Separator's Digest 2004/1 - GEA Westfalia Separator Group

CONTENTS3 PrefaceTopical4 ➤ Separator´s NewsSeparator’s World➤ Milestones14Westfalia Separator clarifies Russia’s beers10 History of the centrifuge1987 – 1990 – Innovations with perspective➤ Food Tec12 How does it work?How a disc-type separator works14 Westfalia Separator clarifies Russia’s beersThe market requires quality and cost-effectiveness17 What is Kwas?The Russian summer drink is improvedby fine clarification20 Dry fractionation with STEPThe oleochemical industry likessustainable raw materials17What is Kwas?➤ Industry22 Kaolin for the paper industryRecovering the 2µm fraction24 Isolated soya proteinFood source of the future➤ Mineraloil Systems26 SMS instead of SOSSystems for monitoring solidsholding space and water content28 Proper exposureMini separator cleans developer liquid in print shops➤ Environmental Technology24Isolated soya protein30 Mega-size clarification plant in SingaporeNew dimensions in environmental technology32 Hops and malt – for the sake of the environmentProcess-integrated environmental protectionwith centrifugal separating technology➤ Service34 Act localClear focus on regional service concept30Mega-size clarification plant in SingaporeIMPRINTPublisher:Westfalia Separator AGProject management: Peter ArensEditors:Peter Arens, Dr. Jörg Bückle, Manfred KaiserDesign and Layout:RTS Rieger Team, DüsseldorfPhotography:Michael Dannenmann, Jens Dietrich,Heinz-Günter Spasic, archive Westfalia Separator AGThe information contained in the brochure merely serves as a non-binding descriptionof our products and is without guarantee. Binding information, in particularrelating to capacity data and suitability for specific applications, can only be providedwithin the framework of concrete inquiries.2Separator´s Digest 1/2004Contents

Stefan Rehnert and Holger HeinrichThe Westfalia SeparatorPLUS PrincipleIt is actually quite easy. Once the switch in our head hasbeen set to positive, the result is like a domino which sets apositive reaction chain in motion. Westfalia Separator hascommitted itself to the PLUS principle: absolute customerorientation. The principle of offering total customer careand additional benefits beyond what is normally expectedcan be traced throughout the whole world of WestfaliaSeparator.There are many examples, for example, Life Cycle Benefitcomprises the idea of customer benefit throughout the entireservice life of a centrifuge or processing plant. We arenot in the business of short-term sales success but ratherconvincing and calculable benefits are at the focus of theWestfalia performance portfolio. Sound advice, process integration,maximum innovative ability, financial services,WECARE service right from the very beginning and intelligentconcepts for buying back your used machines, round offthe Westfalia Separator PLUS principle.PROPLUS defines innovative maximum performance by averitable quantum leap for protein yield in milk processing.It is simple calculation which is profitable and can also befollowed Cent by Cent.With JOBPLUS, Westfalia Separator offers qualified employeesand high-school graduates the benefits of a globallyoperating high-tech company combined with the PLUS of acoordinated management trainee programme.In line with the motto: only when we offer a high level ofsupport are we justified in making high demands.Everything, absolutely everything at Westfalia Separator,focuses on ensuring that customers are more successful andthus more satisfied with the machine quality and the personalservice provided.This is your PLUS!This is our PLUS!This is the ultimate PLUS!New separator programmes such as ECOPLUS ensure optimumseparation and minimum expenditure. Basic modelsnot only meet all requirements in terms of optimum qualityand reliability from an economic point of view; they alsoprovide access to new market segments.Stefan Rehnert,Chief Executive OfficerHolger Heinrich,Executive Director of the BoardPreface3Separator´s Digest 1/2004

Separator’s NewsSuccess Model Westfalia Separator➤ Values defined in corporate guidelineAnybody who wishes to be successful in society, in a partnership,in a profession and in finance, requires values to guide them;they also require careful planning if they are to achievetheir life’s aims and wishes.In the case of humans, this usuallyoccurs intuitively, and the process isalso determined by education,nature and experience. However, thenecessary clarity regarding a person’sown ideas, and the context of the possibilitiesthat are available, are frequentlyonly achieved when the valuesand aims are set out in writing. In thecase of a company, this process is muchmore complex, as it has to be implementedand experienced by all employees.Westfalia Separator has accordinglydefined its internal and externalvalues: the attitude of the companywith regard to quality, production andsales, the market and customers, in anenterprise mission statement. This missionis the binding commitment of thecompany that must be shared by everyoneinvolved. Day-to-day experience4Separator´s Digest 1/2004Topical

of these success factors represents aconsiderable part of the corporate cultureof Westfalia Separator. A culturecharacterized by momentum, innovativeability, and the willingness toimprove continually and cooperatewith colleagues for the benefit of all.1. Technology leadershipBy way of customer-oriented innovationsfor products as well as for theproduction processes of customers,Westfalia Separator aims to becomethe clear market, cost and technologyleader in its core area of competence,namely mechanical separation technology.Westfalia Separator concentrateson what the company is best at doing:producing, selling and servicing separatorsand decanters. Westfalia Separatorhas clearly become the technologyleader. The company also wishes toprovide maximum value for money toits customers.2. Life cycle benefitWestfalia Separator sells its productson a value-oriented and not on a priceorientedbasis. If price pressure increases,more service has to be provided.Dialog with the customer is so importantthat the company assumes its ownresponsibility for world-wide marketingand does not delegate this responsibilityto third parties. WestfaliaSeparator offers its customers a lifecycle benefit for the entire life of theproduct. This benefit is greater thanthe benefit provided by the company’scompetitors. This approach imposesstringent demands on the quality ofadvice provided by Westfalia salesengineers. Accordingly, the companymaintains direct contact with its customersin more than 47 subsidiaries throughoutthe world.3. Entrepreneuriallythinking employeesEmployees who think and act entrepreneuriallyidentify significantly withthe company’s aims. The success factorsdescribed above achieve their maximumimpact only if this strategic focusis developed, experienced and implementedby all employees.4. Maximum qualityThe company’s competitiveness, andthat of its customers, is assured bymaximising the quality of the productsand processes. High quality and lowquality costs have for many years beena major competitive advantage of thecompany. A quality assurancesystem employed throughoutthe world, certified in accordancewith DIN ISO 9001, ensuresthat this will continue.5. Core competenceWestfalia Separator concentrates onthe core areas of manufacturing, sellingand servicing separators anddecanter models. Westfalia Separatoroffers its customers what it can dobest, and has now been doing so formore than 110 years: production andprocess know-how for centrifuges.6. Cost awarenessCost awareness in all areas not onlyboosts the earnings and financialstrength of the company; it also formsthe basis of sustainableand successfulPeter Arensmarketing. The simpleprinciple that everyoneobserves pri-and Multi Mediavately – avoiding unnecessaryexpenseand reducing costsMarketing, Business CommunicationWestfalia Separator AG, OeldeTel.: + 49 25 22/77-26 92arens.peter@gea-westfalia.dewhere possible – is also applicable tothe same extent for daily life in a company.Only with pronounced cost awarenessis a company in a position to provideits customers with products for areasonable price and to thus providethem with a benefit.7. Absolute customerorientationWestfalia relies on its customers to paythe wages and salaries of its employees.For this reason, all actions focus oncustomers, and in particular customerbenefits that can be produced. If therewere no customers, there would be noWestfalia Separator, so absolute customerorientation has become the normthroughout the company.WECARECustomers Are Really Everything!8. Responsibility awarenessWestfalia Separator is a companyaware of its responsibility in societyand towards the environment. As anenvironment-certified company, thecompany has a permanent obligationto make proper use of the environmentand the limited resources. Thesesuccess factors have been anchoredpermanently within the company andare experienced accordingly by WestfaliaSeparator employees. ■Topical5Separator´s Digest 1/2004

Separator’s NewsAbsolute Separationabsoluteseparationfocussed on your benefit➤ HyVOL the standard for leading-edge performanceWestfalia Separator has developed the clarifier with a self-cleaning bowl type GSE 75 specifically for clarifying beerin the lower volume range. This completes the company’s HyVOL series of machines.This new performance class combines the traditional Westfalia know how in brewery technology with the latestdevelopments in centrifuge engineering. When the machine was being developed, the focus was on the customer’swishes for economical process management and improved product quality.Gentle, economic, reliableThe new separators are equipped with the hydrohermetic feed system for extremely gentle product treatment. Thistechnology ensures gentle feed and treatment of the product in the separator. The hydrohermetic seal between themachine and the atmosphere also prevents the absorption of oxygen. The optimized and extremely high-speeddischarge technology means that high solid concentrations are achieved. In combination with the modern servicefriendlydrive concept, which uses flat belts as well as the wear-free liquid seal, extremely high efficiency in thisperformance class is guaranteed.However, this generation of separators is also setting new standards with regard to robust design. As a result of thenew development of the separator type GSE 75, the area of application of the HyVOL machines has now been extendedto cover the entire range between 10 hl/h and 1000 hl/h.The following are now available as HyVOL generation separators: GSE 30, GSE 75, GSE 125, GSE 200, GSE 300 andGSE 400. Performance and quality on which customers can rely, simply “absolute separation”.6Separator´s Digest 1/2004Topical

