11
9
10
COOLING AND REFRIGERATION ARE AMONG
THE MOST SIGNIFICANT TECHNOLOGICAL
DEVELOPMENTS OF THE PAST CENTURY.
THEY HAVE PROFOUNDLY CHANGED THE
WAY WE LIVE.
PHOTOGRAPHY: GARETH SAMBIDGE
STYLING: SABRINA JARD
GENERATE MAGAZINE ISSUE 11
11
Ice houses were used to store ice
throughout the year, before the invention
of refrigeration. They were usually
underground chambers built close to
natural sources of winter ice such as
freshwater lakes.
During the winter, ice and snow would be
taken into the ice house which was packed
with insulation such as straw. It would
remain frozen for many months, often until
the following winter, and could be used as
a source of ice during summer months.
And the ice was used for much the same
purposes that we use fridges and freezers
today – storing perishable foods, cooling
drinks, or allowing the production of
ice-cream!
I
n December 2009, Christine Stevens, who
lives in Avondale Arizona, was obliged
to live in her car for 11 days after the
city authorities condemned her home. The
reason for their action was that Stevens did
not have a refrigerator and, according to
local building codes, all Avondale
homes are required to have a fridge.
And air conditioning.
Living without a refrigerator is not an
offence in most jurisdictions, but it certainly
put Stevens in a tiny minority of Americans,
99.5 per cent of whom do have a fridge. In
fact, a recent survey suggested that the
refrigerator would be the one domestic
appliance that Americans would find the
hardest to live without.
Americans, of course, are not alone in this.
But nonetheless it represents a remarkable
change in the way we live our lives. After
all, the first mass produced domestic
refrigerator was only introduced in 1918.
As an appliance category they are less than
a century old. Yet it has been estimated
that there are currently around 500 million
fridges in the world, and that they are being
produced at a rate of approximately 60
million a year.
Everyone, it seems, wants to keep things
cool. This, of course, is not a recent
requirement. Man has been doing it for
thousands of years. The first recorded
ice house was built in Iran around 1700 BC.
12
In the 19th century, American entrepreneur
Frederic Tudor made his fortune by selling
ice cut from ponds in the Massachusetts
winter to customers in the Caribbean. By
1833, he was even shipping ice to Calcutta
in India – at that time some 26,000
kilometers (16,000 miles) and four months
away from Boston.
Ice boxes – rudimentary fridges – were in
common use in the 19th century amongst
the reasonably well-off to keep food fresh
for two or three days. However, they
required regular purchases of fresh blocks
of ice from the ice man.
THE IMPACT OF
REFRIGERATION ON OUR
DAILY LIVES HAS BEEN
IMMENSE. IT HAS, FOR
EXAMPLE, RADICALLY
CHANGED WHAT WE EAT,
HOW WE BUY FOOD AND
WHERE FROM.
HOW REFRIGERATION WORKS
The fundamental concept of refrigeration – and of air
conditioning – is that it involves the removal of heat
rather than the addition of cold.
High Pressure
High Temperature Vaporizer
Compressor
Condenser
Low Pressure
Low Temperature Vaporizer
Evaporator
High Pressure
High Temperature Liquid
Low Pressure
Low Temperature Liquid
Expansion Valve
The basic rules of physics mean that by using
compression and expansion to change the state of
the refrigerant (normally a liquid with a low boiling
point) from liquid to gas and back again, heat
can be drawn from the inside of the fridge leaving
it cooler, and dissipated on the outside. This is
generally done by circulating the refrigerant through
a set of metal coils in a closed system.
An air conditioner works in essentially the same way.
It is basically a refrigerator without the insulated
box, and will also remove moisture from room air.
BEING COOL
Refrigeration has clearly affected where and how
we live. But it has also influenced our psyche and
our souls!
People not only want to keep cool, they also want
to be ‘cool’ and to buy ‘cool’ products.
FRIDGES
It has been estimated that there are currently around
500 million fridges in the world, and that they are
being produced at a rate of approximately 60 million
a year.
FRESH FISH
Fish begins to decline in quality immediately after
it has been caught. Freezing it as soon as possible
retains freshness. Paradoxically, therefore, frozen fish
can be fresher than fresh fish.
‘Cool’ is difficult to define as it is constantly
changing. But you can recognize it when you see
it. Sunglasses are almost always cool. Michael
Jackson dancing to Billie Jean in 1983 was cool.
For two or three years at the end of the 1990s
the entire UK became cool apparently, as
Cool Britannia.
Although the concept of ‘cool’ has been around
for hundreds of years in one form or another, the
term itself was first used by black American jazz
musicians in the 1940s – around the same time
that refrigerators became popular!
It is unusual for a slang word to remain in use
for so long, and even more unusual for it to move
from one language to another – but the French,
who know a thing or two about ‘cool’, use the
same word.
AIR TRAVEL
Everyday air travel is dependent upon sophisticated
control of air temperature and quality in an
environment of altitude and pressure changes.
ICE ENTREPRENEUR
By 1833, American entrepreneur Frederic Tudor was
shipping ice to Calcutta in India – at that time some
26,000 kilometers (16,000 miles) and four months
away from Boston.
GENERATE MAGAZINE ISSUE 11
13
Refrigeration catches on
The first experiments in producing artificial
refrigeration had taken place in the 1750s,
and a small number of crude systems were
in operation by the 1850s. But once viable
electric refrigerators became available, they
quickly caught on. In 1920, about 75,000
American homes had a fridge. But between
1921 and 1935, annual production rose
from 5,000 machines to 1,700,000.
By 1937, nearly half of all Americans
had one.
Take-up in Europe was much slower. In the
1930s, only wealthy European families had
fridges, and it was not until after the
Second World War that ownership became
more commonplace.
Even in 1958, just 10 per cent of French and
12 per cent of British homes had a fridge,
while ownership levels were as low as two
per cent in Spain, the Soviet Union and
Japan. Sweden, the home of Electrolux,
was the European exception where by the
end of the 1950s just over half of families
were supporting the national brand.
The impact of refrigeration on our daily lives
has been immense. It has, for example,
radically changed what we eat, how we buy
food and where from.
to the butcher's, and the milkman made his
rounds every morning.
Over the past 75 years, since Frederick
McKinley Jones invented a portable aircooling unit for trucks, it has been possible
to transport perishable food long distances
at any time of the year.
As a result, countries such as Spain and
Holland have transformed their agricultural
economies by shipping fresh produce around
Europe. We now expect to be able to buy
seafood from Asia, fresh fruit and vegetables
from South America and Africa whenever
we go to the supermarket. The very idea of
a supermarket itself, where a family can
buy an entire week's food in one trip, is
dependant on refrigeration and a cool
supply chain.
