PETpla.net Insider 03 / 2018

BOTTLING / FILLING PET planet Insider Vol. 19 No. 03/18 www.petpla.net 22 Optimising flavour manufacturing The technology group GEA has specified its process solution for flavour manufacturing and developed a new machine design as well as control and cleaning elements for the production facilities from the handling of raw materials right through to final packaging. With this, GEA helps flavour manufacturers to ensure the taste, consistency and repeat- ability of their products. Filling Special The goal is to create a flavour that mimics, as closely as possible, the real thing. But it is not just the combination of raw materials that contributes to the taste result; the manufacturing process is equally crucial. Any variation in method can cause variations in a product that, for all companies, are unacceptable. GEA uses its experience in the production of mixing, pumping, homogenisation, drying and handling equipment to bring them together, to develop them and provide a consistent quality of the flavours. Technology know-how ensures consistency When producing flavours there is much opportunity for something to go wrong. An ingredient added too quickly into a mixing vessel, inconsistent tem- perature, insufficient mixing or incom- plete homogenisation can all have an effect further downstream that affects the outcome. Similarly, variations in oil droplet size, shearing or drying para- meters can all have an effect that in some subtle way alters the product. All these parameters are critical to produc- ing a consistent product. The process becomes more complex when 300 to 400 different flavours are produced on the same machinery. The control and automation should rule out deviations. The new GEA integrated line con- trols all the individual unit operations precisely and, by doing so, controls the output. But repeatability is not just a question of adjusting a computerised control system. Achieving a consistent product requires very precise engineer- ing to allow the component parts of the line to work together in harmony. For example, feed systems must be cali- brated specifically to match the capa- bilities of the mixer and the size of the mixer must be scaled precisely with the size of the dryer to ensure compatibility. Cleaning removes residues and odours In order to comply with the hygiene regulations, every produc- The ultimate goal is to create a flavour that mimics, as closely as possible, the real thing. The Batch Formula Mixer