Experiencing the Fascination of Quality➤ Westfalia Separator sets new standards with quality management manualIf a company wishes to be successful, it hasto pass the test using the most sensitivemeasuring system in the world: the eye ofthe customer. This analysis is so intense thatthe performance of a company is classifiedonly as good or bad. The customer wants toreceive the best. This is how quality is perceivedby the customer – and this is exactlythe way it should be perceived according toWestfalia Separator AG.This was the reason why Westfalia Separatorsuccessfully introduced the new ISO9001:2000 which is more customer-focussedthan the old standard. The ’guide throughthe quality management system’ is the newquality management manual. The brochure,which has been issued in the form of amagazine, presents the main quality principlesin accordance with ISO 9001:2000 onmore than 70 clearly designed pages. Thelayout and text ensure that the customerorientedsystem comprising the managementprocess, resource process, implementationprocess as well as analysis and improvementprocesses are transparent for thereader and enable the fascination of qualityto be experienced. With its quality managementmanual, Westfalia has again set standardsand demonstrates that quality managementis not a dry subject; indeed, it istangible corporate philosophy.Automatic Standardizationof the Fat Content of Milk➤ Automatic standardization system STANDOMATThe automatic standardization system STANDOMAT from Westfalia Separator permits directstandardization of the fat content of standardized milk and standardized cream.The Vario Control System is used to regulate, quickly and precisely, the fat content of the standardizedmilk and the standardized cream. This type of regulation combines high measuringaccuracy of the fact content (via the density sensor) with a high response speed of the flow sensor.This arrangement avoids significant fluctuations in the fat content. Following any problemsor changes in production, the system is immediately reset to the standard values. User-friendlyoperation of the Standomat is provided via a control panel.Ideal for Small Dairies➤ MTC 3 milk separatorNo bigger than a simple domestic food processor, theMTC is almost just as easy to install, maintain andclean. This means that smaller dairies or laboratoryscaleinstallations can now again use the WestfaliaSeparator technology that has demonstrated itsworth over 110 years. The MTC milk separator hasbeen designed specifically for this target group. It isable to skim milk and whey with a capacity of up to600 l/h. Skid-mounted, it takes up the minimum ofspace.The MTC 3 is attractive because of its ease of operation,simple cleaning and low-noise smooth running.It can also be easily converted to a clarifier making thismilk separator an ideal tool for smaller dairies.Maximum Performancefor Bacteria Removalfrom Milk➤ HyVol CSE 500The flagship of the new separators forremoving bacteria from milk is the HyVOLCSE 500. Bacteria impair the quality of dairyproducts. Separators are used to removeextremely small bacteria reliably to ensurethat such problemsare not encountered.The new E-generation fromWestfalia SeparatorAG is moreadvanced thanever before with amaximum performanceof 50,000l/h and a widerange of technicalinnovations. The HydroSoft system is key tothe achievement of maximum performanceof the CSE series. The HydroSoft system operateswith comparatively low feed pressureand minimizes shearing forces. This achievesmaximum separating efficiency and productquality. With the possibility of fully dischargingthe bowl, the E-generation improvesthe effectiveness of cleaning-in-place comparedwith partial ejection solutions. This isapplicable specifically for the high-performancerange, in which design-specific factorsimpose limits on disk spacing. The CSE500 bacteria removal separator is drivenwith a flat-belt drive without a gear.Topical7Separator´s Digest 1/2004

Separator’s NewsNew Generationof Laboratory-ScaleCentrifuges➤ Simple, for research in the laboratoryThe new generation of Westfalia Separator laboratory-scale centrifugesis ideal for researching and developing new active substanceson a laboratory scale. Ease of handling, compact design and maximumseparating efficiency are only some of the many advantagesincorporated into the small but efficient centrifuges.Depending on the specific product requirement and the customer’swishes, Westfalia Separator can supply a clarifier with a solid-wallbowl or with a self-cleaning bowl and automatic solids dischargefor continuous operation. The capacity ranges up to 100 l/h of fermentationsolution.All product contact components of the centrifuges are made fromstainless steel. All seals comply with FDA requirements. The clarifieris skid-mounted and ready for immediate hook-up. It can accordinglybe used at any time quickly and without any problems in mobileapplications. It’s lightweight, quiet and easy to install making itideal for use in the laboratory.The new generation of laboratory-scale centrifuges features easeof handling, compact design and maximum separating efficiency.36 Separators forMajor Power StationMuara Tawar in Indonesia➤ Reward for excellent team performanceThe excellent relations with customers in Korea and with the end user PT. PerusahaanListrik Negra (Persero), as well as the excellent team performance from Westfalia Separator(S.E.A.) Pte. Ltd., Westfalia Separator Korea Ltdm and Westfalia Separator MineraloilSystems here in Oelde were some of the main reasons for a major order worth millions inIndonesia.The Westfalia Separator Mineroil Systems Business Unit Energy has received an order forsupplying the complete diesel oil processing installation for a major power station inIndonesia. The Korean company Samsung Engineering & Construction is the project leader,and placed the major order for the second stage of the Muara Tawar power station, whichis being constructed in Bekasi on the island of Java/Indonesia.For this power station, the Power Generation Group of Siemens AG is supplying six gas turbines with a total rating of 858 MW. Theseturbines will use diesel oil in common with the gas turbines already installed in the first stage. Westfalia separators will be used for theefficient and cost-effective processing of the diesel oil for all installed gas turbines. The scope of supply comprises six six-fold installationswith a total of 36 separators of type OSC 50. They will enable the total requirement of 1080 cubic metres of diesel oil per hour to beprocessed accordingly.This arrangement means that only clean fuel oil reaches the turbine for faultless operation and reliability. Westfalia also supplied six pumpinstallations, a system for boosting water pressure as well as the complete control facility. The order is worth more than USD 3 million. Theinstallations were shipped to Indonesia in December 2003, and are expected to be commissioned in April 2004.8Separator´s Digest 1/2004Topical

First German Centrifuge Museum➤ 110 years Westfalia SeparatorAs part of the celebrations involving a family day to mark the occasion of 110 yearsof Westfalia Separator, Peter Schenk, CEO of GEA AG and chairman of the WestfaliaSeparator supervisory board, opened the first German centrifuge museum. Numerousmachines ranging from the very first milk skimming separator right through tothe latest high-tech machines demonstrate the ingenuity of our colleagues and thehistory of mechanical separation technology.The museum enables visitors to experience more than a century of centrifugal separationtechnology, and exhibits further masterpieces of engineering art, such as anantique Westfalia motorcycle. However, not only the exhibits are worthy of note.The term “Deutsches Zentrifugen Museum” (German Centrifuge Museum) has beenpatented, it is and will continue to be unique. Interested visitors, who wish tounderstand the fascination of centrifugal force, may visit the centrifuge museum inOelde and be shown around by an expert guide subject to prior notice.Vincenzo Spitaleri • Stephan SeifertNew Managing DirectorsMineral Oil SystemsAs of January 01, 2004, Stephan Seifertjoined Vincenzo Spitaleri who hasbeen Managing Director of WestfaliaSeparator Mineraloil Systems GmbHsince April 01, 2003.The address is:German Centrifuge Museum of Westfalia Separator AG,Werner-Habig-Straße 1, D-53902 Oelde.Used Machines from theManufacturer – The Best Alternative➤ Resale 2004Used machines are now accepted almost asmuch as new. Overall, the sluggish worldwideeconomic conditions have had a lessserious impact on the market for used machinesthan on other branches of industry.Used centrifuges with life-cycle benefitFor Wolfgang Horst, managing director ofWestfalia Separator ACE, “used machinesfrom the original manufacturer are the bestalternative”. ACE purchases, overhauls andsells used separators and decanters for allapplications of centrifugal technologythroughout the world. As a subsidiary ofWestfalia Separator AG, ACE supplies usedcentrifuges with a commitment to providingthe optimized life-cycle benefit of the manufacturer.“Depending on the specific requirementsand operating conditions, the user isable to choose between the quality levels’factory rebuilt’ or ’function tested’,” saysHerr Horst.In Eastern Europe, the trend is moving inthe direction of investments which makefinancial sense; the purchasers wish toacquire long-life products with trouble-freeoperation, and also expect to receive comprehensivetechnical support.Unlike newcomers, anybody who has extensiveexperience in his particular area ofbusiness will tend to choose a long-terminvestment strategy. High-value used machineswill then be preferred to cheap newproducts.Resale 2004 in KarlsruheHowever, demand for used products has fora long time not been restricted merely todeveloping countries, as indicated by a surveycarried out by the Bundesagentur fürAußenwirtschaft (bfai) in Cologne. Thereare also good opportunities for selling suchmachines in Western Europe. The next usedmachine exhibition Resale 2004 is due to beheld between 26 and 28 April 2004 inKarlsruhe. Westfalia Separator ACE will bethere.Topical9Separator´s Digest 1/2004