As a result, we eat better.
Freezing food converts its water content
into ice crystals. This reduces the amount
of water available to micro-organisms such
as bacteria which spoil food, and the low
temperatures slow down the rate at which
bacteria can multiply. The vitamin content
of frozen food is often higher than that of
fresh food – because it has not had time to
deteriorate while in transit from farm to fork.
The fitting of a compression refrigeration
unit to a New Zealand ship in 1882 led to a
boom in the meat and dairy industries of
countries such as Australia, Argentina and
Brazil. In the second half of the 19th century,
Britain, for example, was able to import a
similar proportion of its food as
it does today.
Or indeed from ocean to fork. Fish begins
to decline in quality immediately after it
has been caught. Freezing it as soon as
possible retains freshness. Frozen fish in
our supermarkets is largely frozen at sea
on board the fishing vessel, or frozen in port
within hours of being caught. Paradoxically,
therefore, frozen fish can be fresher than
fresh fish.
Nonetheless, before the widespread use of
domestic refrigeration, fresh foods still had
to be purchased and used each day – even if
they had already traveled half way around the
world. Meat was bought during the daily trip
Freezing can also help us to reduce the
amount of food we waste. In November 2009,
a UK government agency which looks at
reducing waste, estimated that around one
14
COUNTRIES SUCH AS
SPAIN AND HOLLAND
HAVE TRANSFORMED
THEIR AGRICULTURAL
ECONOMIES BY SHIPPING
FRESH PRODUCE AROUND
EUROPE. WE EXPECT TO
BE ABLE TO BUY SEAFOOD
FROM ASIA, FRESH FRUIT
AND VEGETABLES FROM
SOUTH AMERICA AND
AFRICA WHENEVER WE GO
TO THE SUPERMARKET.
third of all of the food that is bought in the UK
is thrown away – some 6.7 million tonnes. Not
only is this a shocking waste of the resources
that went into the production of the food, but
each tonne of food waste was also said to be
responsible for 4.5 tonnes of CO2.
The prodigious growth in the variety of
dairy products that are available, and the
development of whole new food industry
sectors such as fresh fruit juices and
smoothies, relies entirely on the ability of
refrigeration to prevent them from spoiling.
If refrigeration has radically altered what we
eat and how we live, its impact – in the shape
of air conditioning – on where we live and what
we do has been almost as profound.
GENERATE MAGAZINE ISSUE 11
15
AIR CONDITIONING WAS NOT DEVELOPED
TO AID PERSONAL COMFORT, BUT
RATHER TO OPTIMIZE MANUFACTURING
PROCESSES. THE FIRST MODERN AIR
CONDITIONING SYSTEM WAS DEVELOPED
IN 1902 TO IMPROVE AND REGULATE
PROCESS CONTROL IN A PRINTING PLANT.
KINGS OF COOL
GEA is a global market leader in refrigeration and
cooling technology through its two segments –
GEA Heat Exchangers and GEA Refrigeration
Technologies. Each offers a comprehensive portfolio
of products and services, supported by a worldwide
network.
With more than 400 different heat exchanger models,
GEA Heat Exchangers provides the world’s most
extensive offering in the industry from a single source.
This unrivalled portfolio includes tubular and plate
heat exchangers, air conditioning systems, air coolers,
condensers and cooling towers. Customers benefit not
only from GEA’s design and production expertise but
also from its comprehensive know-how and experience
of the heat exchanger market.
Using plate heat exchangers in cooling systems is
well established as they require little space, are easy
to maintain and can be used for many refrigeration
applications. However, with critical products such
as ammonia their industrial use has been limited
due to the resistance of the gaskets in the plate heat
exchanger. To solve this problem GEA has developed the
laser-welded plate heat exchanger (LWC). Two plates
are welded together to form a flow channel that is
hermetically sealed.
For commercial refrigeration, brazed plate heat
exchangers have become the industry standard. This is
because they are gasket-free, hermetically sealed and
cost effective. They come in a wide range of shapes and
sizes to suit the application.
GEA plate heat exchangers can be found in air
conditioning and process chillers, supermarket
installations and in domestic heat pumps. They are
used in both industrial applications (such as cold
stores, tunnel freezers and slaughter houses) and semiindustrial/ commercial applications (fresh produce
storage, flowers and processing units). GEA Heat
Exchangers companies are also leading manufacturers
16
of heat exchange equipment used in food processing,
storage and distribution.
More than 80 per cent of GEA heat exchangers are
developed in close co-operation with customers to
meet their particular specifications. Companies within
the GEA Heat Exchangers segment with a presence in
the sector include GEA Küba, GEA Goedhart, GEA PHE
Systems, GEA Searle and GEA Raffel.
Customers of GEA Refrigeration Technologies rely on
refrigeration as a key value-adding technology in
their primary processes. Typically those processes
might be in the food and beverage industries, in the
marine sector, oil and gas, building services, or in
leisure facilities such as indoor ski centers and
ice-skating rinks.
Over more than 150 years the company has built up
a vast knowledge of refrigeration technology and
industrial refrigeration systems that it uses in the
continuous development of innovative and efficient
technical solutions, often tailored to very specific
local needs.
In addition to the development of new energy-efficient
solutions, GEA Refrigeration Technologies use natural
refrigerants such as NH3 and CO2 to reduce the carbon
footprint of refrigeration installations and make a
positive contribution to preserving the environment.
Here are some examples of how GEA technology is
keeping the world cool.
GEA GRASSO
Three screw compressors from GEA Grasso are at the
heart of the first indoor snow center in the Middle
East – and the world’s largest indoor ski slope. Dubai,
where daytime temperatures can reach 50º C, is now
able to host international winter sports events as the
entire slope is covered with at least one meter of snow,
generated by GEA snow makers in an environment
maintained at -1 to -2º C.
GEA MATAL AND GEA GENEGLACE
Both businesses, based near Nantes in western
France – use technologies to enable their customers
to tailor solutions to end users’ needs. For example,
the GEA Geneglace flake ice generator produces
dry flake ice that has been designed specifically for
transporting fish and seafood but also for chemical
and concrete cooling industries. The flake-ice is a fluid
ice, facilitating handling and reducing costs. There
is no wasted water, 100 per cent is transformed into
ice, allowing an accurate quantity calculation. It can
be easily stored, melts very slowly and completely
surrounds the product, thus cooling it quickly.
GEA Matal, a contracting and services company,
is working with Bonduelle Group to deliver a new
vegetable cold store in northern France. The building is
38 meters high and providing cooling for such a facility
requires sophisticated air circulation systems which
GEA Grenco has developed in conjunction with
Wageningen University in the Netherlands.