MilestonesA new generation in created in 1987with the introduction of theCA 450 decanter series.The clarifier HSA 200, used here forclarifying green beer, achieves a largeclarifying area with a relatively steepangle of slope.Oil is obtained from avocadoswith the aid of decanters.1987 1988History of the Centrifuge➤ 1987–1990 – Innovations with perspectiveMechanical separationtechnology andWestfalia Separatorhave been linkedvery closely sincethe company wasoriginally foundedin 1893.Aglance at the past will identifythe milestones of technologicaldevelopments. Theyears 1987 to 1990 further refine themethods of food and beverage production.A new design for decantersA new generation is created in 1987with the construction of the decanterseries of the type CA 450. Externalfeatures: a so-called pedestal bearing/hooddesign is used instead of theself-supporting cast housing; shock absorbersbetween the frame and theground prevent the transmission ofmost vibrations.Separator with asteep angle of slopeThe separator HSA 200, which is usedprimarily in the food and beverageindustries, is also the focus of muchattention in 1987. The bowl has a relativelysteep angle of slope, resulting ina large clarifying area. Product streamsof up to 80,000 l/h can be processedeffectively giving excellent value formoney. The brewery sector sees theintroduction of the beer clarificationand stabilization method as well as theimproved method of recovering beerfrom tank bottoms.The high-pressure method (HOmethod) for recovering starch from10Separator´s Digest 1/2004Separator´s World

Secondary CyclogearPrimary Cyclo gearMain motorScrollBowl wallClarified productProduct feedSecondary motorSolids dischargeThe company delivers its200th latex separator in 1989.The patented two-gear drive permits automatic torque measurementand differential speed regulation.1989 1990corn, corn grit and wheat is successfullyintroduced. 1988 sees the introductionof new steam-sterilizable quark separatorstype KDC, which increase productsafety and improve the quality ofthe fresh product. Vegetable oil refiningsees the development of centrifugaltechnique that significantly reducesthe effluent load compared to previousalkaline refining methods.“Self-thinking” separatorSeparators and decanters are now alsoused for recovering avocado oil. RSA 200is the name of the new and the largestself-cleaning separator for vegetable oilrefining.The largest decanter CA 505 in aspecial design is used for direct extractionof antibiotics. The new clarifier typeSC 120 is equipped with the Hydrostopsystem and a short-spindle drive forhandling large product streams of up to70,000 l/h.The ’self-thinking’ LUBOTROL separatoris used for lube oils in diesel enginepower plants; this machine separatesdust, condensation water, decomposedproducts, fines, and combustionresidues, as these would otherwiseresult in damage to bearings, pistonsand cylinders.Latex: A surprising order boomThe latex separator LTA 110 originallydeveloped in 1979/80 is redesigned in1989. The drive for the new LTC 110 isnow transmitted from the motor tothe spindle via belts, as the motor isexposed to considerable strain due toviscous natural rubber or latex. Morethan 200 machines are delivered in thisyear to Malaysia.Two-gear drive for decantersThe patented two-gear drive permitsautomatic torque measurement and differentialspeed regulation.The main motor drives the bowlsimultaneously via the housing of theprimary Cyclo gear and via the housingof the secondary Cyclo gear. The speedregulatedsecondary motor drives theinput shaft of the secondary Cyclo gear.Instead of the three-phase decanters,only two-phase decanters are used forolive processing.Only a very small amount of freshwater is required for processing theolives, which means that virtually noeffluent is produced. The reduction inthe amount of fresh water is approximately90 percent. As a result of thenew method, Westfalia Separator AGsells between 20 and 30 decanters peryear. ■Separator´s World11Separator´s Digest 1/2004

Food TecHow Does it Work?➤ How a disc-type separator worksEver since Newtonworked out the secretof the falling apple,it has been known thata particle under gravityaccelerates at a rateof 9.81 m/s 2 . This is thelimit. So the clarifyingperformance of asedimentation tankcan only be increasedby increasing its size.However, such expansion rapidlycomes up against economiclimits. On the other hand, centrifugalforce turns the limiting factorsof conventional sedimentation intovariables. In a disc-type separator, theparticle is exposed to a force equivalentto up to 16,000 times gravity. Theclarifying areas in the bowl are equivalentto the size of 80 football fields.There are virtually no limits to theextent to which disc-type separatorsincrease the efficiency and speed ofthe separating process.The separator bowl achieves its extremelyhigh equivalent clarifying areaas a result of the installation of a largenumber of conical discs. These discsbreak down the product to be separatedinto a large number of thin layers.The disc stack accordingly increases theeffective clarifying area and reducesthe sedimentation distance which aparticle to be separated has to cover;short distances mean fast clarification.Heavy towards the centre,light towards the edgeThe disc stack of a disc-type bowl hasspecial rising channels. The position of12Separator´s Digest 1/2004Separator´s World

The disc stack in the separator bowl breaks down the product to be separated into a large number of thin layers. It thusincreases the effective clarifying area and reduces the sedimentation distance to be covered by a particle to be separated.these channels depends on the liquidcomponent to be recovered to thehighest degree of purity. For instance,if the heavy component (water) is tobe obtained from an oil-water mixture,the rising channels will be locatedtowards the centre of the disc stack. Ifthe light component (oil) is to be recovered,the rising channels are locatedtowards the edge of the bowl. If bothcomponents have to be separated withequal purity, the rising channels arelocated in the centre of the disc stack.Solid sediments settle in the solids-holdingspace making three-componentseparation possible.Battle against timeIn a clarifier bowl, the particle to beseparated has to reach the bottom ofthe disc before it leaves the gap. Thefactors of flow, centrifugal force andgap geometry result in a particle sizewhich just meets this requirement. Thisdiameter represents the separatinglimit. In theory, the separator removes100 percent of particles with a diameterwhich is equal to or greater thanthe separating limit. The separationrate is lower for smaller particles.“In such cases, smallerparticles have to dischargeinto the channel near thedisc bottom to win thebattle against time.“Acceleration and clarifyingarea – the tools of the designerTo optimize clarification and separation,the design engineer is able toincrease the rate of acceleration. However,the bowl material imposes limitson the maximum speed and externaldiameter of the bowl as the forcesgenerated are not permitted to imposeexcessive strain on the material.The second method is to increasethe number of discs. This can be achievedwith thinner discs and narrower spacesbetween the discs. However, the minimumdisc thickness is defined by thenecessary mechanical stability. Thereare also restrictions applicable forreducing the space between the discsas otherwise these spaces would becomeclogged up. In theory, the designengineer is able to choose which of thetwo parameters he wishes to change.A large area with a low speed is equivalentto a small area and a highspeed.Vibration-free operationNowadays, high-alloy special steelspermit bowl speeds of more than 750km/h.These high speeds generate strongforces that can have an effect on themachine components and the foundation.If the separator has an optimumdesign, the two systems that vibrate,namely the frame and the rotor, actagainst each other. The forces neutralizeeach other to a large extent internally.Only small foundation forcesoccur.Optimum machine momentumaccordingly guarantees maximum operatingreliable and minimum wear andtear. ■Separator´s World13Separator´s Digest 1/2004

Food TecWestfalia SeparatorClarifies Russia’s Beers➤ The market requires qualityand cost-effectiveness14Separator´s Digest 1/2004Separator´s World

The rate of growth is one of thehighest in the world. In 2003,beer consumption increased byaround six percent to a total of 75.5million hl, compared with an increaseof just two percent on the Europeanmarket. This is consistent with theexpectation of the Ministry for EconomicDevelopment and Trade, accordingto which gross domestic product isexpected to expand by 5.9 %.No longer “Do you have anybeer?” The question is now:“What type?”It is a long time ago that beer used tobe in short supply and was used as asubstitute currency; it is also a long timeago that beer used to be merely distributedby breweries and consumedimmediately. The question nowadays isno longer “Do you have any beer?”; insteadthe question is “What type?” Today,the influence of western Europe isone of the factors which means thateverybody has to focus to a much greaterextent on quality and maintainingit. It is also necessary to work efficientlyand cost-effectively to cope with thepressure posed by the competition. Anycompany that does not keep up withthe latest production methods will experienceproblems.Pioneering role of BaltikaThe brewing industry in Russia experienceda veritable boom during the past decade.Since Perestroika, the largest country inthe world has become the fifth largest beermarket. Sales figures and revenues in recentyears have confirmed this trend.Quality is also important for the filtrationand clarification of beers. The Russianmarket leader BBH Group with itsmain brewery Baltika in Sankt-Petersburg,which alone produces 12 millionhl beer per year, has successfully positioneditself in this area. Baltika had installedseveral clarifiers upstream of thefilter. In the year 2000, the brewery triedWestfalia Separator for the first time.An HSA 200 was to be used as a singleseparator to replace the existing machines,and was simultaneously expectedto meet the stringent requirements interms of optimum clarifying efficiency,minimum oxygen absorption and considerablylonger filter life. The aim was tomeet maximum quality criteria and si-Separator´s World15Separator´s Digest 1/2004

multaneously to reduce the costs of filteraid and the amount of work whichhad to be carried out on filters. The result:the filter life was extended by almost300 %, and oxygen absorption remainedin the minimum range of 0.02 mg/l.“The managers were sosatisfied with the acceptanceprocedure that thebrewery immediatelydecided to install threeadditional HSA 200machines, each with acapacity of 650 hl/h inthe Sankt-Petersburgbrewery.”The HSA 200 was the preferredmachine on this occasion, because the13 types of beer at Baltika mean thatgreen beers with fluctuating yeastcontents had to be filtered. With itsefficient clarification, the HSA 200 wasable to solve this problem with ease.At the same time, machines of thesame type were also installed in thetwo new BBH breweries in Samara onthe Volga and in Chaborowsk on theAmur. As a follow-up order, BBH alsoequipped the effluent clarification installationsin the three breweries withdecanters from Westfalia Separator.Longer shelf life means widedistributionstop system, this machine permits veryprecise product discharges, thus removingthe solids content at rapid intervals.Interbrew has chosen the samesolution for its breweries in Kaliningradwith an SC 35and in Kaluga withArnold Jakubczykan SC 70. The wellknownMoscowService Managerbrewery Otschakovouses several separatorsfrom WestfaliaSeparator for Kwasfiltration. Rubin inMoscow will also use Horst Günnewiga Kwas separatorwhich simultaneouslyclarifies fruit juices.Most breweriesalso take out ser-Westfalia Separator Food Tec, OeldeTel.: + 49 25 22/77-17 72jakubczyk.arnold@gea-westfalia.deService Technical Customer ServiceWestfalia Separator Food Tec, OeldeTel.: + 49 25 22/77-22 62guennewig.horst@gea-westfalia.deOther breweries also wished to takeadvantage of the benefits enjoyed bythe market leader. The stability andshelf life of beer is improved by goodclarification and lower oxygen absorption.The breweries are able to operatebetter on the market and are alsoable to distribute their products morewidely. The Turkish Efes Group decidedto install a separator of the SC series inits Moscow brewery; with its hydrovicecontracts. The advantage: theyreceive clearly defined services forfixed prices. The maintenance costs canbe planned and budgeted. WestfaliaSeparator guarantees the availabilityof the machines during the periodcovered by the contract by way of preventivemaintenance and replacementof spare parts.Many other applications in thebrewing processApart from clarifying green beerupstream of the filtration stage, theseparator can also be used in numerousother applications in the brewingprocess. These processes are also gainingfriends among Russian brewers.For instance, wort separation as a substitutefor the whirlpool in the brewinghouse which takes up a lot ofspace or cold wort separation and tankbottom processing to save further costsand improve quality. The separator alsomakes a contribution towards reducingcosts in the bottle cellar. It can accordinglybe used for processing thewashing lye of the bottle cleaningmachine, thus resulting in less loss ofwashing lye and longer lives of thecleaning machines. The Russian beermarket, and thus the process technologywhich is used still, has much room forimprovement, even if tremendous progresshas been made in the brewingindustry in recent years. ■16Separator´s Digest 1/2004Separator´s World

Food TecWhat is Kwas?➤ This Russian summer beveragebenefits from fine clarificationKwas is the traditional summer drink in Russia and theUkraine. It has a refreshing, slightly acidic taste due to thelow CO 2 and alcohol content.Separator´s World17Separator´s Digest 1/2004

Kwas has been known since 1056 and, besides Vodka, is the national beverage of Russia and the Ukraine. This beerhas a slightly acidic taste, a low alcohol content, and is frequently sold fresh from the barrel in summer in the streets.In the past – and even today in thecountryside – Kwas was made fromcrushed bread, mixed with waterand allowed to undergo natural, lacticacid and alcoholic fermentation.Depending on the climate, season andtaste, there were more than 50 typesof Kwas. This homemade product onlyhas a short shelf live.For industrial-scale production, theuse of bread involves too much effort.Various concentrates are used instead.Some manufacturers for instance usemalt extract. These concentrates arediluted with water and fermented withtop-fermenting yeast. Lacto-bacilla arealso used occasionally. The lactic acid,which forms naturally in this way, is responsiblefor the pleasantly acidic taste.The fermentation process is completedafter approximately one day. Yeast,bacteria and other turbidity particles areremoved, and sugar is added to theKwas. In general, Kwas is sold from smallmobile tanks in the street. However,Kwas is now also filled in PET bottles.Optimum clarification isthe vital factor for qualityThe process of clarifying the Kwas,mainly involving the removal of yeast, isof vital importance for the yield andthus the cost-effectiveness of Kwasproduction. This is because less productis lost if the dry matter of the separatedyeast is higher. A further factor is thatclarification of the Kwas is of vitalimportance for the product’s shelf life.Consideration has to be given to twoaspects in this respect.The lower the quantities of yeastand bacteria remaining in the Kwas, thelower the speed of the fermentationprocess – the Kwas remains in the statein which it was delivered for longer. If itwere allowed to ferment completely,the product would be excessively acidic.If the Kwas has to be pasteurized, mostof the turbid particles have to be removed.If not, the surfaces of the flashpasteurizers would become coated withturbid particles, and the heat transferprocess would be impaired. High yeastcontents also have a negative impact onthe taste of the product during pasteurization.The manufacturers operatewith various clarificationmethods:– Natural sedimentation in the tank.This is a relatively time-consumingmethod involving high losses, and theclarification process has to be supportedby cooling, which involves additionalenergy input. Process control isalso imprecise.18Separator´s Digest 1/2004Separator´s World

– Filtration using diatomaceous earth,possibly in combination with centrifuges.The high costs of filtration andthe losses are negative aspects of thisprocess.– Use of separators. However, thesemachines must have sufficient clarifyingefficiency if they are to enable theoperator to do without filtration.Using separators makes senseAfter the fermentation process hasbeen completed, the Kwas is pumpeddirectly from the fermentation tank tothe separator and discharged via a buffertank for bottling. If the Kwas has tobe pasteurized, it makes sense for abuffer tank to be installed between theseparator and the flash pasteurizer.“The performance ofthe separator can beautomatically adjusted tothe solid content of theKwas; when the clarificationprocess of a tankcommences, the capacityis reduced to compensatefor the higher yeastconcentration.”The clarification of the Kwas ismonitored continuously by a turbiditymeter in the separator discharge. If theturbidity falls below a preset limit, theyeast is automatically discharged fromthe bowl without any loss in performance.Of course, a separator can beused not only for Kwas but also forother products, e.g. beer or juice, outsidethe season. Such an arrangementreduces the specific investment costs.Otchakovo brewery is ableeliminate filters by usingseparatorsA new type GSC 100 clarifier fromWestfalia Separator has been installedrecently for Kwas clarification at theOtchakovo brewery in Moscow. Althoughseparators of older designshave long been used for Kwas clarification,the use of this modern separatorproduced much better results than hadbeen originally anticipated. For instance,the Otchakovo brewery was able to getby without its existing filters. With acapacity of 25 – 30 m 3 /h, significantlyfewer than 10,000 yeast cells/ml wereachieved in the separator discharge.This results in adequate stability ofthe Kwas as well as the possibility ofpasteurization. Otchakovo bottles Kwasin PET bottles, which ensures a shelf lifeof six weeks.The perfect results of the GSC 100are achieved by using a specially designeddisk stack, the gentle feed whichenables even fine particles to be separatedwithout being damaged, a powerfuldischarge system for optimum yieldwith maximum dry substance in theyeast, and optimum CIP ability. The installationoperates fully automaticallyand continuously. The capacity is adjustedin an optimum manner to the properspecifications. As a result of theeffective Hydrostop discharge system,product losses are minimized, and productionand disposal costs are reducedbecause filtration is no longer necessary.Practical experience has shownthat even such traditional productionmethods as those used for Kwas can beimproved even further by modern separatingsystems. Together with Vodka,Kwas is the favourite drink of Russians.Why should it not be possible for othernations to enjoy Kwas in the New Agebeverage era? ■Wolf-Dietrich HerbergProduct Management BeerBusiness Unit Beverage TechnologyWestfalia Separator Food Tec, OeldeTel.: + 49 25 22/77-17 18herberg.wolf@gea-westfalia.deSeparator´s World19Separator´s Digest 1/2004