GEA HAPEL KLIMATECHNIK
A seal sanctuary on the coast of north-west Germany
has had a GEA CAIRplus SX air conditioning system
installed, which not only keeps the center’s 250,000
visitors cool, but also protects the sensitive hearing
of the orphaned seal pups. All of the components for
the system were specially selected to keep noise to a
minimum, and to ensure that it provides many years of
service in the salty North Sea air.
Turn to page 26 for more on GEA Refrigeration
Technologies and GEA Heat Exchangers.
Climate control
Keeping cool is something that mankind
has sought to do for thousands of years, and
protecting people from extremes of summer
heat has influenced the architecture of many
civilizations. Buildings would be designed
with high ceilings, deep, shaded porches and
arcades, and windows placed to maximize
cross-ventilation.
For personal comfort, hand held fans
were used in China from at least the 2nd
century BC. In the 15th century Leonardo
da Vinci designed and built a mechanical
ventilating fan. In British India large swinging
fans called punkahs were used to avoid
discomfort for the Ladies and Gentlemen of
the Raj. Indeed when things got too bad for
them and their French counterparts in South
East Asia, the colonials physically removed
themselves from the plains to hill stations,
such as at Darjeeling in the Himalayas,
where altitude provided a cooler climate.
Extreme heat made many areas of the south
western United States marginal places to live
until the 20th century. But, since the advent
of air conditioning, former desert states such
as Arizona, Nevada, New Mexico and Texas
have seen the fastest rates of population
growth in the country. Some 98 per cent of
new homes in the southern states are now
built with air conditioning.
Air conditioning enables us to regulate and
control our physical environment, and people
feel better – and work better – when the
environment that they are in is within their
comfort zone. For a clothed person that
is around 20-24° C in summer. Above this
range, most people begin to feel a degree
of discomfort.
Air conditioning has meant that architects
no longer have to take account of windows
and natural ventilation in order to provide
comfortable working environments when
designing offices. As a result, they have been
able to create buildings with acres of glass
stretching from street level to skyscraping
upper floors. Office buildings can now be
built with large floor plates in which space
many meters from an exterior wall can be
occupied by desks and workers.
But air conditioning was not developed to
aid personal comfort, but rather to optimize
manufacturing processes. The first modern
air conditioning system was developed in
1902 to improve and regulate process control
in a printing plant. It was then quickly applied
to other industries such as the production of
photographic film and tobacco processing.
Temperature and humidity control
are still essential for some of today’s
vital manufacturing processes: the
production of microchips, for example,
and pharmaceuticals. Some hospital
procedures, such as open heart surgery
require controlled low temperatures, while
others, such as birthing suites, demand
consistent warmth. And where would we be
without climate control in computer centers
which indirectly affect so many areas of our
everyday lives?
It is safe to assume that people are going to
want to continue to keep cool, and that with
increasing affluence in countries such as
China, India and Brazil, further expansion
of the market for refrigeration and air
conditioning will follow.
But making sure that short-term cooling
doesn’t come at the long-term cost of global
warming is a challenge that all equipment
manufacturers face, and, for example, energy
efficiency is now a central design criterion
for much of the machinery and equipment
produced at GEA.
One imaginative way in which GEA is
making significant savings in energy
requirements is to use the heat created by
air conditioning systems to provide heating
in the same building.
This approach recognizes the fact that in
many buildings heating and cooling are
required simultaneously and the demands
on air conditioning are contrary. In a
supermarket, for instance, dairy products,
meat and vegetables remain fresher longer
when they are cooled, but the rest of the
shop needs to be at a normal ambient
temperature. Service stations cool their
shops in the summer, but need hot water
in the car wash. And cooled air is often
required even on cool days in office buildings,
hospitals or universities, in data processing
and communication centers.
So GEA has developed a single unit that
combines a heat pump and chiller to provide
for simultaneous heating and cooling. This
simple but effective solution is particularly
energy efficient when cooling and heating
requirements are about equal – which is the
case in most temperate climates for about
one third of the year.
This means that places can be warm enough
and cold enough at the same time – which is
what mankind has always wanted.
GENERATE MAGAZINE ISSUE 11
17
THE
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18
GENERATE MAGAZINE ISSUE 11
19
The European Environment
Agency estimates that, by
2050, electric vehicles could
make up 60 per cent of new
sales and a quarter of the
global car fleet. Nissan is
investing EUR 200 million in its
UK plant ready for producing
the new LEAF electric car as
Colin Lawther, Vice President
Production Engineering,
Quality Engineering and
Manufacturing Strategy for
Nissan Europe, explains.
20
In 1984 Japanese car giant Nissan
established a manufacturing plant at
Sunderland in the North East of England.
Two years later the first cars rolled off the
production line and today Nissan is the
largest manufacturer and exporter of cars
in the UK. Now the Sunderland plant is
gearing up for its next milestone: it will be
the company’s first European site to produce
the new LEAF all-electric car, securing
thousands of jobs in the process.
Colin Lawther is part of the Sunderland
success story. He joined Nissan in 1985
to establish the laboratory function at the
plant and to evaluate and localize European
materials and components. He has held
a number of key roles in engineering,
quality assurance, production control and
logistics, rising to his current position of Vice
President Production Engineering, Quality
Engineering and Manufacturing Strategy for
Nissan Europe in 2008. With the arrival of
the electric car Lawther’s career has come
full circle – his background in chemical
engineering means he is well equipped for
overseeing the manufacturer of the
lithium-ion batteries that will power the
new vehicle.e.
Q. What is the LEAF?
A. It’s a five-seater family-size hatchback,
powered by a rechargeable lithium-ion
battery which means there are zeroemissions. The 80 kilowatt electric motor
provides a good starting performance from
zero and is capable of speeds up to 140
kilometers an hour. It has a power range of
160 kilometers and, because it only costs
around EUR 2 to recharge the battery, the
running costs are very low.
Q. Apart from zero-emissions, are there
any other notable differences?
A. Because the electric motor is compact,
the engine bay is smaller than a standard
car which means that the front bulkhead
containing the instrument panel can be
moved forward to provide more space inside.
Instead of a gearbox there is a two-speed
reducer box and the braking system is
designed so that regenerative energy from
braking is absorbed into recharging the
system. There isn’t the same wear and tear
on the discs and, with fewer moving parts
than a typical internal combustion engine, it
is pretty maintenance free.
Q. How long does it take to recharge?
A. The car has been designed for a rapid
charge – up to 80 per cent of battery capacity
within 25 to 30 minutes. But for full capacity
it needs a nice gentle charge of eight hours.
This is best done overnight when electricity
is cheapest.
Q. Given that the car has a shorter range
than a petrol or diesel-driven engine are
you confident that drivers will switch to
electric vehicles?
A. Market research shows that the zeroemissions and attractive purchase price
appeal to many consumers. We realize that
there are hurdles to overcome, especially
the ‘range anxiety’. There’s little that Nissan
can do about that at the moment but we
are working really hard to encourage local
authorities to build an electric infrastructure
network, with charging points in public
places across Europe.
We recognize that electric cars are not for
those who have to travel long distances but
all of our intelligence shows that 80 per cent
of people drive no more than 160 kilometers
a day.
Q. When will the LEAF be available?
A. The first models are being built in Japan
and they will go on sale later this year in the
US, Japan and selected European markets.
Work has started on building a battery plant
in Sunderland. This will be up and running
by the end of 2012 and the site will start
producing the LEAF in 2013.
Q. So you are building the batteries first?
A. Our strategy is to build battery plants
along the lines of the one pioneered in Japan
in joint venture with the electrical giant
NEC. Sunderland will be the first of Nissan’s
overseas battery plants, with a capacity of
60,000 units a year. The company is investing
EUR 200 million on building the new 25,000
square meter plant. In the first year it will
supply batteries to Nissan’s alliance partner
Renault. Meanwhile, a second battery facility
will be built at the Renault gearbox plant at
Cacia in Portugal, transferring the know-how
from Sunderland. Then there will be a third
facility at the Renault plant in Paris. Together
they will provide a total annual capacity of
210,000 units.
Q. How crucial is the battery technology to
the success of the LEAF?
A. Nissan has been developing this
technology for more than 20 years to provide
maximum power density, while reducing the
battery size. Ours is 1.5 meters long by one
meter and only 300 milimeters deep so it fits
easily under the car floor. Also our batteries
only require four kilograms of lithium,
compared with 40 kilograms for some
competitor versions.
Q. It’s estimated that electric vehicles will
account for a quarter of the world’s cars
by 2050 but will there be enough lithium to
meet demand?
A. Lithium is one of the most prolific
elements on the planet and there are enough
stocks for 350 years’ worth of electric
vehicles. We are convinced that these
batteries will have 80 per cent of life left
after five years. Even at 20 per cent capacity
you still have a fully serviceable battery
which can be recycled for use elsewhere, for
example in hospitals. We have many ideas for
improving this technology and having a spare
battery is a possibility.
Q. Will the LEAF built at Sunderland be
an improvement on the current model?
A. Yes. Unlike gas and diesel engines where
improvements were spread over 100 years,
we expect them to be more rapid with
electric technology, on a par with computers
and mobile phones. I’m excited about the
current generations but the LEAF we build at
Sunderland will be the next generation, and
that’s even more exciting.
PROCESSING LITHIUM-ION MATERIALS
Spray drying technology from GEA Process Engineering
company GEA Niro plays an important role in producing
the next generation of batteries for electric vehicles and
other high energy applications. Cathode materials for Liion batteries can be made using spray drying technology
to achieve a battery with a high energy density.
So far, Li-ion batteries have found their application
in mobile phones and laptop computers but with the
predicted large growth in the electric vehicle market in
the coming years spray dried powder manufacture is
expected to move from small to large-scale capacities.
Activities in this field are worldwide and GEA Niro is
participating with advanced spray drying technology in
many projects in various stages of development from
R&D to industrial production in Europe, US, China,
Japan, Korea and Australia.
Also for the automotive sector, GEA Refrigeration
Technologies provides screw compressors that can be
used to simulate extreme weather conditions for vehicle
testing. Many car manufacturers use GEA’s screw
compressor packages and chillers to create temperatures
ranging from as low as -50 °C to as high as 50 °C. Tests
include wind tunnels (the car is stationary while cold or
hot air is blown through the tunnel), a climatic chamber
for roller test rigs (the car drives on rollers while the
chamber reaches a certain temperature to assess the
driving operation) and motor test rigs (to test the motor
characteristics at a certain temperature).
GENERATE MAGAZINE ISSUE 11
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22
tomato ketchup’s distinctive pungent taste
and thick texture. Earlier ketchups tended
to be more watery, partly because unripe
tomatoes contain less pectin, which acts as
a setting agent.
RED, GOOEY AND
FAMOUSLY DIFFICULT
TO DECANT FROM
THE BOTTLE, TOMATO
KETCHUP IS A UNIVERSAL
ACCOMPANIMENT TO
HAMBURGERS, HOT DOGS,
FRENCH FRIES AND MANY
OTHER FOODS.
eleasing tomato ketchup from a new
bottle is no easy matter. The usual
method is to shake the bottle vigorously
before striking the bottom with your hand, but
only to risk evacuating the sauce in a scarlet
splurge on your plate – and sometimes
your clothes. This ritual is almost part of
the enjoyment.
Viscosity, together with a piquant flavor, is
behind tomato ketchup’s iconic status in the
world of condiments. Yet it could have been
a different story without Dr Harvey W Wiley
and sodium benzoate. Or, more precisely, the
lack of it.
Sodium benzoate is a widely-used food
preservative but in the 1920s Dr Wiley,
the US government’s chief chemist, tried to
get it banned in America because he
believed that the chemical was harmful.
Although his attempt failed, the threat was
enough to encourage Henry J Heinz and
other ketchup manufacturers to find an
alternative preservative.
However, the first ketchups were not made
from tomatoes but fish: it is commonly
believed that the name ketchup is derived
from the Chinese ke-tsiap, a pickled
fish sauce. Similar sauces were found in
Malaysia, called kechap, and in Indonesia,
where they were known as ketjap. In the 17th
century, Dutch and English sailors introduced
them to the West. Originally, Western-style
ketchup recipes were based on fish brine or
mushrooms with herbs and spices. And in
some countries, including the UK, mushroom
ketchup is still available. In those early
days there were almost as many variations
of the name as recipes. They included
catsup, catchup and katchop but ketchup
has prevailed.
National phenomenon
Tomato ketchup is basically an American
invention. One of the first recipes was
published in 1824 in The Virginia Housewife,
a cookbook written by Thomas Jefferson’s
cousin, Mary Randolph. Farmers soon
began to take advantage of their fellow
Americans’ love of tomatoes by making
and selling ketchup locally. Jonas Yerkes
made it a national phenomenon. By 1837
he was distributing his sauce in quart
and pint bottles around the country. Other
manufacturers soon latched on and by the
end of the century there were around 100
tomato ketchup brands in the US. One of
these was Heinz.
The brand has become synonymous with
ketchup and the company still manufactures
its sauce to a tried and tested formula.