Food TecDry Fractionationwith STEP➤ The oleochemical industry likessustainable raw materialsA clean solution:mechanical separationtechnology usingseparators is thepreferred technologyfor environmentallyfriendly conversion ofvegetable raw materialsinto consumer durables,e.g. soaps or householdproducts.There are few areas of the chemical industry that permit suchinnovation as the oleochemical industry, the technical applicationof oils and fats. Many new ideas and numerous patents deal withthe substitution of mineral oil products by sustainable raw materials.20Separator´s Digest 1/2004Separator´s World

➤Process development by pilot-scale trialsTo be in a position to offer complete solutions to its customers, Westfalia Separator maintains its own centrifugal process technologydepartment (ZVT) in Oelde; this department is also responsible for investigating oil and fat products for their properties and ability tobe treated in centrifuges. It also cooperates closely with research and development as well as the various business units to develop newprocesses. It is also possible for pilot-scale trials to be run on small production installations with the customer’s products; these trials simulatethe subsequent process as closely as possible. ZVT is responsible for the machine trials and also for determining process parametersfor commissioning test installations; it is also responsible for performance tests with production installations and for generally optimizingprocesses.The production of biodiesel as analternative to mineral oil dieselis just as important as the productionof soaps and domestic products.Environmentally friendly processes forconverting vegetable raw materialsinto consumer durables are becomingmore and more important, and mechanicalseparation technology with separatorsis increasingly becoming the preferredtechnology. With a new processinvolving detergent-free dry fractionation,Westfalia Separator now offers areliable and environmentally friendlysystem that is able to replace the previousmethod of wet fractionation thatwas beset by problems. This new systemis equivalent to dry fractionation involvingfilter technology and providesconvincing arguments in terms of qualityand cost-effectiveness.Optimum adjustmentof olein qualityThe problem of processing with wetfractionation is the detergent: a surface-activeagent that harms the environment,should not be discharged ineffluent, and can only be partially recycled.For this reason, industry is movingtowards dry fractionation. In the past,this method has involved large filterinstallations (either vacuum filters ormore recently membrane filter presses).These are applications that separatethe crystallized fats or fatty acidsinto olein and stearin in two stages.With the stearin extraction processSTEP, Westfalia Separator now offersinnovative technology for separatingsolid stearin crystals from a liquid oleinphase with the aid of centrifugal forces.This method has many advantagesfor users.The main advantage is that theolein quality of special oils such as fishoil, butter oil or cocoa butter substitutecan be adjusted much more efficientlyto the desired customer specificationthan is possible with filters oreven filter presses. Separators and filters/filterpresses have similar processingcapacities; however, the separatorprovides much better value for money.This is owing to the lower spare partand maintenance requirements, lowerinstallation costs, more compactdimensions and the possibility that acooling room might not be needed formaintaining the crystal fracture of thestearins.Product enhancement byway of additional benefitThe separator also offers the unbeatableadvantages of hygienic design andcleaning-in-place. Maintenance andcleaning times aloneenable the separatorto provide more productionavailabilityper year than a membranefilter press.The separator operatesautomaticallyand as a continuous process. As a very reliableproduction stage, separating technologyoptimizes the overall process.“STEP is the onlyseparator technologyin the world whichsuccessfully handles theprocess of olein/stearinseparation as dryfractionation.”The combination of crystallizationand the STEP process enables products tobe enhanced and also enables additionalbenefit to be created. For example,Olein from palm oil, which is liquid atroom temperature, is used as frying fatin commerce and industry.Oleins from butteroil can be mixedwith butter to obtain spreadable butter.Clear and concentrated olein, richin Omega-3 from fishoil, is used as avaluable food supplement. The possibleapplications of STEP are constantlyincreasing. ■Klaus-Peter EickhoffHead of Oils and Fats ProcessingWestfalia Separator Food Tec, OeldeTel.: + 49 25 22/77-23 84eickhoff.klaus-peter@gea-westfalia.deSeparator´s World21Separator´s Digest 1/2004

IndustryKaolin for thepaper industry➤ Recovering the 2µm fractionKaolin is the white gold of the mining industry. Its properties areappreciated in many branches of industry as a filler and whitener.Every year, 40 million tonnes of refined kaolin are sold. Of this figure,one third is processed into hyperpure kaoliln for demanding productssuch as paper filling agent and coating. This represents 70 % of thesales value of kaolin.High-grade kaolin is used primarilyin the paper industry,where it is used as a bright fillertone for a wide range of printingand writing papers and also as a coatingtone with high brightness for highpaper surface quality.High-grade kaolin is also used as afiller for special plastics.Particle size distributionis the vital factorAs is the case with other white pigments,product quality and thus themarket price are determined by brightness,opacity, purity and gloss, in theproduction of kaolin for the paper industry.These parameters are determinedby the particle size distribution, andthis factor determines the quality ofthe pigment.Very precise classifyingIn the production of white pigment,particles smaller than 0.2 µm are notrelevant because they do not refractlight.On the other hand, particles whichare larger than 2 µm have a negativeimpact on whiteness. In particular, theresidue of coarse particles with a diameterin excess of 20 µm must be minimizedif good paper quality is to beachieved.“Westfalia Separatortechnology reducesthis fraction toa few ppm.”The aspect of process flexibility forobtaining various quality stages inorder to increase yield is becomingmore and more important. This alsocomprises recovery of the 2 µm fractionwhich was previously lost in theindividual process stages.With its decanter and separatortechnology, Westfalia Separator candetermine the particle size distributionby means of very precise classifying, in22Separator´s Digest 1/2004Separator´s World

➤The Physics of Separating Technology Using CentrifugesThe fundamental formula for the settling process of particles is provided by Stokes.According to this formula, the settling velocity is related to the square of the diameter ofa particle. This physical law provides optimum conditions for using centrifuges, eitherdecanters or separators for recovering and classifying minerals in the low µm range. Thecentrifuge is able to recognize the difference between particles with a size of 1 µm and 2µm extremely, namely with a factor of 4 according to Stokes. This fact means that the centrifugaltechnology of Westfalia Separator is extremely efficient for recovering minerals.such a way that the user obtains thedesired quality with minimum losses. Ayield which is increased by several percentagepoints and a higher degree ofwhiteness make themselves felt ininstallations which produce thousandsof tonnes per year. Relatively smallquality improvements boost profits significantlyin this industry.Newly developedrecovery processlia decanter, the current product losscan be converted into the requiredhigher quality without any problem.The pay-back period of this process isvery short.Based on the test results using atest decanter CA 225, the pay-backperiod of the 2 µm recovery processwith a high-performance decanterCCA 635 is an estimated nine months.Around 1.9 tonnesper hour can be recoveredwith thisKim Traegersystem.Assuming 8,000operating hours peryear and a price ofapprox. USD 80 perWith a newly developed recovery process,Westfalia Separator has succeededin significantly reducing the lossesof the 2 µm fraction. By connecting asecond classifying stage with a Westfatonnefor this quality, the additionalproceeds total approx. USD 1.2 millionper year. At the same time, the manufactureris able to continuously producetwo different pigment qualitieswith the first and second stage. This isbecause the paper industry is constantlysearching for new pigment formulationsand recipes. This provides addedvalue for the user. ■Head of Mineral Processing, Business UnitChemicals, Pharmaceuticals, BiotechnologyWestfalia Separator Industry, OeldeTel.: + 49 25 22/77-16 35traeger.kim@gea-westfalia.deSeparator´s World23Separator´s Digest 1/2004