According to its website, Heinz sells more
than 650 million bottles of ketchup a year
globally, plus 11 billion single-serve packets.
That’s two packets for every person on
the planet. Another interesting snippet of
information from Heinz is that its ketchup
exits the bottle at 0.045 kilometers an hour.
If the viscosity of the ketchup is greater than
this speed, then it is rejected for sale.
Modern food production techniques have
also played a part in the ketchup success
story. In the early days ketchup was made
from fresh tomatoes soon after harvesting.
Vacuum evaporation makes it possible to
produce ketchup all year round by turning
the tomatoes into a thick paste that is easy to
store at room temperature.
Today it’s hard to imagine eating hamburgers,
hot dogs and French fries without ketchup.
It’s also a popular condiment for scrambled
eggs, with fried meats and as a base for
other sauces. Former US President Nixon
liked it on cottage cheese, while the Japanese
eat it with rice. Some people like to pour it
directly onto the food, while others have it on
the side of the plate. Baskin Robbins even
tried it as a flavor for one of their ice creams.
The high concentration of vinegar and
natural acid in the tomatoes has made
ketchup more than just a food. It has been
used successfully to clean copper and silver.
Another application is to combat the effects
of chlorine from swimming pools on bleached
blond hair. Chlorine can turn the hair green
but the acid in ketchup helps to remove the
chemical that causes the reaction.
At one time ketchup was used as blood in
low-budget horror films. Hitchcock famously
used chocolate sauce for the shower murder
scene in Psycho (it was filmed in black and
white) but legend has it that he mixed it with
tomato ketchup for a better effect. Perhaps
it’s the association with blood that drives
some people to develop ketchup phobia. And
the fear can be so great that just the sight
of a ketchup bottle can make sufferers feel
dizzy, nauseous and panicky.
In general, though, tomato ketchup remains
a much-loved regular in fast food restaurants
and in shopping baskets around the world.
GEA AND TOMATO KETCHUP
GEA TDS, part of the GEA Process Engineering segment,
supplies and installs complete ketchup processing lines,
including the mixing of the ingredients and the main
unit consisting of plate heat exchangers or tubular heat
exchangers (depending on the viscosity and the product
mix to be produced on the unit), which are manufactured
by GEA companies.
High pressure homogenizers from GEA Mechanical
Equipment company GEA Niro Soavi are used within the
process of manufacturing tomato ketchup. The most
important part of this machine is the homogenizing
valve. GEA companies also produce the auxiliary
equipment such as valves, pumps and instrumentation
and last but not least the complete automation of plants
and processing lines.
Their answer was to increase the
concentration of vinegar and use ripe instead
of unripe tomatoes. This is the secret behind
GENERATE MAGAZINE ISSUE 11
23
FREEZING CAN HELP TO REDUCE
THE AMOUNT OF FOOD THAT WE
WASTE. AND GEA TECHNOLOGY
CAN REDUCE THE AMOUNT OF
ENERGY WASTED IN THE
FREEZING PROCESS.
et’s be honest about it. No-one eats
French fries because they are good for
you, or ‘green’. We eat them because they
are delicious.
And French fries are not going to feed the
world: though potatoes might.
In 2050, there are forecast to be two billion
more people on Earth. This is two billion
more mouths to feed, and more demands on
limited water and energy resources.
Global demand
The United Nations declared 2008 to be the
International Year of the Potato, praising
its contribution to the diets of hundreds of
millions of people in the developing world.
The potato is the world’s fourth largest food
crop (after maize, wheat and rice), and the
UN’s Food and Agriculture Organization
estimates that between 1993 and 2020,
global demand for potatoes will double.
China and India – historically rice growers –
are now among the world’s top five potatoproducing countries. “Growing potatoes
can have an advantage over rice because
they need less water for production,” says
Cindy Van Rijswick, an analyst at the Dutch
Rabobank. “The potato yields more dietary
energy per unit of water than any other
major crop.”
About half of the world’s potatoes are eaten
fresh; but an increasing proportion are
processed into products such as French
fries. Since 1997, Americans have eaten
more fries than fresh potatoes, and many of
those fries have been cooked from frozen.
24
Countries such as China, Russia, Mexico
and Poland where potato consumption is
growing, are also moving towards eating
more fries as the influence of fast food
restaurants expands.
While in the developed world frozen foods
are popular because they are convenient,
freezing as a technology can help make
significantly better use of the food the
world produces. Only around 70 per cent of
global agricultural production ever reaches
a consumer – the remaining 30 per cent is
wasted. Chilling and freezing can help to
minimize this spoilage.
Around 80 per cent of UK households have a
bag of frozen chips in their freezer at some
time during the year, and almost 75 per cent
of the French fries eaten in UK homes are
cooked in the oven rather than fried in a chip
pan (with six per cent more coming out of
the microwave).
The likelihood is that these fries will have
been produced by the Canadian food
company McCain. McCain, which is a
privately owned business created by four
brothers in New Brunswick in 1956, now
makes one third of all the frozen French fries
produced in the world.
contains about half the recommended
daily intake of vitamin C.
And fries aren’t actually as bad for you as
you might think. A portion of chip shop chips
contains less fat than a prawn mayonnaise
sandwich. A serving of oven fries with
three fish fingers contains one third of the
saturated fat found in a serving of lasagna.
McCain is also a leader in making fries less
bad – reducing the sodium content, and
cooking in oils that contain significantly
reduced levels of saturated fat.
Energy consumption
But the freezing process requires huge
amounts of energy. It has been estimated
that some 50 per cent of the cost of a frozen
food product relates to the energy cost
for freezing it. McCain’s frozen fries, for
example, are cooked in a fryer at 200ºC,
then sent to a chilling and freezing tunnel
that decreases the product temperature
from +95 to -18°C.
With energy prices increasing, major food
companies are naturally interested in new
methods for reducing energy consumption.
GEA Refrigeration Technologies has come up
with a solution, in the shape of the Predictive
Energy Control system. GEA freezers and
refrigeration systems enable food processors
to continuously adjust the freezing capacity
of their line to specific product needs,
resulting in energy consumption being
reduced to the minimum. Waste energy
from the cooling and freezing process can
be reused to continuously heat water
from 30°C to 80°C thanks to GEA
Refrigeration Technologies heat
pump solutions.
Globally, its plants process 450 tonnes of
potatoes every hour.
Energy savings using this control technology
can total 30 per cent – representing annual
savings of approximately EUR 500,000 on
an 18 tonnes per hour French fries
processing line.
McCain is passionate about the humble
potato which they describe as “a nutritional
powerhouse”. One potato has twice as much
potassium as a banana, and as much protein
as half a cup of milk. A medium potato also
And with a pay-back time of less than
two years the Predictive Energy Control,
which includes heat pumps solutions, can
contribute to the bottom line as well as
the environment.
GENERATE MAGAZINE ISSUE 11
25
FOR THREE DAYS
IN OCTOBER THE
GERMAN CITY OF
NUREMBERG WILL
BE THE COOLEST
PLACE ON EARTH.
veryone who’s anyone in the field of
refrigeration and heat exchange knows exactly
where they’ll be on October 13-15 this year –
Chillventa 2010.
Designed by the industry, for the industry, it’s
the most important International Trade Fair for
Refrigeration, Air Conditioning, Ventilation and
Heat Pumps. The first Chillventa event, in 2008,
was an unqualified success, attracting 29,500 trade
visitors from more than 95 countries and over
800 exhibitors.
And this year’s event promises to be even bigger.
Such has been the clamor to take part that
exhibition organizer NürnbergMesse has had to
provide an extra hall in the Nuremberg Exhibition
Center to meet the demand for display space.
The Industrial Heat Pump Village – a highlight of
Chillventa 2008 – will feature once again. New this
year is the Cleanroom Village which will
showcase advances in cleanroom technology
that are becoming increasingly important in
many industries.
As one of the market leaders in air conditioning and
refrigeration the GEA Group will be prominently
represented by companies from GEA Heat
Exchangers and GEA Refrigeration Technologies.
26
Cooling towers
Building corrosion-free cooling towers that are efficient and
low on noise is another specialty of the GEA Heat Exchangers
segment. Through a combination of stainless steel, fiberglass
and plastic, sound design and engineering experience, the
company provides cooling towers that are low maintenance,
energy efficient and have long life spans. This expertise is
provided by GEA Polacel.
A plan of the GEA booth for Chillventa 2010.
Industrial refrigeration
GEA Refrigeration Technologies designs, engineers, installs
and maintains innovative refrigeration solutions and
components for the food processing, brewing, beverage,
marine, chemical, pharmaceutical and metallurgical
industries, as well as special installations for the power and
process industry. It will be represented at Chillventa 2010 by:
GEA AWP
For all feasible applications, GEA Heat Exchangers offers
Founded in 1992 GEA AWP is one of the best-known and
the best possible solutions for the refrigeration industry
most highly qualified business partners in the refrigeration
from one source. It will be showcasing its market-leading
industry. Over the past 18 years the company has supplied
expertise in the field of heat exchangers, air conditioning
more than one million valves to refrigeration plants. GEA AWP
systems, air coolers, evaporators, condensers and cooling
uses specialist software to simulate operational conditions to
towers at Chillventa 2010.
ensure the optimum performance of each valve.
Heat exchange
GEA Geneglace
Whenever media need to be cooled, heated, condensed or
Ice is essential for controlling temperatures in many food and
evaporated reliably and precisely GEA Heat Exchangers
industrial processes and GEA Geneglace has the broadest
companies have the right technology for the job. The
range of flake-ice machines on the market. The company has
main product categories – for plate heat exchangers – are
60 years’ experience of providing customers with the bestEcoFlex, gasketed plate heat exchangers; EcoWeld, fully
in-class ice generators. The company also manufactures
welded plate heat exchangers; and EcoBraze, brazed
automatic ice storage, delivering, weighing and blowing
plate heat exchangers from GEA PHE Systems and finned
systems.
heat exchangers from GEA Goedhart. All offer high heat
transfer capability, convincing energy-saving potential and GEA Grasso
Reciprocating and screw compressors are GEA Grasso’s
enhanced operating conditions.
forte – the company has more than a century of experience
The company is also at the forefront in manufacturing
in this field. In pride of place on the exhibition stand will be
heat exchange equipment for the processing, storage,
a new chiller which will be unveiled to the public for the first
distribution and retailing of food, as well as for power
time. The unit is currently being tested but promises to be an
generation, process cooling and air conditioning.
advance in compactness and energy efficiency.
Air conditioning
Also on show will be the ACR screw compressor and
If the subject concerns heating, cooling, cleaning,
the Grasso V series. The ACR is the world’s first screw
humidification, and dehumidification of air, GEA Happel
compressor for transcritical CO2 systems in the refrigeration
Klimatechnik can provide customized heating, ventilation,
industry. It can withstand pressure up to 120 bar and reduces
and air conditioning treatment. No matter what solutions
operationally-related CO2 emissions by 40 per cent. The
are needed – central air handling units, terminal units for
Grasso V series is designed for the lowest Total Cost of
commercial or industrial use, fan coils or air unit heaters,
Ownership, combined with efficiency and reliability. Grasso
chillers or controls – GEA Happel Klimatechnik is
V compressors are used where industrial refrigeration or
the competent partner: as a manufacturer as well as
heating is an essential part of the primary process in the
a consultant.
food, brewing and leisure industries.
Air Coolers and Condensers
Come and see us in Hall 4, Stand 318.
GEA Heat Exchangers Air Cooler portfolio is provided by
GEA Küba, the leading manufacturer of high performance
Air Coolers, Air Cooled Condensers and Dry Coolers.
It offers two main Air Cooler product lines. Küba
Blue Line is the best technical solution for complex
refrigeration, while Küba Green Line is more suited to
basic refrigeration requirements. GEA Küba is the only
manufacturer to provide both options.
Other GEA Heat Exchanger companies strong in this
sector are GEA Searle and GEA Raffel who will be
exhibiting their ranges of Air Coolers, Condensing Units
and Condensers.
GENERATE MAGAZINE ISSUE 11
27
28
With many western European customers
expanding into eastern Europe, Bostock
is also in touch with colleagues there.
He believes that having a representative
in each country, so that customers are
fully supported wherever they choose to
do business, is one of GEA Refrigeration
Technologies’ main strengths. In other
words, ‘act local, think global’.
DAVID BOSTOCK, PRESIDENT OF SALES, WEST EUROPE
FOR GEA REFRIGERATION TECHNOLOGIES, HAS DEVOTED
ALMOST 30 YEARS TO INDUSTRIAL REFRIGERATION. AS
GENERATE DISCOVERED, HIS ENTHUSIASM FOR THE
BUSINESS IS AS STRONG AS EVER.
f there’s one subject that doesn’t
leave David Bostock cold it’s industrial
refrigeration. “Our business is as much
a passion as a profession,” he says.
“Industrial refrigeration is a specialist
industry segment and that makes us a small
community. My brother also works in the
industry and, when we get together, we drive
our wives crazy talking about refrigeration,
new projects and new developments. It is
a small industry, so everyone knows
each other.”
Shop floor to boardroom
Since leaving school at 16, Bostock has spent
his entire career in the refrigeration industry,
a journey that has taken him from shop floor
to boardroom.