IndustryIsolatedSoy Protein➤ Food source ofthe futureAp Apart from soy oil recovery,the glycine from the family oflegumes is also a very efficientand inexpensive supplier of protein.This is because the soy beans containapprox. 20 % oil and around 50 %protein. This is a virtually ideal compositionfor human nutrition. However,raw soy beans are inedible – they containnatural substances such as trypsininhibitors which inhibit the digestionof protein.The potential applications of soyprotein are extremely varied. It is estimatedthat up to 30,000 food productscontain soy components in some form,e.g. sports drinks, confectionery, dietfoods, bakers’ additives and baby food.In addition, soy protein is often usedfor technical products, for instancewater-soluble dyes, in textiles and plastics,in cosmetics and packaging film.Isolate recoverywith centrifugalseparating technologySoy is nowadays anessential componentof many foods. Half acup of soy beans forinstance supplies asmuch protein as a150g steak. Soy alsocontains the aminoacids which manrequires but is notable to make himself.Soy is the global protein and oil plant.More than half of vegetable oil producedthroughout the world is derived from thesoy bean. The inconceivable quantity of184 million tonnes was harvested in 2002,90 % of this figure in the USA, Brazil,Argentina and China.The raw material for all these applications,namely isolated soy protein, issupplied by a process in which separatorsand decanters from WestfaliaSeparator play a major role.Roughly speaking, the soy bean isinitially cleaned, broken, peeled andprocessed into flakes. To enable theprotein to be recovered, the soy oilmust first be removed, so that the oilcontainingphase and the aqueousphase, in which the proteins are contained,do not result in an emulsionsimilar to mayonnaise.The oil is extracted by means of solvent,in general hexane, which is subsequentlyremoved. This process producesso-called “white flakes” whichderive their name from their whitecolour – all originally yellow pigmentsof the glycine are combined with theseparated oil. This is the point atwhich centrifugal separating technologycomes into action. In a two- ormulti-stage extraction phase, the pHvalue is increased by adding, for example,caustic soda.24Separator´s Digest 1/2004Separator´s World

The proteins are dissolved, and canideally be separated with decantertechnology into an aqueous proteinphase and solid fibre material. Thetwo-gear drive of, for example, adecanter CB 505, achieves optimumdewatering of the solids and excellentclarification.“As the protein tobe recovered is usedfor food, the decantershave hygienic designand are CIP-capable.”Two-stage extraction can be usedconsistently in the counters-currentmode, i.e. most of the protein ispumped into the second stage andthen returned to the first stage to enablefurther protein potential to be released.Stringent requirementsregarding regulating accuracyThe next step is to precipitate theproteins from the aqueous solution byadjusting the solution to its isoelectricpoint. The solids that are obtained inthis way are also recovered by decanters.Because the protein is in the formof a very fine solids suspension, therequirements regarding the decanterdrive are extremely stringent as far asregulating accuracy is concerned. Thisis because the decanter is operated ina very low differential speed range.Westfalia Separator machines areaccordingly equipped with specialfeatures such as a gentle feed througha rotating inlet tube, special conicalangle, measures for avoiding foamingand immersion discs for optimumdewatering. An important requirementfor sanitary operation is a facilityfor efficiently cleaning the machines.The machines have special features toachieve this. Under certain circumstances,the low density differencemight not allow the extremely finesuspended solids to be removed entirely.An additional separator of theHSB series can be used for clarifyingthe overflow to assure product safety;this solution of course meets the samehygiene criteria as the decanter.High value and strong growthIsolated soy protein has to feature aprotein content of more than 90%.After initial precipitation, the figuresare normally below this level. A seconddecanter is therefore used for proteinwashing. The soy isolate protein,obtained in this way, can be processedspecifically into functional protein as araw material by physical or chemicalmeans. Depending on the specificnature and application, these proteinsare extremely valuable and are sold forprices of up to EUR 5,000 per tonne.“Soy protein is clearlya growth market.China alone will tripleproduction during thenext five years.”Westfalia Separator recently installeda protein recovery process withfive decanters in Israel; the developmentis ongoing. In parallel with isolate,the process also enables proteinconcentrate to be recovered in highervolumes and with correspondinglylower margins.More new ideas are already maturingat Westfalia Separator. ■Markus SeilerHead of Starch Technology, Business UnitStarch Technology/Industrial BiotechnologyWestfalia Separator Food Tec, OeldeTel.: + 49 25 22/77-18 34seiler.markus@gea-westfalia.deSeparator´s World25Separator´s Digest 1/2004

Mineraloil SystemsSMS insteadof SOS➤ Systems for monitoring solidsholding space and water contentSMS is not the abbreviation for “Short MessageService”, the form of voiceless communicationwhich is extremely popular, particularly withyoungsters.However, nowadays, Morse codeis experiencing a sort of revivalas many mobile devices ofthe third digital generation notify theirowners that a new SMS has arrivedwith the tone sequence three short,two long (instead of three long), threeshort. Tradition and modernity crossingpaths?Unsupervised operationNot quite. At Westfalia Separator, SMSstands for Sludge Monitoring System,and is an integral component of thenew D-Type mineral oil separators.Indeed, it is a significant componentbecause SMS ensures that the bowl isdischarged fully automatically at theoptimum moment. This is a characteristicwhich distinguishes the D-generationfrom all other separator systemson the market. SMS enables the ejec-A second control system rounds off thesophistication of the D-type generation,namely the water monitoring systionprocess to be controlled as a functionof the amount of sludge. Thisresults in significant advantages comparedwith the normal ejection methodwhich is based on time intervals andwhich is adjusted on the basis of theaverage solids content.For instance, bad weather at sea canquickly increase the level of sludge infuel oil or lubricating oil, and the separatorfeed receives a lot, and possibly toomuch, sludge. The separator is no longerable to cope with the solids content.“SMS on the other handis a self-thinker whichdetects the high contentof sludge andimmediately initiatesa discharge process.”This is essential for ensuring reliableand unsupervised operation with asingle-stage fuel oil and lube oil processingfacility, which reduces costs. Theprocess is as follows: A small quantityof liquid is diverted from the bowl. Thisis channelled via a pressure monitorand recycled back into the feed. If thesensor liquid inlet becomes clogged upas a result of solids accumulating in thesludge holding space, the pressure sensorgenerates a signal to the controlunit and the automatic discharge programis initiated. This control andmonitoring system ensures trouble-free24-hour operation.Effective assistance in efficientheavy fuel oil processing26Separator´s Digest 1/2004Separator´s World

tem. This ensures water-free oil discharge.By way of analogy with theSMS, the diverted flow on this occasionis channelled via a conductivity sensor.If this device senses water, it opens asolenoid valve and the water is dischargedinto the dirty water discharge. Ifthe conductivity changes as a result ofoil flow, this solenoid valve closes, asecond solenoid valves opens intermittentlyand enables the flow of liquid tobe recycled back into the dirty oil feed.WMS and SMS are small but extremelyeffective aids to efficient heavy oil processing.Most powerful machine forheavy oil processingFollowing the introduction of its D-Type series, Westfalia Separator hasbeen overrun by users. Since the firstpresentation in mid-2002, orders havebeen placed for around 1,500 D-Typeseparators within a year. These machineshave opened up new dimensionsin centrifugal processing in the shippingindustry (gas turbines and dieselengines) as well as in power stations,oil production and industry. With evenbetter separating efficiency, lowerfresh water consumption, extendedmaintenance intervals and reducedweight, the D-Type separators meet thedemands created as a result of shipsbecoming faster and faster as well aslarger and larger. The flat belt insteadof a gear ensures simpler maintenancedue to a 30 % reductionin the numberof components, less Jürgen Mackelsusceptibility tovibrations, low-noiseoperation, lessweight and bettervalue for money.With the four sizes OSD 6, 18, 35and 60, Westfalia Separator is able tocover all ratings currently required bythe market. The OSD 60 is also the mostpowerful machine available on themarket for processing heavy fuel oil.The modular design of the compactunits has also been very well received.This uniformity of the D-Type designallows easy maintenance of all sizes ofmachine. ■Head of Development and DesignWestfalia Separator Mineraloil Systems, OeldeTel.: + 49 25 22/77-27 07mackel.juergen@gea-westfalia.deSeparator´s World27Separator´s Digest 1/2004

Mineraloil SystemsProper exposure➤ Mini-separator cleans developer liquid in print shopsPrinting and alsosaving costs: Theseparator OTC 2 ofWestfalia Separatorpermits inexpensiveprocessing ofdeveloper liquid.The advantages –longer operatingtimes and reducedcleaning anddisposal costs.Conventional offset printing or high-techcomputer-to-plate (CtP) processes –print shops and the pre-print stagerequire developer liquid in order to printmonochrome letters and colour images.28Separator´s Digest 1/2004Separator´s World