He began as a mechanical engineering
apprentice with Findus frozen foods in his
home town of Grimsby on the east coast of
England. After completing a higher national
diploma (HND) in refrigeration, Bostock
spent 13 years with Star Refrigeration, a
contracting and servicing company. He
then took a break to study mechanical
engineering at the University of Strathclyde
in Scotland. Armed with his degree, Bostock
returned to Star for a time before leaving
with a group of colleagues to join Morrison
& Young’s Industrial Section.
“After about four years GEA Grenco bought
the company, so I joined GEA through
acquisition,” he explains. Bostock spent
four years at GEA Grasso International –
the Netherlands-based contracting export
operation, covering mainly Eastern Europe.
In 2007 he was appointed Managing Director
of GEA Grenco UK and Ireland. Following
the recent reorganization, Bostock is also
now President of Sales, West Europe at GEA
Refrigeration Technologies.
It’s a huge remit, covering contracts,
servicing, and component sales for all GEA
Refrigeration Technologies’ operations and
activities in Germany, France, Italy, Spain,
Belgium, Luxemburg, the Netherlands and
Scandinavia. The main customers are in the
food, marine and oil and gas industries.
“I spend at least 30 per cent of my time
in the UK in my capacity as Country
Sales Organization Manager,” Bostock
reveals. “There I am involved in negotiating
individual contracts and projects,
working with the management team
and coordinating the different activities
associated with sales of refrigeration
installations and compressor components.
“The rest of my time is spread between
the different countries, discussing with
the managers there about their business
and sales activities. GEA Refrigeration
Technologies faces many challenges
in Western Europe – business and
technological; and a number of the country
organizations are undergoing major
improvement projects.”
Another strength is people. He says: “We
have a lot of very talented individuals and
seeing people develop and grow with the
company gives me an enormous amount of
job satisfaction.”
With his engineering background and
business experience Bostock is equally at
home talking technical with field service
engineers as he is discussing figures in
the boardroom.
“I enjoy being connected to our people at all
levels of the different companies and my aim
is to try and maintain the spirit of a familyrun company within a large corporate base,”
he adds.
Challenges
A key challenge will be EU climate change
legislation which will have an impact on
refrigeration. “As well as adapting our
existing technology we aim to lead the way
with innovations,” says Bostock. Distributing
food supplies to growing populations in
developing countries, plus the pace of
change in emerging economies, also offer
new challenges and potential for the future.
He has a keen interest in new refrigeration
technologies and the Air Conditioning and
Refrigeration Industry Board in the UK, of
which he is Chairman, provides the ideal
forum for this. Although, Bostock admits:
“Presenting technical papers in front of your
peers can be nerve-racking. But it helps to
build confidence.”
With such a wide-ranging responsibility and
frequent travel – volcanic ash from Iceland
permitting – Bostock devotes his weekends
to his family. He is a keen rugby fan,
supporting Saracens in the UK and, with his
wife being South African, he also follows the
fortunes of the Cape Town team Stormers.
GENERATE MAGAZINE ISSUE 11
29
This dramatic picture taken at GEA
Brewery Systems located in Kitzingen,
Germany may look like a modern artist’s
impression of stainless steel soldiers going
into battle. But in reality these objects
play an important role in the modern beer
production process. Called double-shoe
knives, they are part of GEA Brewery Systems’
filtration technology LAUTERSTAR™.
30
‘Lautering’ separates the insoluble substances
in the mash from the liquid. The special design
and dense arrangement of the double-shoe
knives on the racking machine leads to an
intensive but gentle filtration and washing
of the spent grains, resulting in an efficient
process and a consistently high wort quality.
GENERATE MAGAZINE ISSUE 11
31
GEA HEAT EXCHANGERS WINS CONTRACTS
IN RUSSIA AND TURKEY
AUTOMATIC FEEDING TECHNOLOGY ADDED
TO GEA FARM TECHNOLOGIES’ OFFER
Systems was the only manufacturer of process
equipment invited to make a presentation.
GEA Heat Exchangers has received two major power
plant orders in Russia and Turkey. In Russia, GEA Heat
Exchangers has received an order for the design, supply
and erection of a Heller® indirect dry cooling system
for Gazprom's new 360 MW combined cycle power
plant in the Black Sea coast city of Sochi in Russia.
GEA Farm Technologies’ expansion strategy continues
apace with the acquisition of MULLERUP A/S, a
leading Danish manufacturer of automatic feeding,
manure handling and bedding systems for cows.
The FDA stressed its belief that the use of
continuous processing in pharmaceutical
production will lead to an improvement in product
quality which will enhance patient safety.
“This is another important stepping stone in our
strategy to enhance our product portfolio, now including
automatic feeding technology, an increasingly important
success factor in modern livestock farming,” says Dirk
Hejnal, President of GEA Farm Technologies’ segment.
Two aspects of the ConsiGma™ Continuous Processing
approach (which allows continuous production from
powder to tablets in only 20 minutes) were particularly
well received: the assurance of plug flow over the entire
process, and the increased number of measurements of
critical quality attributes (CQA), which was confirmed
by data from an uninterrupted 50-hour run resulting in
1.800.000 tablets. During this 50-hour test more than
960 in-line measurements were taken to determine
CQAs such as Loss in Drying (LOD) or particle size
distribution, while the content uniformity of the final
tablets was assessed in-line more than 100 times.
The new power plant is being built as part of the
upgrading of the local infrastructure for the Olympic
Winter Games 2014 in Sochi and at the same time
will support the development of the local economy.
“With this order our resource-saving innovative
Heller cooling system continues its proven track
record and more than 20 systems that have been
sold globally within the last five years,” says András
Balogh, President of the ACC/Heller business unit,
which is part of the GEA Heat Exchangers segment.
Meanwhile in Turkey, GEA Heat Exchangers will
be supplying an ALEX air-cooled condenser for a
new 775 MW combined cycle gas turbine power
plant being built by METKA S.A. in the country’s
Denizli province. The power plant will be owned
by RWE & Turcas Güney Elektrik Üretim A.S.
“The power plant’s location, about 280 km south
east of Izmir, is close to a main gas pipeline as
well as the public grid. As water is scarce in
that region a dry cooling steam condensation
and cooling system was the natural choice for
METKA, because it allows the power plant to run
on minimal water supply,” says Jörg Jeliniewski,
President of the GEA Heat Exchangers segment.
GEA Heat Exchangers is a world leader in heat
exchangers and its products cover numerous
applications in a host of global industries.
www.geagroup.com/hx
32
A century ago, MULLERUP was a small blacksmith’s
shop in Denmark. Since then it has grown into an
innovative company specializing in automation
within dairy farming. Since 1993, the company
has affiliated with the SKIOLD Group, one of the
largest technical equipment and management
systems suppliers to Europe’s pork producers.
GEA Farm Technologies intends to grow MULLERUP’s
product line internationally and also plans to further
strengthen its Farm Equipment Business Unit
globally. MULLERUP will continue to operate from its
Danish headquarters and manufacturing facility.
GEA Farm Technologies’ key competencies include
milk production, manure systems, barn equipment
and automatic feeding systems as well as state-of-theart service and hygiene solutions for all herd sizes.
www.geagroup.com/ft
GEA PHARMA SYSTEMS TAKES PART IN FDA’S FIRST
CONTINUOUS MANUFACTURING SYMPOSIUM
GEA Pharma Systems presented the latest update of
its ConsiGma™ Continuous Tableting Line (patents
pending) to over 120 FDA participants at the 1st
Continuous Manufacturing One Day Symposium.
The FDA recognizes the value of continuous
manufacturing and is working to raise the level of
awareness of this technology amongst its review
staff. As well as FDA personnel, there were speakers
from universities, Pfizer and GSK, and GEA Pharma
www.geagroup.com/pe
GEA SETS UP INSTITUTE OF REFRIGERATION
TECHNOLOGIES IN CHINA
The GEA Suzhou Institute of Refrigeration Technologies,
set up by GEA Refrigeration Technology (Suzhou) Co Ltd
earlier this year, has now held its first training programs.
The Institute is carrying out all aspects of training
for GEA’s Industrial Refrigeration customers in China,
including: basic knowledge of refrigeration, the
structure of refrigeration compressors and control
systems, refrigeration system operation, service and
maintenance and common fault analysis and resolution.
The Institute is committed to improving GEA Industrial
Refrigeration users’ technical skills, providing the users
with the knowledge of the proper use and maintenance
of the refrigeration equipment, and effectively enhancing
GEA Refrigeration Technologies’ influence in the
industrial refrigeration market. The Institute is also
responsible for carrying out the internal training needs
of GEA Refrigeration Technologies business in China.
www.geagroup.com/rt
GENERATE is published by the GEA Group
Aktiengesellschaft, one of the largest system
providers for food and energy processes with
about EUR 4.4 billion revenue in 2009.
Listed on MDAX stock index, the company
focuses on process technology and
components for demanding production
processes in various end markets. The group
generates about 70 per cent of its revenue
from the food and energy industries, both of
which have long-term growth prospects.
As of December 31, 2009, the internationally
operating technology group had a workforce
of over 20,000 employees serving customers
in 50 countries. GEA Group is a market and
technology leader in 90 per cent of its
business areas.
GENERATE is the external
magazine of the GEA Group.
Published three times a year, it
is distributed across the world.
Welcome to the eleventh issue of
GENERATE, published by the
GEA Group Aktiengesellschaft.
GEA FARM TECHNOLOGIES
Dear Readers,
GEA HEAT EXCHANGERS
For thousands of years mankind has
been finding different ways of keeping
cool. But the advent of refrigeration
and air conditioning in the 20th century
irrevocably changed the way we live,
where we live, how we buy food and
which countries we can buy it from. Our
main feature looks at this wide-ranging
area and GEA’s role in developing the
most energy efficient ways of keeping
food, people and environments cool.
GEA MECHANICAL EQUIPMENT
GEA PROCESS ENGINEERING
GEA REFRIGERATION TECHNOLOGIES
Contact
GEA Group Aktiengesellschaft
Dorstener Straße 484
44809 Bochum
Tel: +49-(0)234-980-0
Fax: +49-(0)234-980-1087
www.geagroup.com
Dairy will always be a big part of GEA’s
business – since 1926 we’ve been
helping farmers to manage their dairy
business sustainably and profitability.
In this issue we look at milk’s journey
from the cow’s udder to the consumer.
For many people around the world,
extended shelf life (ESL) milk is more
convenient and you can read how GEA
technology is helping to lengthen milk’s
shelf life while keeping its nutritional
value and taste.
We are one of the world’s biggest
engineering companies and, as you
might expect, we play a role in the
production of many items that are an
everyday part of life. For example, one
of GEA’s group companies is involved
in the manufacture of tomato ketchup,
a favorite the world over. And GEA
Refrigeration Technologies is helping to
reduce the amount of energy needed to
freeze French fries.
But at the same time, we have a
presence in industries where you might
not expect to find us, for example
algae and nanotechnology. To many
people algae are just plants that grow
everywhere – but energy companies
are investigating the possibilities of
using algae to produce the biofuels
of the future. GEA technology is used
to separate algae from the water it is
grown in. Meanwhile, GEA’s Process
Engineering segment is involved in
the development of nanotechnology.
Our team in Denmark has developed
a method of spray drying nano
particles to make them safe to use in
industrial applications. In the future,
nanotechnology could produce car
windows that don’t steam up and fabrics
that won’t stain.
Finally, our Question and Answer
feature looks at Nissan’s plans to build
the world’s first affordable electric
car. Again we have a role to play in this
sector as one of our group companies’
spray drying technology is used to
produce the lithium batteries that power
the next generation of electric vehicles.
GEA continues to makes its presence
felt in traditional and new industries
the world over.
Jürg Oleas
Chairman of the Executive Board
GEA Group Aktiengesellschaft
IMPRINT
PUBLISHER
GEA Group Aktiengesellschaft
Dorstener Straße 484
44809 Bochum
Germany
EDITOR IN CHIEF
Donat von Mueller
(responsible for editorial content)
EDITORIAL STAFF GEA
Gaby Fildhaut
Maren Schneider
PHOTOGRAPHY
Cover, feature: Gareth Sambidge
Page 20-21: Chris Moyse
Page 22-25: Gareth Sambidge
Page 28-29: Nick Dawe
Page 30-31: Frank Freihofer
PRODUCED BY
Merchant
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COPYRIGHT
© 2010 by GEA Group Aktiengesellschaft,
Dorstener Straße 484, 44809, Bochum,
Germany. Reprinting only with the
permission of the publisher. The contents
do not necessarily reflect the opinion of
the publisher.
CONTACT
Questions or suggestions on the contents of
the magazine: [email protected]
THE INTERNATIONAL MAGAZINE OF THE GEA GROUP ISSUE 11 AUGUST 2010
THE INTERNATIONAL MAGAZINE OF THE GEA GROUP ISSUE 11 AUGUST 2010
FOR THE LOVE OF COOL FRENCH FRIES ELECTRIC CARS
FOR THE LOVE
OF COOL
ELECTRIC CARS
FRENCH FRIES