In conjunction with the Munichbasedprinting institute Fogra,Westfalia Separator MineraloilSystems has initiated a research projectto process developers in a cost-effectivemanner, to extend their servicelives and also to reduce cleaning anddisposal costs. Two practical indicationsshow that this has been achievedalong the whole line.Removing particles fromdeveloper solutionsDeveloper liquids for printing plates canhave very different chemical compositions.A common feature of all thesedeveloper solutions is that the particleconcentration increases as the solutionis used. Despite the regeneration process,which normally takes place, the servicelife of these solutions is limited. Oneof the main reasons for this is the increasein the concentration of solid particles.This effect is known as ’sludgeaccumulation’. Despite the use of regeneratorsto extend the service life, largequantities of spent developer liquidsoccur during operation.The process of disposing of suchliquids is relatively expensive. Accordingly,it is desirable for the spent developerliquid, which occurs during plate developmentin offset printing, to be processedor cleaned.minimaXx in bypassThe aim of the research project carriedout by Westfalia Separator MineraloilSystems and Fogra was to solve theseproblems. Contaminated developerliquid is fed continuously to aminimaXx separator for processing ina bypass arrangement. The impuritiesare separated efficiently in thedeveloper liquid in the centrifugalfield of the separator, and the actualplate production process is not affected.“The separatortreats the developerliquid so that itcan be recycled.”The result is impressive. A constantlycleaned development bath guaranteesconstant quality of the exposedplates and the unpopular cleaningintervals are significantly extended.The minimized addition of developerresults in a dramatic reduction inpurchasing and disposal costs and hasobvious benefits for the environment.The high cleaning efficiency of theseparator enables up to 3 CtP systemsto be connected and clarified if necessary,while the same developer liquid isused, aa further demonstration of theconsiderable cost-effectiveness of thisinnovative and unusual system. The separatoris easy and inexpensive toclean.Very good practical valuesThe process was initially installed atDruckhaus Teamsatz & Litho GmbH inNeudrossenfeld near Bayreuth. Thedifference before and after the separatorwas used demonstrates theeffectiveness of the minimaXx OTC 2for cleaning developer.Whereas theRalf Kleinhausdeveloper machineProduct Managerpreviously wasfinished after 1,000Oeldeplates, this now lastsfor around 3,000plates. The numberof plates that can be exposed usingone batch of developer liquid has alsoincreased dramatically from 800–1,500(without a separator) to 2,500–4,000(with a separator). In the previousarrangement, approx. 5 litres of developerhad to be drained from thesystem every two to three days andreplaced by new developer. This is nowno longer necessary. In total, Teamsatz& Litho achieves annual savings ofmore than EUR 5,000 as a result oflower personnel expenses for cleaning,lower developer/regenerate costs andlower disposal costs.The pay-back time for the installationis approximately two years. Anewspaper printer in Münster with athroughput of approx. 1000–1200plates per day has also installed theOTC2, which operates effectively withpotential savings of at least 70 % interms of developer consumption anddisposal. Extrapolated over a full year,this represents a reduction of costsrunning into five figures. And this doesnot even consider the fact that thecosts of cleaning the developingmachines and in particular the developerbath are now much lower than inthe past.The minimaXx separator is ideal forthis task as a result of its compact design.Space is always at a premium in aprinting shop, and the machine can beset up next to the developer batch. Thismeans that the pipe work for the developerliquid is short, the low volume of separatedsolids means that a cleaningcycle of several months is sufficient forthe separator itself. The process representswelcome cost savings for all printingworks and the pre-press stage. ■Westfalia Separator Mineraloil Systems,Tel.: + 49 25 22/77-15 93kleinhaus.ralf@gea-westfalia.deSeparator´s World29Separator´s Digest 1/2004

Environmental TechnologyMega-Size ClarificationPlant in Singapore➤ Singapore: The Cleanest City in AsiaWith about 685 km 2 Singaporeis one of the smallest,and with about 5,500 inhabitants/km2 , it is one of the mostdensely populated, and with a perheadincome of about 23,000 €, it isone of the wealthiest states of theworld. Most of the inhabitants live onthe Isle of Singapore.Singapore owes the privilege of beingone of the richest nations in theworld to its favourable geographicalposition right at the intersection ofvarious ship, air, and commercial routesbetween East and West, North andSouth, to consistent integration in theglobal market and to the promotion ofexternal economic fields by investingin the ASEAN countries. Singapore hasalmost no raw-material deposits. Itskey sectors are rather internationalfinancial services, research and development-intensiveindustrial projects,and, most recently, life sciences andmicro-technology.The country's economy recoveredfrom the consequences of the Asia crisesmore quickly than expected. Themodel of success is as young as 38years. Since 1959 the Singapore Governmenthad developed the model statewith the structures of a successful servicecompany, and since 1965, Singaporehas been an independent repub-30Separator´s Digest 1/2004Separator´s World

lic. Whilst in 2000 the real economicgrowth rate was still as high as 9.9 %,the consumers' paradise had to copewith a shrinking gross domestic productin 2001 for the first time.“To serve the futureneeds of Singapore thePublic Utilities Board isembarking on a projectto build a wastewatertreatment plant (or waterreclamation plant), saidto be one of the largestplant to be built in asingle construction.”No wonder that the order for 30decanters for about 35 million € is oneof the biggest orders received throughoutthe history of Westfalia Separator.30 giant machines for sludgethickening and dewateringIn order to remain prepared for thestill unending increase of population,currently almost 4 million, Singaporesucceeded in enlarging its land surfaceby 15 % in the last 20 years, by recoveringland from the sea.The new wastewater treatmentplant will be erected on a 54-hectaresurface of sea recovered land. InFebruary 2002, the Metax EngineeringCorporation, a mechanical engineeringcompany from Singapore, receiveda large-scale order for the equipmentof a mechanical sludge separationsystem for the plant. Westfalia SeparatorUmwelttechnik and Metax are goingto fullfill this order.The heart of the system will be 20decanters type CA 1036 for sludgethickening and 10 decanters type CA1035 for sludge dewatering. In additionto these gigantic scroll type centrifuges,peripheral gear such aspumps, conveyor units, flocculent stations,and switching units will be supplied.Simultaneously, a time-limitedmaintenance contract was concluded.ContinuouslyperfectCompared with othereffluent treatmentmethods, decanterscan offer the advantageof continuousoperation – with considerably lowerspace requirements, which is of vitalimportance in the dense-ly populatedcity state. Moreover, the operatingexpenses will be clearly lower.The first decanter will be suppliedin early 2004 and then, one machinewill follow each month. The wholeorder will be achieved by April, 2007.Plant erection will be carried out onthe basis of a detailed time schedule.Once completed in 2007, the plant willbe able to treat about 800,000 m 3 ofwaste water daily. The city of Berlin,with 3.5 million inhabitants, clarifiesabout 650,000 m 3 each day.Waste water will be delivered tothis mega size waste water treatmentplant via a new subterranean sewagetunnel having a 3.6–6 m diameter overa distance of about 40 kilometres fromvarious parts of Singapore so Singaporeremains clean and pure. ■Michael WünschGeneral Project ManagerSingapur Changi WRP EP 7Westfalia Separator Umwelttechnik, OeldeTel.: + 49 25 22/77-19 76wuensch.michael@gea-westfalia.deSeparator´s World31Separator´s Digest 1/2004

Environmental TechnologyHops and Malt –For the Sake of theEnvironment➤ Process-integrated environmental protectionwith centrifugal separation technologyParameters Values UnitsWaste-water treatmentSpecific valuesSpecific water consumption 0.4 – 0.8 m 3 /hl VBSpecific effluent volume 0.25 – 0.6 m 3 /hl VBSpecific BOD load 0.3 – 0.6 kg/hl VBSpecific COD load 0.5 – 1.0 kg/hl VBConcentrationsBiological oxygen demand BOD 1,100 – 1,500 mg/lChemical oxygen demand COD 1,800 – 3,000 mg/lNitrogen N 30 – 100 mg/lPhosphorus P 10 – 30 mg/lEffluent from productionWet-sludgedisposalWaterSieving filteranaerobicreactoraerobicallybiological cleaningSludgeWaterpH adaptation to nutrient supplyBiogasSand filterIndustrial waterClarificationplantLarge volumes of effluent occur in the production andbottling of beer. Sharply rising effluent charges arecausing a significant financial strain on breweries.Solids disposalThe international brewing industry requires innovative technologies thataddress both ecological and economic requirements. Process-integratedenvironmental protection with centrifugal separation technology meansthat these requirements are met.32Separator´s Digest 1/2004Separator´s World

Separators and decanters operateon a continuous basis, areextremely efficient at separationand clarification and require minimumenergy and labour input. Downstreamprocessing methods for theentire effluent production can be minimizedin terms of size, thus reducinginvestment costs. There is no doubt thatcentrifugal separation is a practicaland economic technology for the environmentalprotection of breweries.Lower costs,higher yieldBrewery effluent consists primarily oftwo main streams. The first streamconsists of residues discharged fromthe production process. In addition tosubstances in solution, such as fermentablesugar, a wide range of solids canbe present in this product stream –yeast and diatomaceous earth forexample.“If such a productionstream is separated intoits solid and liquidcomponents with aseparator or decanter,the effluent volume andload are reduced.”At the same time, valuable substancescan be recycled back into production.This approach not only reducescosts, it also increases the process yield atthe same time. The necessary size of theinstallation for processing the effluentcan also be reduced, and this in turn reducesthe size of the overall investment.Extremely versatileThe second main stream of breweryeffluent comes from the cleaning processes.Fermentation and storage tankcleaning as well as cask and bottle rinsingare the main contributory factors.It also makes sense for centrifuges tobe used in this effluent stream. Forinstance, environmentally friendly andeconomical recycling of bottle washlye with separators or decanters hasproduced good results and makes amajor contribution towards protectionof the environment.Initially anaerobicor aerobic treatmentUnlike the processused for recoveringvaluable substances,direct separation ofthe overall effluent isgenerally not advisable.In most cases,the effluent containstoo many dissolved substances whichcannot be separated using separationtechnology. An anaerobic or aerobictreatment in a works effluent treatmentplant should, therefore, be carriedout first. The production effluent firstundergoes preliminary purification ina strainer filter. After the pH value hasbeen adjusted and nutrient has beenadded, the water can be pumped intoan anaerobic reactor. The biogas whichis obtained in this reactor can be usedby the brewery for generating energy.The wet sludge is then disposed of andthe water then passes to the aerobicstage in the second step. The waterdischarging from this stage can first bepassed through a sand filter and theneither be discharged into the seweragesystem or used as industrial water inthe plant.Sludge volumereduced by decantersIdeally, a decanter for sludge dewateringis installed downstream of theaerobic stage. Decanters continuouslyseparate suspensions into liquids andsolids. Separation takes place in a rotatingbowl, a coaxially installed conveyorscroll. Compared with the processof sedimentation under gravity,decanters generate forces which areup to 4,000 times higher on the solidparticles. Under the effect of centrifugalforce, the solids sediment out andsettle very quickly. The scroll catchesthe solids and conveys them out of thedecanter. The sludge is dewatered inthis way, and the liquid phase is recycledback to the aerobic stage. The volumeof the dry substance is reduced,which means that disposal is simplerand less expensive. ■Uwe CarstädtProject ManagementWestfalia Separator Umwelttechnik, OeldeTel.: + 49 25 22/77-27 84carstaedt.uwe@gea-westfalia.deSeparator´s World33Separator´s Digest 1/2004

ServiceAct local➤ Clear focus on regional service conceptCustomer satisfaction has maximum priority at Westfalia Separator.The aim is to achieve this satisfaction in every product, every machineand installation in two different phases.The first phase is the planning,purchasing and commissioning.This is an important initial period.The second phase lasts much longer,namely years or even decades, as aresult of the long service life ofWestfalia machines. This is the periodof practical operation of installations,in which the machines have to carryout their assignment reliably as componentsof an overall process.A vital factor in this long period ishow the after-sales service of a companyfunctions, how quickly spareparts can be delivered, what the formof interpersonal cooperation takesbetween works manager, machine operatorand maintenance specialist onthe one hand and service employeeson the other. This customer supportphase is extremely important for WestfaliaSeparator.World-wide service hasa key functionTo set up a customer-oriented, countryandmentality-specific service organizationand thus to attain maximum customersatisfaction, Westfalia Separatorputs together specific regional-orientedservice packages.“In ‘regional servicemanager meetings’,service employees developconcepts for optimumcustomer support.”The third four-day meeting of thistype was held in September 2003 inBeijing. The service managers of WSChina, WS Korea and WS Japan, wereinvited to attend the meeting, as wererepresentatives of the market companiesWestfalia Separator Industry,Mineraloil Systems, Food Tec andEnvironmental. Within the frameworkof global service strategy, it was emphasizedthat world-wide service has akey function to perform at WestfaliaSeparator, with the following objectives:– Maximum customer satisfaction– Partnership between customersand Westfalia Separator– Full utilization of the entireservice potentialPartnershipIt was demonstrated that the focus isclearly on local and regional serviceconcepts, which in total result in a glo-34Separator´s Digest 1/2004Separator´s World

Directly on sitethroughout the world:The local and regionalservice concepts ofWestfalia Separatorin total result in aglobal service concept.For a partnershipwith the customer,maximum customersatisfaction andcomprehensive service.bal service concept. A local and regionalsolution has been chosen becausecustomers also have a local understandingwith regard to service. Even majorgroups work together with the relevantWS-subsidiaries and service organizationsat their production locations.This results in the partnership that istransferred to the parent companies.The service comprises just-in-time deliveriesof spare parts, suitably qualifiedand certified service personnel and thefacility for on-site repairs and exchange.Position of Product ManagerService strengths customersatisfactionThe position of the ’Product ManagerService’ has been created in every marketcompany to support the subsidiariesand to act as service contacts forkey customers; experienced personnelare employed in these positions. ProductManagers Service are responsiblefor a range of key tasks. They ensureindividual solutions with active customersupport. In the event of problems,they are on site and can alsoprovide support by telephone.„By accessing the globalservice and repairnetwork, they are ableto organize help quickly.“They advise customerswith regardto WEWATCH servicecontracts and agreementsfor deliveriesof spare parts, andcalculate the entire service life costs ofmachines and installations with theusers at the point at which the equipmentis sold. They are responsible forproviding training to operators andservice engineers for individual machines.They are responsible for consistentquality of the installations, achievingmaximum customer satisfaction, andproviding support to the branches. Theprocess of cooperation between regionalservice managers and brancheswill be continued. ■Arnold JakubczykService ManagerWestfalia Separator Food Tec, OeldeTel.: + 49 25 22/77-17 72jakubczyk.arnold@gea-westfalia.deSeparator´s World35Separator´s Digest 1/2004

Separation Technology + Beverage Technology + Dairy Technology + Oils and Fats Processing + Chemicals,Pharmaceuticals, Biotechnology + Oils and Fats Recovery + Starch Technology + Industrial Biotechnology + Marine+ Energy + Oilfield + Industry + Environmental Technology + Engineering + Second Hand Machinery + Service2300.105What appears to besimply natural at firstglance ...... can unleash immensepower when you look atthe big pictureTake the Best - Separate the RestWestfalia Separator is moving your businessforward. Now, using its robust separatorsand decanters, you can recover bothedible oil and valuable biodiesel (methylester), from oil seed rape – naturally. Asreliable workhorses, they perform a vitalrole in converting the renewable raw materialinto environmentally-friendly fuel.The system is extremely economical andprovided as turnkey process lines usingthe tried and tested Connemann process.Problem-free process integration, simplemaintenance, high operating reliabilityand an intelligent service packagetailored to your needsprovides optimumvalue addedthroughout the entirelife cycle of the plant.Harness the power!Whether you choose stand-alone separatorsor turnkey plants, Westfalia Separatorwill find the ideal solution to meet yourneeds.So in future you can tap all energysources.Westfalia SeparatorFood TecWestfalia Separator Food Tec GmbHWerner-Habig-Straße 1 · D-59302 Oelde · Tel.: +49 25 22/77-0 · Fax: 77-20 89www.westfalia-separator-food-tec.com · E-Mail: foodtec@gea-westfalia.deKlaus-Peter EickhoffHead of Oils and FatsProcessing9997-1050-000/0304 ENPrinted in GermanyPrinted on chlorine-free bleached paper

To the editors of theSeparator’s DigestMy address has changed.I have entered my new address overleaf.I am not yet a subscriber to Separator’s Digest.Please add me to the distribution list.Please send me further information aboutWestfalia Separator.Please briefly let us know what you think of theSeparator’s Digest by giving marks on a scale from1 (excellent) to 5 (poor)!PleaseaffixpostagestampReply CardWestfalia Separator AGMarketingWerner-Habig-Straße 1D-59302 OeldeDesignand Layout1 2 3 4 5EditorialContentI have the following suggestions, wishes etc.:PleaseaffixpostagestampReply CardWestfalia Separator AGMarketingWerner-Habig-Straße 1D-59302 OeldeName, First nameCompanyPosition / DepartmentP.O. box / StreetZIP / CityPhone / FaxE-mailName, First nameCompanyPosition / DepartmentP.O. box / StreetZIP / CityPhone / FaxE-mail✂To the editors of theSeparator’s DigestMy address has changed.I have entered my new address overleaf.I am not yet a subscriber to Separator’s Digest.Please add me to the distribution list.Please send me further information aboutWestfalia Separator.Please briefly let us know what you think of theSeparator’s Digest by giving marks on a scale from1 (excellent) to 5 (poor)!Designand Layout1 2 3 4 5EditorialContentI have the following suggestions, wishes etc.: