Separator's Digest 2012/1 - GEA Westfalia Separator Group

Separator’s Digest® 

The Magazine of GEA Westfalia Separator Group Edition 1 | 2012 

INTERNATIONAL MILK MARKET 

Dairies with a strong tradition 

of innovation 

MODERN BUTTER PRODUCTION 

Milchwerke Schwaben 

DECANTER FOR MANGO PURÉE

GEA Westfalia Separator Group | Separator’s Digest ® GEA Westfalia Separator Group | Separator’s Digest 1 / 2012 

® 1 / 2012 

Contents 

Preface 

2 

3 Modernise and Expand 

Separator‘s News 

4 Outstanding Centrifugal Separation Technology 

at Anuga FoodTec 2012 

5 A Week of Highlights at Nor-Shipping 

Present at Agro + Food + Drink + Tech in Tbilisi 

Success at NEVA 2011 in St. Petersburg 

6 Celebrity Silhouette with the Latest Fuel and 

Lube Oil Processing “Made in Germany“ 

7 Biodiesel Plant for Argentina Again 

GEA Westfalia Separator Group 

8 International Dairy Market Shows Stable Growth 

12 Additional Energy Savings in the Dairy 

16 The Synonym for the Extension of Enjoyment 

20 Everything is Fine 

24 Milchwerke Schwaben are Modernising the 

Butter Making Process 

30 GEA Westfalia Separator Successfully Delivers 

First Milk Pasteurising Unit to Latin America 

32 Optimised Requeijão Production 

34 Practical Training for Pakistani Dairy Engineers 

36 BestPractices dairy: China, Central America, South Africa 

44 The Cradle of Chinese Brewery Training 

48 More Performance with the Same Size 

Lifestyle 

56 Source of Youth 

Imprint 

Publisher: 

GEA Westfalia Separator Group GmbH 

Project management: Dr. Bertram Melzig-Thiel 

Editors: 

Dr. Bertram Melzig-Thiel (person responsible according 

to German press law), Manfred Kaiser, 

Lilian Schmalenstroer 

Photography: 

Michael Dannenmann, Tim Luhmann, 

archive at GEA Westfalia Separator Group GmbH, 

corbis, iStock, Fotolia 

Conception and Layout: 

Kabutz Communication GmbH 

Feldstraße 5 · 59423 Unna 

info@kabutz.de · www.kabutz.de 

The product information included in this magazine is 

solely for information purposes and is non-binding. 

Binding information, in particular regarding performance 

and suitability for specific applications, can only be 

provided in response to a specific enquiry.

Modernise 

and expand 

The new building of GEA Westfalia Separator Group at our 

headquarters in Oelde is running according to schedule. The 

production halls for the most modern separator production in 

the world are already making recognisable progress. At the end 

of 2012, we will be able to commission the new plant on schedule. 

With positive consequences for our customers: for instance, we 

will then be able to produce the GEA Westfalia Separator 

ecoclear separator family for small and medium volumes with a 

significantly improved delivery time. 

Building work is ongoing not only in Oelde. The construction of 

the new production plant is also in the final phase at the 

Bengaluru location in India. The production of decanters, skid 

units and control panels will start by the end of 2012. In addition, 

the official foundation stone was laid at the end of November 

2011 for the new production plant in Wuqing in China. The 

starting signal for a plant with a floor area of approximately 

30,000 m² was sounded in festive surroundings. The production 

facilities being built here are the largest of GEA Westfalia 

Separator Group outside Germany, and will primarily supply the 

regional sales markets in Asia starting from the end of 2012. 

Markus Hüllmann 

Segment President GEA Mechanical Equipment 

GEA Westfalia Separator Group | Separator’s Digest ® 1 / 2012 

Quality and efficiency pay off – This is 

the experience of an increasing number 

of our customers. And this is the reason 

why we are modernising and expanding 

our operating facilities so that we are 

able to develop and produce our 

products for you even more efficiently 

and effectively. 

Customer proximity on site is also the aim of the road show 

“BestPractices dairy seminar” which was held by our Business 

Line Dairy Technology last year in China, Costa Rica and South 

Africa to extremely positive reviews. We will inform you in this 

issue of the dairy markets in these regions and the seminar 

highlights. 

Without doubt, the Anuga FoodTec in Cologne will be the 

most important date for dairy and beverage technology in 

March 2012. You can look forward to the exhibition stand of 

GEA Westfalia Separator Group. In Cologne, we will be 

demonstrating an entirely new generation of separators for 

separating milk with an integrated direct drive, as well as the 

new ecoclear series for small and mid-size volumes, combined 

with GEA Westfalia Separator proplus, as well as the completely 

new service concept serv&care as a guarantee of permanently 

high availability and in particular budget reliability. You will 

certainly not want to miss it. GEA Westfalia Separator Group 

will continue to be an innovation leader for you. That is our 

promise to you. 

3


outstanding Centrifugal 

separation 

teChnology at 

anuga foodteC 2012 

GEA Westfalia Separator Group is presenting a new separator 

generation for milk skimming at Anuga FoodTec from 27. to 

30. March 2012 in Cologne. For the first time in a medium 

capacity range, the new milk skimming separator MSI 140 

with integrated direct drive will be presented. This separator 

will be combined with a GEA Westfalia Separator standomat 

MC for automatic fat content regulation of cream and milk at 

the fair. The new GEA Westfalia Separator ecoclear has 

likewise been developed for small and medium flow rates in 

the dairy technology sector – combinable for the first time in 

this capacity class with proplus. The proplus system enables 

extending the ejection intervals and consequently a reduction 

of the solids discharge. The ecoclear separator is optimal 

for bacteria removal from high-grade dairy products and 

is suitable for producing cheese-making milk. Thanks to 

the self-cleaning bowl, the machine is suitable for fully 

automated cleaning-in-place. The ecoforce decanter series 

of GEA Westfalia Separator Group in 2-phase and 3-phase 

design with integrated summationdrive stands for high 

performance efficiency and absolute reliability. It is used 

specifically in beverage technology, in the processing of 

4 

renewable resources and in dairy technology. In addition, 

GEA Westfalia Separator Group will be showing its range of 

ceramic membrane elements for microfiltration and ultrafiltration 

which complements the mechanical separation 

technology perfectly. 

A completely new service concept is also having its premiere 

at Anuga FoodTec: serv&care for permanently high availability, 

process efficiency and budget security. With this whole bundle 

of new developments, GEA Westfalia Separator Group is 

emphatically underlining its claim to innovate.

a Week of 

highlights at 

nor-shipping 

Nor-Shipping 2011 in Oslo has never been so popular – this 

was demonstrated by the record attendance figure for the 

year. With 33,400 visitors and exhibitors, Nor-Shipping 2011 

achieved the best values since the first event of this type was 

held in 1965. The presence of the international specialist press 

also underlined the fact that Nor-Shipping is the meeting 

place for the global maritime industry. The week was packed 

full with events and attractions, most of which were making 

their first appearance at Nor-Shipping. There was an offshore 

conference, a geographical expansion with the exhibition 

on the Nor-Shipping Campus into the heart of Oslo, a “Brazilian 

Day”, and the formation of an online community. 

GEA Westfalia Separator Group shared the stand with two 

other sister companies – GEA Bloksma and GEA PHE Systems. 

Exhibits included the new generation GEA Westfalia Separator 

BilgeMaster ® cleandesign with SafetyMaster, without a filter. 

Visitors and customers were particularly impressed by the 

limited space requirement and the option of choosing between 

less than 15 ppm or 5 ppm residual oil content in the bilgewater 

with or without a filter. The next Nor-Shipping will be held in 

Oslo again from 4th to 7th June 2013. 


present at 

agro + food + drink + 

teCh in tbilisi 

In November 2011 GEA Westfalia Separator Group took 

part in the exhibition Agro + Food + Drink + Tech in Tbilisi, 

the capital of Georgia. The International Exhibition for 

Agro, Food and Drink Products and Food Processing 

Equipment is a well-established fair in the region. Shortly 

before the exhibition the subsidiary GEA Westfalia 

Separator Group in Kiev, Ukraine, was given responsibility 

for the Georgian market. This exhibition was a great 

opportunity to meet the existing partners, to find new 

customers and to learn the business traditions of Georgia. 

Georgia, located in the Caucasus region, is blessed with a 

strategic location, beautiful physical features and historical 

treasures. Georgia has been developing gradually in the 

past and demonstrating good results in different economic 

sectors. Due to the fact that Georgia has a centuries-old 

history of wine-making and even its own traditional winemaking 

technology, this sector is highly developed. 

suCCess at 

neVa 2011 in 

st. petersburg 

The 11th Jubilee International Exhibition on Shipbuilding, 

Navigation, Port Activities, Ocean and Shelf Development 

“NEVA 2011” was held in Saint Petersburg, September 

21– 24, 2011. The NEVA 2011 exhibition that ranks very 

high among international marine exhibitions was attended 

by more than 650 companies and enterprises from 

43 countries. In the course of the exhibition two contracts 

were concluded. One of them is the contract with Okskaya 

Shipyard for delivery of 15 ship units for the project RST 27 

designed by DO MEB. Each ship unit includes two OSE 5 

separators for HFO treatment, one OSD 2 separator for DO 

treatment, two OSE 5 separators for LO treatment and one 

VBU. This contract is part of the RST 27 project series of 

oil tankers which will be built for JSC Volga-Flot Tanker. 

The second one is the contract with Almaz Shipbuilding 

Company. Two OSE 10 separators for DO and LO treatment 

will be delivered for the project 22120 designed by DO 

Petrobalt. This is a coast guard vessel for the Russian 

Coast Guard. 

5


Celebrity silhouette With 

the latest fuel and 

lube oil proCessing 

“Made in gerMany“ 

On 21 July 2011, the Celebrity Silhouette, the latest addition of 

Celebrity Cruises, was officially christened in Hamburg. Also 

on board: the latest fuel and lube oil processing and sludge 

treatment facilities of GEA Westfalia Separator Group. In line 

with the premium message and innovative design of the 

cruise liner, Celebrity Cruises has also placed its trust in firstclass 

engineering “Made in Germany“ in the engine room. The 

Celebrity Silhouette is 319 metres long, and 37 metres wide, 

and spoils its 2886 passengers with many attractions such as a 

genuine lawn, numerous fine restaurants or the unique design. 

The Celebrity Silhouette was built at the Meyer yard in 

Papenburg, which this year will be celebrating its 25-year 

anniversary in building cruise liners. 

Reliable supply for marine engines 

In order to ensure reliable fuel supply to the drive systems, 

a GEA Westfalia Separator centripack with four OSD 60 

separators was installed. The concept of the centripack 

provides the opportunity of combining all necessary separators 

into a single unit, supplying this unit to the yard with all 

pipework and control modules in place, which very much 

simplifies the installation process. An installed GEA Westfalia 

Separator ViscoBoosterUnit ensures optimum adjustment of 

the viscosity, temperature and pressure of the engine oil to the 

6 

requirements of the manufacturer. A further centripack with 

four OSD 35 separators and one OSD 6 is used to continuously 

remove water and other contaminants from the lube oil. The 

trend towards using high-viscosity fuel and lube oils means 

that the volume of sludge is increasing. With the SludgeMaster ® 

system, GEA Westfalia Separator Group has found a 

convincing solution to efficiently process sludges which 

contain oil and water and to reduce the sludge volume by up 

to 95 percent. This protects the ecosystem of the oceans and 

dramatically reduces disposal costs. A SludgeMaster ® 300 is 

used for these purposes on the Celebrity Silhouette. 

The Celebrity Cruises will write history. It is the fourth of a 

total of five planned vessels in the Solstice class built in 

Papenburg, and is the first vessel of its class which has been 

christened in Germany – a clear commitment to the German 

cruise liner market. The Celebrity Cruises fleet currently 

comprises ten vessels. Overall, a total of USD 3.7 billion is 

being invested in building new vessels of the Solstice class to 

be built at the Meyer yard in Papenburg. The construction of 

the five vessels between 2008 and 2012 is the largest ever 

investment volume of this type for a single cruise liner brand.

iodiesel plant for 

argentina again 

GEA WESTFALIA SEPARATOR SCORES WITh CD PROCESS 

GEA Westfalia Separator Group has received another order for 

the delivery of a complete biodiesel plant to Argentina. The 

Spanish engineering office Isolux is the ordering party, which 

is responsible as main contractor for the construction of the 

entirely new plant. The plant is operated with an annual 

capacity of 300,000 tonnes in General Lagos located near the 

city of Rosario by Louis Dreyfus Commodities, a world-market 

leader in processing agricultural products. Four years ago, 

GEA Westfalia Separator Group already supplied a plant to 

this location. 

Argentina offers favourable conditions for the production of 

biodiesel as well as an ideal basis for the supply of raw 

materials. One of the largest soya bean extraction plants in the 

world is located at the Rosario site - the best condition for 

quantitative production of biodiesel. In addition, the location 

on Rio Paraná River with a deep-sea port facilitates the export 

logistics, providing a direct connection to the Atlantic. 

Environmentally-friendly process 

GEA Westfalia Separator Group has been dealing with the 

development of biodiesel plants since 1991, and supplied the 

first industrial-scale plant in 1996. 


Biodiesel produced by means of the exclusively licensed CD 

process fulfils all the parameters of the “Biodiesel Standard” 

and is characterized by excellent quality. Apart from the gums 

produced by the degumming process and some excess water, 

the fully integrated process does not produce any waste 

matter. Thus, environmental pollution is correspondingly low, 

but the oil yield at relatively low steam consumption is all the 

higher. The CD process is very well suited for business sizes 

from 35,000 to 500,000 tonnes per year. The larger the plant, 

the more economical the process is. 

The new biodiesel plant in Rosario was commissioned at the 

beginning of 2012. 

7


8

international 

dairy Market 

shoWs stable 

groWth 


notable innoVatiVe strength 

of dairy CoMpanies 

The economic recovery in practically all milk markets together with 

enhanced opportunities for investment financing have rendered 2011 

a successful business period for many milk processing companies and 

their partners. 

9


seruM usage for yoghurt 

produCtion pt = paMf + pyoghurt i (Milk) + pyoghurt ii (α)* 

It may reasonably be presumed that milk production and the 

consumption of milk products will continue to show stable 

growth, both in terms of overall and individual consumption. 

Making a particularly significant contribution in this respect 

are not only countries such as Brazil, India and China, but 

also, for example, Mexico and export countries such as 

Argentina. This development is the result of growing incomes 

and further ongoing urbanisation, which with ever-greater 

regularity is making milk an everyday product for many 

people, including in fledgling industrial nations. 

Unrest on the financial markets, political uncertainty and the 

regional scarcity of resources will also continue to generate 

price fluctuations on the global markets. Nevertheless, the 

price of milk products remains at an attractive level – partly 

as a result of the growing global demand, but also equally due 

to the innovative strengths of many dairy companies. 

Even greater willingness to invest 

Alongside a constant increase in milk production, the growing 

demand for milk products also generally stems from an even 

greater willingness to invest in innovative technologies in 

order to secure a leading role in the competition for 

consumers and market shares. A careful approach to resources, 

increased availability of facilities and innovative products are 

all important prerequisites for ensuring successful survival. 

10 

Anhydrous 

milk fat (AMF) 

AMF separators 

Raw milk 

Skimming separator Yoghurt separator 

Serum 

P = Profit, P T = Total profit 

*Whey and β-serum are excluded for the moment 

Yoghurt 

Accordingly, these trends also provide the basic guidelines for 

GEA Westfalia Separator Group when it comes to developing 

machines and processes for the international dairy industry. 

2011 was marked by a stark increase in orders from a whole 

host of regions, particularly North America. In Canada and 

the USA, the massive demand for systems to manufacture 

strained yoghurt was maintained and looks set to continue 

further. A healthy investment climate is also apparent 

in relation to butter oil. This special process, which 

GEA Westfalia Separator Group similarly dominates with 

great success in its capacity as a technology leader, also 

generated business in Oceania and South East Asia. 

Additional protein utilisation is playing an ever-greater role in 

the use of excess cream extracted from milk and whey, with 

comprehensive analysis revealing extremely attractive 

possibilities in relation to the utilisation of cream. Added to 

this are the indirect, but likewise significant and quantifiable 

benefits from increased facility exploitation, enhanced output, 

a reduction in the dependency on external purchasers 

and also, not least, sustainable, environmentally-friendly 

economies due to diminished transport and a reduced 

application of raw materials. GEA Westfalia Separator Group 

has received a plethora of projects from a number of dairies in 

Europe, primarily relating to cheese production and whey 

processing. In this respect, successfully established company

turnkey proCessing lines for 

butter oil extraCtion 

Thanks to its specific experience of the milk industry, 

GEA Westfalia Separator Group is able to offer turnkey 

processing lines and system concepts for the production of 

butter oil with a capacity of 500 to 12,000 kg / h. Depending on 

individual customer requirements, the process can be 

configured for batch or continual production. Above all, the 

increasing demand for a serum phase with phospholipid 

content is afforded consideration through special process 

concepts. To this end, a concept allowing for separation of 

α-serum and β-serum is also possible upon request. The result 

is additional added value from by-products. In addition, the 

equipment periphery has also been expanded, meaning that 

GEA Westfalia Separator Group is now able to offer complete 

butter oil solutions ranging from cream silos to packaging 

machinery and system controls, all from a single source. Upon 

request, the company can also provide full pre-assembly 

on skids. 

innovations, such as the integrated direct drive system and 

GEA Westfalia Separator proplus, were frequently decisive 

factors in influencing investors‘ decisions given that they 

immediately generate distinct customer benefits. 

2012: significantly reduced delivery 

periods for smaller milk separators 

The above-stated technologies remain important building 

blocks for 2012. Nonetheless, development continues: in the 

form of expansion of the machinery range and technology 

application for cold milk separation, for example, and also 

expansion of the machinery portfolio with the outstandingly 

successful integrated direct drive offering flow rates already 

in excess of 10,000 l / h or the introduction of proplus for cold 

milk separation. GEA Westfalia Separator Group has also 

received highly positive feedback on the new prolong process, 

which affords priority to the freshness and naturalness of 

milk while facilitating an extended shelf life and attractive 

overall costs. Dispensing with an additional application of 

heat in the milk and the laborious process integration of 

filtration systems was a conscious decision that has already 

impressed four European drinking milk producers and 

resulted in orders for GEA Westfalia Separator Group. Despite 

heavy demand, the company has succeeded in maintaining 

stable delivery periods. In a number of areas, an example 


being the smaller milk separators in the GEA Westfalia 

Separator ecocream series, delivery periods have even 

been significantly reduced to only three months. The new 

GEA Westfalia Separator Group manufacturing facilities that 

are currently under construction at its Oelde site will ensure 

that the company is also optimally equipped to meet the 

considerable international demand for milk separators 

anticipated for the future. 

Christian Frahm 

Director 

Business Line Dairy Technology 

GEA Westfalia Separator Group, Oelde 

Phone +49 2522 77-2686 

christian.frahm@geagroup.com 

11


additional 

energy 

saVings 

in the 

dairy 

neW generation 

gea Westfalia separator 

directdriVe 

What do successful dairy companies in Australia, 

Belgium, Brazil, Germany, Great Britain, India, 

Ireland, Italy, the Netherlands, Norway, Poland 

and also in the USA have in common? 

They have decided to use separators of 

GEA Westfalia Separator Group for the 

clarification or separation of milk or whey 

and also for removing bacteria from 

milk or whey. 

12


13


In addition to the excellent application-specific performance of the machines, 

the dairies placed particular emphasis on the high reliability and availability 

as well as energy and cost efficiency, and have decided to use the directdrive ∞ . 

GEA Westfalia Separator Group enables dairy companies to achieve energy savings of 

up to 30 percent with the integrated direct drive, if this innovation which was presented for 

the first time at the Anuga FoodTec 2009 is compared with conventional-drive machines. 

A further element of this development is the GEA Westfalia Separator smoothdiver, with 

which the savings potential in the discharge energy of the separators can be achieved in lowenergy 

design. This is also available as an upgrade for many models from GEA Westfalia 

Separator Group with the tried-and-tested flat-belt drive. 

An unbeatable combination 

The latest generation of the directdrive ∞ will permit additional energy savings of up to a 

further 10 kW per machine. A vacuum achieves a maximum reduction in the air friction – in 

addition to the actual drive, this is one of the main reasons for the mechanical energy 

requirement of separators. Dairies will be able to benefit particularly from the combination of 

directdrive ∞ and GEA Westfalia Separator proplus. This is because, especially in the case of 

maximum extended discharge intervals which are guaranteed by proplus, optimum use can 

be made of the energy savings. 

In addition, GEA Westfalia Separator Group is now also introducing the integrated direct drive 

in a further market segment. Anuga FoodTec 2012 will provide the first opportunity for seeing 

the directdrive ∞ in a medium performance category for milk and whey applications for flow 

quantities in excess of 10,000 l / h with the new milk separator MSI 140. At the exhibition, this 

separator is combined with the GEA Westfalia Separator standomat MC for automatically 

regulating the fat content of cream and milk. 

exaMple of 

double baCteria reMoVal 

Inflow 

1st bacteria removal separator 

1st bacteria 

removal phase 

Inflow 

2nd bacteria removal separator 

2nd bacteria 

removal phase 

Shelf life 

of the fresh milk 

is extended to 

21 days plus x

neW gea Westfalia 

separator eco faMily 

With the development of the new eco generation of 

GEA Westfalia Separator Group, operations with installations 

for small to mid-size volumes in the capacity range 3000 – 

15,000 l / h are now also able to benefit from the process 

engineering skills and innovative ability. The new 

eco family covers all central processes and is customised to 

meet the requirements of dairies. ecoclean is the first choice 

for pre-cleaning and milk clarification, ecocream is responsible 

for perfect separation, and ecoclear guarantees reliable 

bacteria removal. This is ideal for bacteria removal in the 

production of high-quality dairy products and for the 

production of cheese milk. This is the first time that the new 

ecoclear, which is to be exhibited at Anuga FoodTec 2012, can 

be combined in this performance class with proplus (in the 

same way as the ecocream) – without any additional costs. A 

common aspect of the three separators in the eco family is 

In the new process, two bacteria 

removal separators are installed upstream 

of the cream separator. The bacteria 

are reliably removed from the entire 

quantity of raw milk, including the 

cream content, and non-milk components, 

somatic cells, bacteria and spores are 

separated out. The second bacteria 

removal phase produces a total 

reduction in bacteria and a separation 

of bacillus cereus of up to 99 percent. 


that maintenance costs are reduced considerably as a result of 

the flat-belt drive without a coupling. The use of highly 

efficient motors which are controlled by frequency converters 

permits a gentle start-up and variable speeds of the bowl, and 

results in energy savings of up to 10 percent compared with 

conventional drives. The separators are controlled by way of a 

colour touch screen. A further advantage: GEA Westfalia 

Separator Group has been able to reduce the delivery time for 

the eco generation to less than three months. 

Extended shelf life of at least 21 days 

Various processes are used in practice for producing ESL milk, 

ranging from steam injection right through to microfiltration. 

The prolong method is a noteworthy alternative in this respect, 

as the positive characteristics of fresh milk are retained in 

this method. For this purpose, two bacteria removal separators 

are installed upstream of the separator and the pasteurisation 

process in order to enable bacteria to be removed efficiently 

from the complete milk flow. prolong offers the benefits of 

lower investment and operating costs, it can easily be 

implemented in existing installations, provides a high bacteria 

removal efficiency and in particular does not require any 

additional heat or cream treatment. With prolong, fresh milk 

with an extended shelf life of at least 21 days can be produced. 

High-performance efficiency and perfect reliability are 

guaranteed by the new ecoforce decanter series with 2-phase 

and 3-phase separating technology and an integrated 

GEA Westfalia Separator summationdrive for dairy 

technology: the best features from 50 years of decanter design. 

At Anuga FoodTec 2012, it is possible for all these innovations 

to be inspected in a compact timescale. Very recommendable. 

Christian Frahm 

15


16 

gea Westfalia 

separator prolong 

the synonyM 

for the 

extension of 

enjoyMent

Moderate extension 

of the shelf life of Milk 

for Moderate Costs 


17


18 

prolong 

is a significant 

alternative 

to the 

production 

of esl milk 

If all recommendations of 

GEA Westfalia Separator Group are 

followed, prolong can attain a 

shelf life of 21 plus x days for fresh 

milk if the overall installation is 

designed appropriately, thus 

providing the most elegant 

solution for producing extended 

shelf life milk. 

A technology with a strong 

chance of achieving maximum 

acceptance among dairies, 

particularly because the 

positive characteristics of 

fresh milk are retained. This is 

also the view of dairies in 

Europe, and they are planning 

the specific implementation 

of initial projects for the 

first half of 2012. 

One project was successfully completed in Southern Europe in 2011. A Greek 

dairy was able to benefit from the use of prolong in the production of milk 

with various fat contents. 

For various Greek producers as well as for consumers, the shelf life of fresh 

milk which is produced, and which in Greece has so far been only approximately 

seven days, is not sufficient. By way of comparison, milk in Germany has a 

minimum shelf life of ten days. Only by subjecting milk to ultra-high 

temperature processing has it been possible so far to achieve such an extended 

shelf life. However, this process results in the loss of valuable components of 

the milk, and there is a significantly negative impact on the fresh taste. The 

aim therefore, for instance in Greece, is to enable fresh milk to be supplied 

with a shelf life of more than ten days (possibly even fifteen days) and also not 

to use the conventional processes for producing ESL milk in which the milk is 

additionally subjected to heat treatment or undergoes microfiltration. In order 

to ensure that the costs remain moderate, the solution should where possible 

continue to use the existing equipment of skimming separators and 

pasteurisation. 

The most elegant solution: prolong 

After many years of intense deliberations concerning this challenge, a decision 

was taken in Greece to use the most elegant solution which was presented 

by GEA Westfalia Separator Hellas with the support of GEA TDS Greece and 

the Business Line Dairy Technology of GEA Westfalia Separator Group: the 

prolong process. For this purpose, two bacteria removal separators of the type 

CSE were integrated in the existing pasteurising line of the Greek customer in 

the summer of 2011. 

This customer uses the traditional process of making fresh milk, and pumps 

the raw milk which is to be processed from a buffer tank, which stores the raw 

milk to enable air inclusions to escape, to the pre-heater, where the milk is 

heated to a separating temperature of around 55° Celsius. The milk is then 

forwarded to the skimming separator, where the raw milk is separated into 

skim milk and cream. Some of the cream is subsequently recycled back into 

the skim milk in order to obtain a product with a standard fat content. 

Following this standardisation process, the milk is held at a temperature of 

76° Celsius for between 15 and max. 30 seconds in order to be pasteurised. The 

milk is then buffered and packed into milk cartons.

Bacteria removed from the entire milk 

In order to achieve the defined aim of extended shelf life milk, 

the prolong process installs two bacteria removal separators 

with hourly capacities of 20,000 litres per hour upstream of 

the skimmer and the pasteurising process in order to efficiently 

remove bacteria from the entire milk flow. With prolong, the 

spores which have a negative impact on the shelf life are 

removed from the milk by means of centrifugal force and are 

discharged discontinuously from the bowl. The special feature 

of this process is that bacteria are removed in reality from 

the entire milk, i.e. the skim milk and the cream, whereas, 

in other processes, only the skim milk or at best the 

standardised milk is treated. GEA Westfalia Separator Group 

deliberately emphasises complete bacteria removal from the 

whole milk, as early as possible in the process. This means 

that bacteria have already been reliably removed from the 

excess cream which is used elsewhere in the process. This is a 

much more reliable solution. Compared with heat treatment, 

mechanical separation also provides a further benefit in 

addition to avoiding problems caused by heat. The spores 

are removed quantitatively from the product and are not 

merely inactivated. 

Fresh premium milk 

The initial bacteria count of the raw milk (total bacteria count) 

was around one million per millilitre. prolong enables this 

figure to be reduced by 99 percent. The relatively high 

incidence of Bacillus Cereus (approximately 100 spores per 

millilitre) is also reduced below the relevant limit (one spore 

per millilitre). These reductions are guaranteed by the high 

separating rate of the separators, whilst maintaining the 

valuable milk components. In the final analysis, they are 

crucial for the reliable extension of the shelf life of the milk to 

a minimum of 15 days in Greece. With prolong, dairies are 

now able to produce a fresh premium milk which has an 

extended shelf life compared with the previous shelf life. They 

are thus able to achieve a much better positioning in the retail 

chains and improve the organisation of distribution. They 

thus enjoy a comparative advantage compared with their 

competitors. In addition, the bowls of these separators have 


been equipped with the tried-and-tested GEA Westfalia 

Separator proplus system. This has considerably extended the 

discharge interval, i.e. the time between the bowl discharges. 

Low operating costs 

The costs of the process also play a welcome and not 

inconsiderable role in the decision-making process. It is 

necessary to consider not only the pure investment costs but 

also, and in particular, the operating costs. The prolong 

process does not involve additional costs for steam or hot 

water, and its power consumption is much lower than that of 

heat treatment or microfiltration. The familiar CIP cleaning 

process can also be carried out with the existing cleaning 

installations in conjunction with the pasteurising unit. For 

many dairies, this means that the desired moderate extension 

of shelf life can be achieved in conjunction with equally 

moderate costs. In the specific case of Greece, the very good 

cooperation between the parties involved ensured a short 

installation and commissioning time for the separators. It was 

possible to commence production of extended shelf life milk 

after two weeks. Other German, Austrian, Scandinavian and 

even Japanese dairies have now also become interested in 

prolong. For instance, an additional bacteria removal separator 

was recently also integrated in an existing pasteurising line in 

a dairy in Southern Germany. Several tests have established a 

minimum shelf life of 20 days for the milk which is produced 

in this way. If all recommendations are followed, prolong can 

attain a shelf life of 21 plus x days provided the installation is 

designed accordingly. 

Ralph Vennewald 

Area Sales Manager 



Phone +49 2522 77-1515 

ralph.vennewald@geagroup.com 

19

eVery thing 

is fine 

20

MaxiMuM deMands in 

terMs of hygiene and 

long operating tiMes 

21


in the butter making industry, 

there is a demand for modern 

procedures with which 

maximum hygiene 

standards and cost-efficient 

operation can be achieved. 

the design of a butter 

making installation is 

particularly important for 

meeting these requirements. 

As the heart of the butter making installation, the butter 

making machine BUE from GEA Westfalia Separator Group 

satisfies the most stringent requirements in terms of hygiene 

and sanitary design. Seven BUE machine types cover a 

performance range of 800 to 13,000 kilograms of finished 

butter per hour. Additives are continuously mixed with the 

butter stream by way of metering pumps with a flow monitor. 

The water content can be reliably determined by way of NIR 

(near infrared) or capacitor measuring elements on the butter 

making machine. This also means that it is easy to install an 

automatic subsequent addition facility. In conjunction with a 

water content measuring device, this means that it is nowadays 

possible for operating data to be consistently recorded from 

the control facility in modern butter making machines. 

Design of a butter making installation 

The butter silo installed downstream of the butter making 

machine with the necessary pumps for feeding the packing 

machines should be used only as a buffer in the event of 

problems or when paper has to be changed. Storing large 

volumes of unpacked butter leads to quality problems. With 

regard to the design of butter lines, it is necessary to consider 

cross sections and radii of the tube bends in order to minimise 

the pressures in the lines. The operating system should be 

placed directly next to the butter making machine. In this 

way, the operator on the machine receives all information 

concerning the environment and the product parameters, and 

can select the optimum adjustment on the machine. The 

installation in a butter making operation is cleaned nowadays 

with a special lye which contains a silicate content for 

minimising adhesion in the pipework or on the metal surfaces. 

This lye cannot be mixed with the conventional lye in dairies. 

22 

In order to minimise costs, GEA Westfalia Separator Group 

developed a reusable system several years ago. This system 

uses a chlorine-free cleaning concentrate. Before the lye 

cleaning process takes place, it is important to remove residual 

fats from the system by melting the residual butter with hot 

water. Adequate subsequent flushing with hot water to remove 

residual fat is an essential precondition before lye cleaning 

can be carried out. As a precaution therefore, dead spaces 

should be avoided at the planning stage of the installation in 

order to prevent residual fats in the pipework system. 

Storing unpacked fresh butter 

As butter making machines are constantly becoming larger, it 

is necessary for the butter to be distributed over several 

packing machines. Additional pipework is necessary for this 

purpose. This has accordingly resulted in a further processing 

stage in the chain between the butter making machine and 

the pack of butter. This has also increased the strain imposed 

on the butter. This was one of the reasons for the problem of 

layering and friable butter; quality problems have occurred. 

Depending on the arrangement used for the packing machines, 

the pipework has to cope with extremely high pressures of up 

to 12 bar. Because butter crystallises when it stands in a line, 

there may be a 1.5-fold increase in the pressure necessary to 

overcome the starting resistance, i.e. up to 18 bar. This has 

resulted in high shearing forces in the pumps and pipework. 

Accordingly, when the butter making technology is being 

designed, due attention should be given to pipework which is 

as short as possible, suitable cross sections, large-dimension 

bends and the nature of the surface in the lines, and 

crystallisation due to excessive contents in the silo should 

be avoided.

Extending operating times to 

up to 72 hours 

The certification by the USDA/FDA has resulted in the 

implementation of further hygiene requirements with which 

all butter making machines are equipped. These include 

design measures such as minimised seals, revised radii, 

sealing materials or surface quality. The purpose of generating 

a high vacuum is to minimise layering. Nowadays, butter 

making machines operate with large-dimension beaters, with 

a separating bowl for butter grains and buttermilk, a 

buttermilk recycling facility and a baffle plate in the churning 

cylinder II as well as a twin-stage texturiser with an integrated 

displacement pump. The process of recycling cooled 

buttermilk produces a cooler butter, which can be packed 

with fewer problems on the packing machines. Texturised 


buttermilk with butter granulate from the texturiser is 

recycled back into the separating bowl. This has resulted in a 

closed design for the machine. 

Butter making operations world-wide are nowadays able to 

benefit from all of these improvements, irrespective of the 

influence of the USDA/FDA. The optimisation of the hygienic 

design has resulted in a further major advantage, namely the 

extension of operating times to up to 72 hours. As a result of 

the cold-hot-cold procedure, the specific technologies and 

design features have resulted in a positive effect on the 

structure and spreadability of the butter, water distribution 

and binding as well as the yield. In technology terms, 

the BUE butter making machines from GEA Westfalia 

Separator Group achieve a fine water distribution of between 

3 and 4 µm as well as a buttermilk fat content of less than 

0.6 percent fat. 

Arnold Uphus 

Dipl.-Ing. 

Sales 

GEA Westfalia Separator Deutschland 

Phone +49 8321 6185442 

arnold.uphus@geagroup.com 

23


MilChWerke 

sChWaben are 

Modernising 

the butter 

Making proCess 

neW generation of the 

butter Making MaChine 

bue With optiMised driVe 

teChnology and fully 

hygieniC design 

Milchwerke Schwaben in Neu-Ulm are one of the first dairies 

in Germany to have commissioned a butter making machine of 

the new generation BUE from GEA Westfalia Separator Group. 

With this replacement investment, the co-operative dairy has 

succeeded in making a forward-looking investment with stateof-the-art 

technology for the butter making process in terms 

of quality, user-friendliness, operating costs and hygiene. 

24


25


broad range 

of Milk 

proCessing 

Milchwerke Schwaben were originally established in 1922, 

and are organised in the form of a co-operative. The 

approximately 1200 milk producers who daily supply around 

one million litres of milk in 15 tankers are also shareholders in 

the company. The catchment area for milk deliveries covers 

some areas of Bavaria and in particular Baden-Württemberg 

in the South of Germany. The headquarters of the dairy are to 

be found in Ulm (Baden-Württemberg), but the production 

facility itself is located on the other side of the Danube in the 

Bavarian town of Neu-Ulm. 13 May 1968 was the first time 

that the entire milk delivery was supplied to the (at that time) 

most modern dairy in Germany. 

The company nowadays produces fresh milk products, yoghurt, 

desserts, butter, semi-hard cheese as well as milk and whey 

powder. Some of the products are made in organic quality. 

Most of the products are destined for sale via retailers to the 

end consumer. However, fresh products are also made for 

large consumers. The company’s own brands are Weideglück, 

Donautaler (cheese with large holes) and Danubia. Slogan: 

“I know what’s in it!” 

Approximately two thirds of the milk delivered to the dairy is 

used for making cheese or recovering the resultant whey. 

Additional whey is also bought in from neighbouring dairies 

for further processing. With this wide range of products, 

Milchwerke Schwaben are one of the few dairies in Germany 

which, apart from soft cheese, are able to cover almost the 

entire range of milk processing. “This means that we are 

flexible and also to a certain extent independent of the dictate 

of the market” says plant manager Meinrad Schuler. The 

range of fresh products is sold throughout the whole of 

Germany, and is also exported within Europe; cheese, milk 

and whey powder are exported world-wide. 

26 

The control panel was designed 

to the needs of the Milchwerke 

Schwaben. “Control, visualization 

and operation are now on a 

totally different level, with faster 

and more detailed information. 

Operation today is significantly 

easier and more secure. There is 

simply no comparison.“

“ perfect. preparation 

on all sides was 

ideal. it couldn‘t 

be better. the 

machine virtually 

started at the touch 

of a button. ” 

Meinrad Schuler, Operations Manager 


Replacement investment results in 

state-of-the-art technology 

The butter making process has a tradition as long as that of 

cheese making at Weideglück. Old recipes are used for making 

Weideglück sweet cream butter and mild soured butter, which 

is obtained from the subsequent mild acidification of the 

sweet cream butter, as well as butter as a product for resale. 

The main criteria which are relevant for quality are the aroma, 

taste, consistency or spreadability, appearance and structure. 

Butter is packed exclusively in 250 gram packs for the end 

consumer. Every week, Milchwerke Schwaben produce around 

80 to 100 tonnes of butter. One of the corporate aims 

formulated by Milchwerke Schwaben, which nowadays are 

one of the top 50 companies in their sector, is the need to 

constantly improve the quality of products and services, to 

guarantee maximum reliability of the processes and also to 

achieve high cost effectiveness of the company in conjunction 

with sustainable operations. These principles were the 

main reason behind the investment in a new butter making 

installation. In 1985, Milchwerke Schwaben installed a 

BUD 5000 from GEA Westfalia Separator Group with a 

capacity of 6000 kilograms per hour. The latest technology is 

now to be installed. “Of course, we also looked at alternatives”, 

says Meinrad Schuler. “However, in the final analysis, we 

decided to use GEA Westfalia Separator Group clearly for 

quality considerations”, he emphasises. 

27


“higher produCtion reliability, 

siMpler operation, loWer 

operating Costs” 

At 6000 kilograms per hour, the capacity of the new butter 

making installation BUE 6000 is unchanged compared with 

its predecessor BUD 5000. However, this is the only aspect 

which has not been changed. During the 1980’s, there were no 

frequency converters; at that time, direct current machines 

or eddy current drives were state-of-the-art solutions for 

regulating speed. “The aim of the replacement investment 

was to utilise the new drive concepts, new technologies, 

improved controls and enhanced hygiene aspects”, explains 

the operations manager. “With this investment, we expect to 

achieve higher production reliability, simpler operation, lower 

operating costs and a further reduction of the bacteriological 

risks, guaranteed by an optimised design with regard to 

surface quality, radii of components, elimination of dead 

spaces and hygienic design. And of course also in line with 

the latest requirements of EU approvals and certifications.” 

With the BUE 6000, the cream is taken from the cream tanks 

to the churning cylinder 1, where the cream is whipped, 

resulting in butter grains and buttermilk. In the following 

cylinder 2, the buttermilk is separated from the butter 

granules, which become increasingly solid. The following 

twin-stage texturiser kneads the butter grains further and 

removes the remaining buttermilk. Water, salt or cultures are 

then added. The remaining air content of five to seven percent 

is removed in a vacuum chamber by means of a vacuum 

pump in order to avoid layers in the butter. 

28 

Simplified control, visualisation 

and operation 

In the previous installation, the control concept was spread 

over three PCs. In the new BUE 6000, the entire control 

system is concentrated on a colour touch screen which is 

mounted directly on the machine and which provides the 

operating personnel with all information in compact form 

concerning the entire butter making process from the cream 

silo, butter making machine, butter distribution facility and 

cleaning system and permits optimum access. The user 

interface has been customised to meet the specific needs of 

Milchwerke Schwaben. “Control, visualisation and operation 

are nowadays on an entirely different level, with more rapid 

and more extensive information. Operation nowadays is much 

simpler and more reliable. There is no comparison with the 

previous solution”, says Meinrad Schuler. “The process 

has also been optimised in terms of effluent volume and 

energy requirement. We are talking of reductions of between 

five and ten percent in terms of energy costs. This has also 

been achieved by optimising the entire line. The feed 

temperature to the machine via the cream pre-heating facility 

can now be regulated much more simply, and thus has a 

crucial influence on the butter making process and on 

energy savings. The technology for adding cultures or water 

has been modified; a so-called butter quantity computer 

uses the added volume of cream to determine the butter

quantity and define the amount of media to be added. This 

is a reliable method of avoiding excessive or insufficient 

additions of media. 

New cleaning concept 

The cleaning system has been changed in such a way that the 

remaining butter in the BUE machine is no longer melted 

with steam, and instead is now melted with hot water. Changes 

have also been made to the butter distribution facility; these 

changes enable residual butter in pipework to be melted with 

hot water without the need for manual intervention. The 

melted butter, together with the flushing water, is then used in 

another application. The two-fold buttermilk recycling facility 

has also been improved; buttermilk is used for cooling the 

butter granulate, and the texturized butter milk from the 

texturiser is recycled back into the machine. Small butter 

particles are recycled back into the process in this way. At 

Milchwerke Schwaben, the BUE 6000 normally operates for 

eight hours in production with three employees, then it 

changes over to the cleaning mode. In general however, it has 

an operating time of 72 hours. The process of removing the 

BUD 5000 and installing the new BUE 6000 including all 

pipework as well as the new cabling for all components was 

completed during a period of ten days when operation was 

interrupted. “Perfect”, was the comment of operations manager 

Meinrad Schuler. “This has been the result of optimum 

preparations from all quarters. We could not have done better. 

The machine started virtually at the push of a button.” 

Plans for new cheese making operation 

At present, Milchwerke Schwaben are working on setting up a 

new cheese making operation. GEA Westfalia Separator Group 

was awarded the contract for removing whey fines and whey 

skimming. This reflects the consistent continuation of the 

investment policy of making greater use of the quality of the 

machines and installations of the company. During the past 

three years, Milchwerke Schwaben have replaced existing 


OPTIMISED BUTTER MAKING 

PROCESS WITh BUE 

The process of separating milk results in skim milk on the one hand and 

cream with a fat content of 40 or more percent on the other. Some of the 

cream is used to standardise the skim milk to the standard fat content of 

1.5 or 3.5 percent. However, a certain amount of excess cream is left over. 

This cream can be used for making butter. For this purpose, following the 

pasteurisation process, the cream is ripened; during this process, the socalled 

cold-hot procedure is used in order to achieve optimum spreadability. 

After the cream has been pre-heated on its way from the cream silo 

to the butter making machine, the actual butter making process takes 

place; in physical terms, this is a phase reversal from an oil-in-water 

emulsion into a water-in-oil emulsion. The fat globules are broken down, 

the fat escapes, initially creates a butter grain and then the butter. This 

butter is kneaded, salt or cultures are added as required, the fat content 

is adjusted to the national legal requirements (e.g. to 82 percent in 

Germany), the butter is moulded and packed, and is stored in standard 

sizes or in 25 kg blocks. 

In parallel with the above, GEA Westfalia Separator Group has further 

developed the BUE butter making machines into a modular series. Major 

innovations in this respect are the fully hygienic design on the one hand 

and the design with frequency-controlled motors on the other. Milk is a 

natural product and, with the infinitely variable motors, the machine is 

able to adjust in an optimum manner to changing product conditions. A 

patented method also recirculates the buttermilk which is obtained and 

uses it specifically for cooling the butter granules. This reduces the cooling 

water requirement, and the cooler butter also permits an optimised 

packing process. 

machines with bacteria removal and skimming separators 

from GEA Westfalia Separator Group. Each of the three milk 

lines is now equipped with a 35,000 l / h bacteria removal 

separator as well as a skimming separator of the same capacity, 

each with proplus for protein maximising. 

Arnold Uphus 

29


separator 

suCCessfully deliVers 

first Milk 

pasteurising unit 

to latin aMeriCa 

30


Throughout the world, GEA Westfalia Separator Group is well-known and highly respected as 

a manufacturer of excellent high-performance centrifuges. The market share of separators 

from GEA Westfalia Separator Group in the relevant sectors is also considerable in the countries 

of Central and Southern America. However, the company also has more than 25 years of 

experience as a partner, producer and supplier of complete process installations comprising 

separators for the dairy industry. This is demonstrated by production lines mainly for butter 

and butter oil, which have been successfully used for many years at dairies in Latin America. 

Complete milk processing lines 

GEA Westfalia Separator Group has had milk and cream pasteurising installations in its 

programme for the past ten years. The system supplier has specialised in installations which 

are manufactured completely in the works and which require only minimum installation and 

commissioning work on the customers’ premises. 

Whereas in the beginning sales of this new product focused mainly on Eastern Europe, it has 

also been possible for customers to be signed up in other regions of the world in recent years. 

For instance, milk pasteurising lines have been sent to dairies in Turkey, Pakistan and Indonesia. 

Demand for milk and cream pasteurising installations is now also strengthening in Latin 

America. In Quito for instance, approx. 150,000 kg of raw milk every day is processed 

mainly into UHT milk. Following intensive advice provided by the relevant subsidiary of 

GEA Westfalia Separator Group and the Area Sales Manager, the company has now also signed 

up the first customer in Latin America for a pre-assembled milk pasteurising unit. Lechera 

Andina in Quito / Ecuador, a subsidiary of Leche Gloria from Peru, has decided to purchase an 

automated installation with a feed capacity of 15,000 l/h. 

Tried-and-tested and reliable components from a single source 

The self-cleaning type MSE 85 with a standardising capacity of 15,000 l / h is used as the 

skimming separator in this case; this machine is characterised by compact dimensions and a 

robust and maintenance-friendly design. A manual standardisation process is used for adjusting 

the fat content in the milk and cream. GEA Westfalia Separator Group can use not only its own 

separators but also tried-and-tested components of other subsidiaries of the GEA Group for 

production of the installation. The plate heat exchanger for the milk and also the components 

for hot water production are provided by GEA Ecoflex; pumps, valves and switching panels are 

provided by GEA Tuchenhagen. At GEA Westfalia Separator Group, the individual components 

are pre-assembled in the company’s own extensive plant construction facilities. This process 

comprised the installation of pipework as well as the design of the control unit, the wiring and 

pneumatic assembly. And finally, the installation is successfully tested in order to ensure that 

the commissioning period is minimised. 

User-friendly control and automatic cleaning 

A memory-programmable control facility and an operating and visualisation unit are used for 

automatic control of the pasteurising line. The operator starts the programs on a colour monitor 

with a touch screen, and measurements are displayed directly on the screen. The installation is 

also cleaned automatically, whereby the operator is able to enter all parameters such as times, 

temperatures and number of cleaning cycles as required. 

Wolfgang Gruchot 

Manager New Markets 



Phone +49 2522 77-1032 

wolfgang.gruchot@geagroup.com 

31


32 

optiMised 

requeijão 

produCtion 

produCtion and 

ConCentration of 

Cheese Curd froM 

skiM Milk by Means 

of deCanters


Whereas the Germans use butter, Brazilians or the Portuguese use Requeijão. This product is a 

cheese spread which is frequently used for refining food or as a spread. Requeijão can be found 

in every kitchen throughout the country, and is thus one of the most popular cheese products 

in Brazil. Requeijão can be produced from cow’s milk, goat’s milk or ewe’s milk. The Portuguese 

product has a relatively yellow-white colour, it is firm and generally has a characteristically 

strong taste; it is sold in special small baskets or in plastic tubs. The Brazilian equivalent 

product is white and is a type of cream cheese; however, it cannot be compared with our 

normal concept of cream cheese, and instead can better be described as “soft cheese”. It has a 

mild taste, and its consistency can vary between firm and creamy. Traditionally, the home of 

Requeijão has been in the Brazilian province of Minas Gerais, and today it is produced in the 

entire country. The most frequent version is Requeijão cremoso, with a very creamy consistency 

and usually sold in glass jars or plastic tubs. 

Excellent melting properties thanks to decanters 

In the traditional method of production, the curd is obtained from skim milk by means of 

rennet coagulation, agitation, heating with discharging of whey and the addition of hot water; 

it is filled into linen bags or cloths and pressed to a dry matter of 50 – 55 percent. After the 

pressing process, the “cheese block” is cut into small pieces, salt and cream are added, and the 

product is packed in portions. This “Requeijão raw mass” undergoes a cold ripening period of 

seven days, and is then melted in a container, with salt and/or spices being added. The product 

is then packaged while it is still hot. In previous trials, it has been established that the curd can 

readily be separated from the whey and concentrated by means of decanters, and therefore has 

excellent melting characteristics. In conjunction with the Central Process Engineering 

Department in Oelde (Zentrale Verfahrenstechnik – ZVT) and the Business Line Dairy Technology, 

GEA Westfalia Separator do Brasil has now succeeded in re-using this application which has 

existed for a long time and has again successfully carried out tests at a user. Then as now, the 

coagulated skim milk was concentrated directly from a dry matter of nine percent to a dry 

matter of 50 – 55 percent by means of a MCA 225 decanter, resulting in a “Requeijão raw mass” 

with perfect bacteriological properties and with uniform granulation. The “Requeijão raw mass” 

was then further processed as in the traditional process. 

Standardised and hygienically safe process 

The process of concentration with the decanter provides various advantages for the users: 

firstly, the process is standardised, with the consequence of minimal external influences and 

faults. Secondly, there is a reduction in the cheese mass losses in the whey and in the pressing 

process. And finally, the process overall is much more hygienic because manual work such as 

packaging and pressing are no longer applicable. On the basis of the test results and process 

engineering advantages, GEA Westfalia Separator do Brasil received the first order for an 

MCE 305 decanter in this very promising market segment in January 2012. With this 

technological break-through, the cheese-making industry can make long-term use of the knowhow 

for simplifying and successfully concentrating the Requeijão curd. Fans of Requeijão in 

Brazil and Portugal can look forward to receiving continuously constant quality. And it is 

possible that this type of cream cheese/cheese spread production will also find friends in other 

countries in the world as an extension of tastes in the cheese product portfolio. 

Thomas Veer 

Product Engineer 

Dairy Technology 

GEA Westfalia Separator do Brasil 

Phone +55 19 3725-3157 

thomas.veer@geagroup.com 

33


Pakistan is the fourth largest milk producer in the world, with around 

45 million tonnes milk p.a., with a sharply rising trend. The dairy industry 

is a very important component of the Pakistani economy. 

The value of milk alone exceeds the total value of wheat, rice, 

corn and sugar cane of the country. Buffalo milk accounts for 

two thirds of all milk. It is still the case that by far the most 

significant percentage of milk is consumed directly by the 

estimated eight million small farms and their immediate 

surroundings. However, industrial processing is increasing 

rapidly, and thus requires well trained specialists. In order to 

improve the practical training of the dairy engineers, the 

University of Veterinary and Animal Sciences in Lahore 

ordered installation components for a new training dairy 

from GEA Westfalia Separator Middle East in Dubai via its 

Pakistani agent International Traders. 

Cultural centre of the country 

With approximately nine million inhabitants, Lahore is the 

capital of the Punjab, and is the second largest city in Pakistan; 

it is also the undisputed cultural centre of the country. As the 

34 

former capital of the Mogul empire, the city has a wide range 

of historical locations. Lahore is also the city of Pakistan with 

by far the most extensive range of educational services at 

more than 15 universities and approximately 40 colleges. The 

distinguished University of Veterinary and Animal Sciences 

was established in 1882, and is currently providing training to 

more than 3000 students in five faculties as vets, pharmacists, 

biotechnology and biochemistry scientists as well as engineers 

for the production of animal feed, etc. 

Components from the diverse portfolio 

of the GEA Group 

A major advantage was that the portfolio of the GEA Group 

was able to supply by far the majority of the components: 

pumps, valves and switching panels were supplied by 

GEA Tuchenhagen, the plate heat exchangers came from

praCtiCal training 

for pakistani 

dairy engineers 

dairy teChnology of gea Westfalia 

separator for uniVersity in lahore 

GEA Ecoflex and the homogeniser was delivered by GEA Niro 

Soavi. Assembly work in Lahore was organised using local 

labour by international traders with a high degree of 

professionality; GEA Westfalia Separator Middle East was 

responsible for commissioning the installation. With the new 

training dairy and the equipment of the GEA Group, the dairy 

engineers can now receive even better preparation for their 

career in Pakistan’s dairy industry. 

Wolfgang Gruchot 


froM raW Milk 

deliVery to the 

Cip installation 

GEA Westfalia Separator Group has supplied a wide range of 

equipment for the new training dairy: 

• A raw milk delivery facility with a capacity of 5000 litres per hour 

with strainers and raw milk coolers. 

• Equipment for a raw milk tank with a capacity of 5000 litres; 

the tank itself was made in Pakistan. 

• A milk pasteurising unit with a capacity of 2000 litres per hour. 

• The heart of the installation is a skimming separator MSE 25, 

the smallest self-cleaning milk separator from GEA Westfalia 

Separator Group. 

• A high pressure homogeniser ONE 11 TS from GEA Niro Soavi 

also formed part of the delivery. 

• Equipment for a multi-purpose tank with a capacity of 1500 

litres; this tank is used for storing pasteurised milk and also 

for producing recombined milk. This includes a powder mixer 

as well as a combined plate heat exchanger for heating and 

cooling the milk. 

• A 3-tank CIP installation for cleaning the entire system. 

• A switching cabinet with a touch-screen monitor for 

operating the installation. 

35


36 

China 

Central 

aMeriCa 

China 

Central aMeriCa 

south afriCa

south 

afriCa 


fostering 

Closeness to the 

CustoMer 

GEA Westfalia Separator Group fosters closeness to its customers 

through its idea of BestPractices dairy seminars. The idea is to bring 

the latest state-of-the-art dairy technology to dairy specialists in 

their own home country, in the form of a two-day seminar. And this 

does not mean merely the latest GEA Westfalia Separator Group 

developments, it also means advancements in other aspects of dairy 

technology. At the same time, the invited specialists are given 

valuable information by external speakers on each of the markets. 

The Chinese dairy industry, for example, is still in its infancy, but is 

already significantly larger than established dairy countries. China 

was one of the focus countries in the BestPractices dairy seminars 

last year. Seminars also stopped off in South Africa and in Costa Rica 

for the Central America region. The pages which follow contain 

detailed reports. 

BestpraCtiCes 

dairy 

37


exCiting 

Milk Market in China 

first BestpraCtiCes dairy seMinar in China 

38 

China 

As China has the largest population in the world, 

the country is of interest for every branch of industry 

in general, naturally for the dairy industry as well. 

In 2008, about 14 million dairy cows in China 

produced 34 million tons of milk – at a growth of 

10 to 15 percent a year. 

Although lactose intolerance is widespread in China, it is considered safe to 

assume that the demand for milk will increase drastically in the future. This 

increase is due to the continuously improving economic situation, a more 

sustainable distribution of milk products and growing health consciousness, 

and last not least the massive support of milk consumption by the government. 

The melamine scandal in 2008 disturbed the trust of consumers in Chinese 

milk products and in powdered milk for babies in particular, but in 2010 the 

signs for the Chinese milk market are back to green again. 

Sixty high-calibre decision makers of the 

upper management level 

The first BestPractices dairy seminar in China was organised by GEA Westfalia 

Separator Group at the seaport of Xiamen in the southern coastal province of 

Fuijan in the middle of 2011. About sixty high-calibre decision makers of the 

top management level from twenty-three different dairy companies participated 

in the seminar. Among others the following dairies were represented: Yili, 

Mengniu, Bright Dairy, Wondersun, Sanyuan, Want Want, Danone, Beingmate, 

Wyeth, Wahaha and other well-known companies. The GEA Group presented 

itself with speakers from four affiliated companies and two segments: 

GEA Process Engineering as well as GEA Westfalia Separator Group, GEA Niro 

Soavi and GEA Tuchenhagen from the GEA Mechanical Equipment segment. 

The guest speaker was Song Kungang, the Managing Director of the Chinese 

Dairy Association, speaking about the situation of the Chinese dairy industry 

after the clean-up in the aftermath of the melamine scandal. 

Per capita consumption still differs 

The biggest dairies (Mengniu and Yili in particular) are located in Inner 

Mongolia. Mengniu and Yili are the market leaders in the Chinese dairy 

market with a market share of just under 70 percent. According to the figures 

of the Rabobank, Mengniu produces about 3.3 million tons per year and Yili 

Dairy follows with 2.7 million tonnes per year. It is noteworthy that the two 

large Chinese dairy factories mentioned were already amongst the twenty 

largest dairies in the world in 2009 already, ranking 16 th and 17 th , at a turnover 

in 2009 of 2.69 billion Euro and 2.53 billion Euro respectively. Mengniu itself 

also sees a giant potential for the dairies in China because the consumption of 

drinking milk per head and year is still distinctly below the average consumption

worldwide. It is about 25 kilograms per head and year, whereas 

the world-wide average is about 100 kilograms per year, and 

the consumption of the developed industrialised countries is 

even around 300 kilograms per head and year. 

Fifty-seven percent of the 1.34 billion people in China still live 

in the country, and 43 percent live in cities. But, 90 percent of 

the dairy products are purchased by the urban population 

whereby Shanghai is the capital of Chinese milk consumption: 

more than 50 kilograms per year and head are consumed 

there – double the quantity of the average consumption 

in China. 

Improvement of the quality of 

dairy products 

Although China – after the USA and India – is one of the 

largest milk producers in the world already, milk and dairy 

products are not part of the typical Chinese shopping basket. 

These products are still considered western and expensive but 

healthy products. The melamine scandal in 2008 has 

consolidated the Chinese dairy market to such an extent that 

larger as well as smaller dairies which could not compensate 

the financial losses at this time, had to leave the market or 

have been taken over by larger dairies. After the melamine 

scandal, the Chinese government cracked down on the market. 

The food control authorities examined all 1176 dairies again 

Around 60 high-calibre decision makers of the upper management 

level from 23 different dairy companies participated in the first 

BestPractices dairy seminar China of GEA Westfalia Separator Group 

at the seaport of Xiamen in mid-2011. 


last year. The licences of 426 smaller dairies were taken away, 

another 107 were requested to carry out process improvements 

within a certain period of time. In 2008 before the melamine 

scandal, there were about 2000 dairies in the market. At the 

time 40 percent of the dairies had to leave the market. In 2012 

also the dairies will be checked with an increased number of 

state food controllers so that the trust returns to the ultimate 

consumers due to the increased quality, which has caused a 

further growth in the Chinese dairy industry. 

Chances for cream cheese 

At present, the Chinese dairy portfolio is still limited to 

drinking milk, UHT milk, yoghurt, powdered milk (together 

about 95 percent) and some butter oil. The demand for butter 

is relatively large in China, but most butter is still imported 

from Australia or New Zealand. A new chance is offered by 

cream cheese and/or strained yoghurt, Labneh and Petit 

Suisse. Compared to the well-known yoghurt, these cream 

cheese products have a better nutritional value and should 

develop into a good alternative. As soon as dairy products 

have established in China more and more, a large demand 

will arise for a wider range of dairy products. The current raw 

milk production is continuing to increase in China – even 

after the melamine scandal. The production of drinking milk 

made of raw milk increased by 20 percent between 2007 and 

2009 alone, which underlines the growing acceptance of 

drinking milk in China. 

There will be no stopping the demand for 

dairy products for a long period of time 

The gigantic population of 1.34 billion inhabitants gives more 

than an idea of the potential in the Chinese dairy market. The 

figures show that the Chinese dairy markets are still in their 

infancy, but nonetheless they are distinctly larger than in any 

other established dairy countries. The large dairies, such as 

Mengniu and Yili, especially are able now already to use 

advanced technology in process technique. Nonetheless, the 

smaller and medium-sized dairies, which participate in the 

market with a share of two to three percent at present, are 

relatively large in absolute figures. For them, for example, the 

separators of the GEA Westfalia Separator eco family 

generation are the perfect choice. 

As soon as the Chinese consumers have got used to milk more 

and more and the trust in the national dairy industry has 

been regained completely as well as the interest in other dairy 

products, such as drinking milk, increases, there is no way of 

stopping the demand for dairy products. 

Ralph Vennewald 

39


Meeting of 

dairy teChnology 

experts 

in Costa riCa 

first BestpraCtiCes dairy 

seMinar for the region 

of Central aMeriCa 

Central America, Mexico and Venezuela in focus: the bestPractices dairy 

no.1 seminar from 21 to 23 November 2011 in San José, Costa Rica, 

attracted strong interest from the Central American dairy industry. 

Eric Palacios-Macedo, Managing Director of GEA Westfalia Separator 

Mexicana, S.A. de C.V. and Christian Frahm, head of the Business Line 

Dairy Technology welcomed approximately 40 guests from the dairy industry. 

The decision makers from the respective Boards as well as the line 

functions production, engineering and maintenance were given 

concentrated information on new developments of GEA Westfalia 

Separator Group and the GEA Group. 

40 

The first BestPractices seminar dairy no. 1 Costa Rica of GEA Westfalia 

Separator Group for the dairy industry in the region of Central America 

was very well received by the participants and will be repeated at 

regular intervals.

The meeting communicated to the experts the synergy effects 

resulting from utilizing the overall skills within the Group 

structure of the GEA Group. For instance, GEA Niro Soavi also 

presented itself with BestPractices examples from the field of 

homogenisation, and GEA Process Engineering presented 

itself with solutions from drying technology, membrane 

technology and information concerning modern project 

management. The product range of pumps and valves of 

GEA Tuchenhagen and the related areas of application were 

also presented. 

Multiplying benefits 

“We wish to provide information concerning the technology 

and market leadership of the GEA Group as a systems provider 

for the production of your dairy products, we also wish to 

share our know-how with you and multiply the benefit”, 

emphasised Iloi Wasen, Sales Manager Latin America, 

Dairy of GEA Westfalia Separator do Brasil, at the 

beginning of the speeches. With its engineering services, 

GEA Mechanical Equipment, which apart from GEA Westfalia 

Separator Group also comprises GEA Tuchen hagen and 

GEA Niro Soavi, creates the essential conditions for technical 

implementation of the latest trends in the field of dairy 

technology. In particular, the examples of best practice 

applications demonstrated exciting future possibilities for the 

development of the Central American dairy industry from the 

point of view of the guests. For instance, the speech concerning 

the production and potential of cream cheese encountered the 

same strong interest as the speeches concerning the processing 

of whey or the production of long-life milk. 

Overview of the Costa Rican milk market 

A further highlight of the seminar was an overview of the 

Costa Rican co-operative dairy, “Cooperativa de Productores 

de Leche Dos Pinos R.L.”, which was presented by Francisco 

Arias C., economist and consultant for marketing policy of the 

dairy. Supplying approximately 400 million tonnes of milk 

annually (equivalent to approximately 85 percent of 

industrially processed raw milk), Dos Pinos is by far the 

largest dairy in Costa Rica, and is one of the largest in the 

region of Central America. The areas of activity of the 

company are limited not only to processing raw milk into the 

various dairy products such as milk, cheese or sour milk 

products and ice cream; they also comprise an entire network 

of agro-industrial areas such as the production of animal feed, 

cattle breeding and milk production, automated milking 

parlours, milk collection and milk collection points. Dos Pinos 

is actively involved in environmental protection with various 

programmes. For instance, product packagings are collected 

Eric Palacios-Macedo 

Managing Director 

GEA Westfalia Separator Mexicana 

Phone +52 777 3201088 

eric.palacios-macedo@geagroup.com 


and recycled throughout the country, effluent is treated and 

compost fertiliser is obtained, and measures for carbonneutral 

production are being introduced. The importance of 

the reliable production of high quality and innovative products 

is demonstrated by the list of markets supplied by Dos Pinos, 

namely the countries of Central America including the 

Caribbean countries as well as Mexico, Venezuela, Chile, 

Algeria, Senegal, Namibia, Vietnam and China. In this 

connection, Francisco Arias again particularly emphasised 

the significance of a technology supplier with international 

operations such as the GEA Group. The first seminar 

BestPractices dairy no.1 Costa Rica of GEA Westfalia Separator 

Group for the dairy industry in the region of Central America 

was very well received by the participants, and will again be 

held in the future at regular intervals. The concept had also 

previously been successfully carried out in South America, 

where two similar events have already been held in Brazil 

(2006 and 2009) and one similar event has already been held 

in Lima, Peru, (2008). 

Central 

aMeriCa 

41


rooM for expansion 

on Milk Market 

in south afriCa 

first BestpraCtiCes dairy seMinar 

in johannesburg and Cape toWn 

Relatively constant milk market 

Milk production in South Africa is relatively constant at approximately 

2.7 tonnes per year from somewhat more than 500,000 dairy cows. The per 

capita consumption of the 50 million inhabitants of South Africa is 

approximately 55 litres. Fresh milk enjoys overriding priority in production in 

the dairies, with approximately 1.27 million tonnes in 2010. This is followed in 

second place by fermented milk products with approximately 300,000 tonnes; 

cream, butter and butter oil, cheese, milk and whey powder are currently 

somewhat less significant. Among the producers, there is a continuing trend 

towards a smaller number of larger farms. There are now around 2600 large 

agricultural operations which produce milk. In the market, demand for milk 

products is rising, although this is primarily due to lower prices; the supply of 

milk is proving to be very price-sensitive, driven mainly by the discounters. 

The global economic crisis hit South Africa very hard, although a recovery 

started at the end of 2009, and continued in 2010 and 2011. This resulted in 

positive economic growth, slightly higher incomes and lower interest rates. Nevertheless, 

unemployment numbers continue to be high and are depressing demand. 

On the supply side, the two dairy companies Clover SA and Parmalat are the 

market leaders, and together account for almost 50 percent of the overall 

market. Woodlands, Dairybelle and Nestlé process much less raw milk, but 

have also established a presence with their products throughout the entire 

country. There is also a large number of mid-size and small regional dairies 

and cheese making operations, particularly in the region of Cape Town, which 

produce their own specialities. For instance, the sour milk drink Amasi, which 

is popular in the region. Liquid milk products are dominated by cooled, 

pasteurised fresh milk, followed by ESL milk and the long shelf life UHT-milk. 

The market share of extended shelf life milk (ESL) is rising constantly and, 

similar to the situation in Germany, this product is increasingly superseding 

pasteurised milk which has a shelf life of only a few days. Demand is not as 

strong for yoghurt, buttermilk and milk-mixed drinks. 

GEA Group present in Midrand 

At the BestPractices dairy seminar in Johannesburg and Cape Town, the 

participants were initially provided with an overview of current and regional 

trends in the milk market, linked with local success stories, by Alwyn 

Kraamwinkel, director of SAMPRO. A major advantage for dairy customers in 

South Africa is the presence of several subsidiaries of the GEA Group, who 

share a building in Midrand near Johannesburg. This is also the home of the 

Service Centre Africa which provides support for South Africa as well as the 

markets in Tanzania and Kenya in East Africa and also Nigeria. Accordingly, 

not only employees of GEA Westfalia Separator Group were able to show the 

42 

south 

afriCa


South Africa was a further station of the bestPractices dairy seminar series of 

the GEA Westfalia Separator Group. More than 60 participants from South 

Africa and East Africa attended the two-day programme which focused on the 

milk market and particularly on milk processing in the dairies. Because of the 

size of the country, GEA Westfalia Separator Group held the seminar in 

Johannesburg and also in Cape Town in mid-2011. 

latest findings with regard to separation, bacteria removal and 

clarification of milk and whey; the affiliated companies were 

also able to present their latest developments to the trade 

public. For instance GEA Farm Technologies for milking 

installations, GEA Process Engineering for milk acceptance, 

complete UHT lines and packaging installations or GEA Niro 

Soavi for homogenisers. This rounded off the picture that the 

GEA Group is able to offer all products and services for the 

milk industry, ranging from initial milk acceptance right 

through to packaging. 

Presentation of the new eco generation 

In the first speech in this series, GEA Farm Technologies 

spoke about the opportunities for optimising milk production 

on the farm. When certain standards of milking hygiene are 

complied with on the farm, there is a corresponding 

improvement in the quality of the raw milk. 

With its presentation, GEA Westfalia Separator Group then 

concentrated on the self-cleaning separators of the new 

eco generation for clarification, separation and bacteria 

removal, the development of which has also enabled 

operations with installations for small to mid-size volumes to 

benefit from the process engineering skills and innovative 

ability. This part of the speech focused on “modern dairy 

equipment”, and also considered the benefits of the integrated 

direct drive on separators, the standardisation of milk fat 

contents, pumps, valves and the butter making process as well 

as homogenisation of milk. GEA Niro Soavi also provided 

contributions for this particular field. The second day 

concentrated on processes, and informed the participants of 

the various ESL and UHT milk procedures, and provided 

room for discussions of the advantages and disadvantages of 

the various process opportunities as well as the market 

opportunities which are available. A further focus was the 

production of soft cheese and the production of double cream 

cheese. Procedures which in South Africa have so far not been 

very well known, with the exception of a small number 

of producers. 

A member of staff from GEA Refrigeration Technologies 

segment demonstrated a concept of how the energy systems 

of an entire dairy can be optimised, by using the heat energy 

required for heating the milk for other processes and also 

using the cooling energy of the milk which is cold when it is 

delivered, thus creating a balance of energy in the dairy. This 

recycling principle has been supported by various references, 

in which energy savings of up to 50 percent have been 

achieved. And finally, the Service Centre Africa also presented 

its service concepts for boosting the machine availability for 

the installations of the GEA Group. 

Soft cheese tasting 

A highlight of the BestPractices dairy seminar was a tasting 

session for soft cheese from Germany. Participants were 

able to sample several products and get to know the various 

tastes and marketing opportunities. The GEA Group also 

combined the presentation of the new ecocream separator 

from GEA Westfalia Separator Group with a small exhibition 

of machines, in which the separator, a homogeniser, a milking 

installation as well as pumps and valves were seen working. 

The first BestPractices dairy seminar in South Africa thus 

enabled many participants to gain entirely new experience 

with modern dairy processes and technologies. 

A highlight of the BestPractises dairy seminar was a tasting session for 

soft cheese from Germany. 

Sebastian Kubitza 

Area Sales Manager 



Phone +49 2522 77-1666 

sebastian.kubitza@geagroup.com 

43


the Cradle 

of Chinese 

breWery 

training 

breWing teChnology 

aCadeMy Wuhan 

44 

“Greetings from Wuhan, where 

separator has arrived today. The 

entire school was very excited about 

this,” wrote teacher and secretary 

Wang Feng Song in May 2011. The 

school is the Brewing Technology 

Academy of Wuhan. And said 

separator was sent by GEA Westfalia 

Separator Group as a sponsoring 

measure for the testing facility.


45

Wuhan is a very popular town in the middle of China and is an important transportation hub 

for nine provinces. For more than a thousand years, the favorable geographic position has 

promoted an economic and cultural upswing, which allowed Wuhan to become the center for 

economics and education in central China. On the South Sea in the district of Wuchang lies the 

educational center of Wuhan with a young and modern school – the Brewery College of Hubei. 

It maintains a certain style and can be considered the cradle of Chinese brewing professionals. 

The entire educational facility currently has 6400 students, 1310 of which are brewers. In total, 

around 7500 students have graduated from the brewery division over the years. They are 

scattered throughout all of China, many in senior positions. Every year, around 300 brewers 

and brewmasters complete their training, which is instructed by 35 teachers. 

The German dual training system adopted 

The school was established by the former Ministry of Light Industry of the People’s Republic 

of China in collaboration with the German Hanns-Seidel Foundation in Munich. With the 

approval from the provincial government of Hubei, the educational center is now a joint venture 

between China and Germany as an institute for higher professional education. Since 1988, the 

school’s objective has been to train qualified specialists for the brewing and beverage industry. 

Training of the brewers and malsters began in the same year. The brewmaster training was 

added in 1992. Both forms of training are very successful. The academy has adopted the German 

dual training system and imported modern equipment from Germany. This means that the 

students spend half of their studies in various breweries as internships. Through the practical 

training in the workplace and the theoretical training in school, the students are capable of 

being employed at a brewery without any additional training in the workplace. It was shown 

that the breweries are very satisfied with the employees trained in this way. 

46

sinCe 2007, 


separator has 

kept Close 

ContaCt With 

the breWing 

teChnology 

aCadeMy 

of Wuhan. 

The training facility is currently attended by 6400 students, 

of whom 1310 are brewers. Approximately 300 brewers and 

brewmasters, having been taught by 35 staff, complete their 

training each year. 

Collaboration Will 

be intensified 

Following initial contact with the technical brewing 

academy in 2007, collaboration with GEA Westfalia 

Separator Group will now be intensified. This year, a 

delegation took part in a technical brewing conference. 

In the future, GEA Westfalia Separator Group will 

participate more strongly in seminars and support them 

with lectures. Wuhan is China’s resource for brewing 

expertise. 


First-class facilities 

The school has a developed area of 70,000 square meters with 

teaching buildings, well-equipped laboratory buildings, student 

dormitories, a library, an auditorium, a teaching brewery and 

classrooms with multimedia, a language laboratory, an ale 

house and a playing field. 

The students receive a diploma and a master craftsman’s 

certificate. After training, they can begin additional training 

in Germany, complete a postgraduate course or work in actual 

operations. The school maintains contact with a total of six 

educational institutes, such as the TU Munich Weihenstephan 

and the Doemens Technikum, and with over 20 international 

companies. Foreign experts are regularly invited for seminars 

and scientific exchanges. Since 2008, the academy, in 

cooperation with a Chinese university and the TU Munich 

Weihenstephan, has offered the degree “Brewing and Beverage 

Technology.” Since 2010, Wuhan has been working together 

with the Doemens Technical Academy and has been training 

production managers for brewing and beverage technology. 

Teaching brewery and research station 

The teaching brewery is primarily equipped with machines 

and equipment of German origin. On the one hand, it 

serves as a training center for the students, where they can 

broaden and expand their technical knowledge gained 

in the classroom. On the other hand, it is the center for 

practical training for brewery employees. The brewery college 

also has a state-approved research station, which creates 

analyses for the brewing industry at the highest level. With its 

own yeast propagation, the brewery college can, depending 

on the requirements of the breweries, offer various yeast 

strains from top-fermenting and bottom-fermenting yeasts 

to dry yeasts. 

The objective of the brewery college is the promotion of 

vocational training and education for the brewing industry. In 

recent years, the school has not only trained numerous 

qualified brewers and brewmasters for the brewing industry, 

but has also carried out well over a hundred different seminars 

and training sessions. The large number of seminar 

participants has strengthened the school’s good reputation in 

the brewing industry. 

Andreas Warneke 

Product Manager Beer 

Business Line Beverage Technology 


Phone +49 2522 77-5067 

andreas.warneke@geagroup.com 

47


48


Mang 

Mango 

deCanters optiMise 

quality in Mango purÉe 

produCtion 

49

there is inCreasing 

deMand for Mango 

purÉe to be used in 

fruit juiCes, sMoothies 

and food – partiCularly 

in southeast asia and 

north aMeriCa. 

The resultant increase in export activities in the producer 

countries required higher processing quality. This in turn was 

achieved by gradually changing over from the traditional 

canning process and instead using an aseptic method. In both 

cases, decanters can be used to treat the purée and remove the 

brown and black specs. Particularly in recent times, more 

and more manufacturers of mango purée are experiencing 

the benefits of the 2-phase decanter GCE 305 of GEA Westfalia 

Separator Group. 

India leads in terms of processing 

India is the largest producer of mangos in the world, followed 

by Mexico and Columbia, and is simultaneously the largest 

consumer. Almost half of the world-wide mango harvest 

comes from the Indian subcontinent. Most mangos are 

consumed in the form of fresh fruit, and only a very small 

percentage has been used in industrial production until now. 

Nevertheless, India also leads the way by a considerable extent 

in the field of processing the fruit into mango purée. In 2010, 

India produced 312 million tonnes, followed by Mexico in 

second place with 83 million tonnes. Of the 728 million tonnes 

of mango purée produced world-wide, approximately half is 

consumed in Asia, one quarter is consumed in North and 

South America, of which somewhat more than 104 million 

tonnes are consumed in India, followed in volume terms by 

30 million tonnes in Mexico. 

Traditionally, mango has been processed into purée in India 

by using large knives, after the ripening and washing 

processes, to manually cut up and de-stone the fresh fruit, 

which is then puréed in a sieving machine and is then heated. 

After this pre-treatment, the decanter starts its treatment 

work. The pulp is then packaged either hot, e.g. in cans, or 

aseptically. Export demand has been calling for the filling 

process to be modernised, and this has resulted in the 

increasing introduction of aseptic packaging lines, which 

admittedly should be available at low cost. The mango purée 

is packaged in 220-kilogram sacks in drums or 20-kilogram 

sacks in boxes. 

50 

Reliable removal of brown and 

black specs 

The most popular mango type Totapuri is affected by socalled 

brown specs and black specs particularly towards the 

end of the ripening period, when monsoon rains result in 

high levels of humidity in the plantations. The black specs are 

caused by insects known as “mango stem weevil”, and the 

brown specs are splits on the skin of the mango stone. These 

specs have to be removed in the production process. This is 

the reason why decanters are used after the pre-heating 

process. Black specs are heavier than the mango pulp and can 

therefore easily be removed by centrifugal means; the 

problem is somewhat more difficult in the case of brown 

specs. International quality standards require a maximum of 

five specs per ten grams of finished pulp. The market value of 

the pulp depends on the number of specs. This issue of brown 

and black specs becomes more pronounced if the finished 

product is mango pulp concentrate of 28 Brix as compared to 

regular pulp of 14 brix. The purée from the widespread and 

high-quality variety “Alphonso” is passed as well over the 

decanter in order to guarantee the absence of any particle 

impurity. The decanter is also used for processing of guava, 

papaya and other fruits.

Numerous tests carried out in a 48-hour continuous test with 

2.7 to 3.0 tonnes per hour and practical experience gained with 

the GCE 305 decanter have shown that it is possible to reduce 

the specs by 95 to 96 percent of the initial figure, or to three 

specs per ten grams. This process results in only minor losses 

of max. 0.1 to 0.3 percent pulp on the solids side. This means 

that the decanter has proved to be a reliable technology for 

processing mango purée. 


The decanters of the type GCE 305 and GCD 305 feature 

various convincing benefits, including their high capacity of 

three tonnes per hour, high g-force with a low power 

requirement of only 15 kilowatts as well as their robust duplex 

steel bowl. 

There is strong interest in these high-quality and highperformance 

decanters, and the processing capacities are 

expanding. For Totapuri alone, it is forecast that the volume 

of industrially manufactured mango purée in India will 

increase from 60 million tonnes in 2010 to a figure of between 

200 million and 250 million tonnes in 2011. The latest 

development for even higher price premium pulp products is 

the use of separators instead of decanters. In this way, it is 

possible to make even thicker pulps, because the separators 

are able to achieve even further reductions in fruit flesh losses 

during the centrifugation process. 

Rüdiger Flocke 

Head of Product Management Fruit Juice / Citrus / Wine 

Business Line Beverage Technology 


Phone +49 2522 77-1964 

ruediger.flocke@geagroup.com 

MANGO PURÉE CONSUMPTION WORLDWIDE 

Total worldwide: 728 mill. t 

364 mill. t 

Asia except india 

182 mill. t 

North and South America 

30 mill. t 

Mexico 

104 mill. t 

India 

48 mill. t 

ROW 

51


52 


separator BilgeMaster ® 

cleandesign 

noW also features 

separators froM the 

eagleClass series


More 

perforManCe 

With the 

saMe size 

53

the eagleClass 

generation sets the 

highest standards 

of perforManCe, 

separation effiCienCy 

and the ratio of 

perforManCe to 

Weight and poWer 

ConsuMption. 

With a new modular concept, the systems of the BilgeMaster ® 

cleandesign series now also consistently incorporate the features 

of the latest eagleclass generation which meets the most 

stringent requirements in terms of performance, separating 

efficiency and the ratio between performance and weight and 

power consumption. With an extended range of features, the 

BilgeMaster ® -E 400 to 5000 cleandesign systems provide a 

user-friendly concept which can be installed in a flexible 

manner and easily retrofitted. 

Various effluents containing oil are encountered in on-board 

marine operations. This bilgewater cannot be discharged 

untreated into the marine environment. Only type-approved 

systems are permitted to be used for processing these effluents, 

and they have to guarantee a residual oil content of less than 

15 ppm (parts per million). Since 1996, GEA Westfalia 

Separator Group has been the first manufacturer to provide 

self-cleaning centrifuges for this application. These systems 

have constantly been improved over a period of time and 

adapted to meet the latest approval regulations and market 

requirements. With the type approval of the BilgeMaster ® 

cleandesign series, GEA Westfalia Separator Group was the 

first manufacturer to launch a mechanical separating system 

which for the first time separates the water / oil emulsion 

specified in the currently valid approval regulation MEPC 

107(49) without using chemicals and adsorption filters. 

Depending on the size of the module, the fact that the 

adsorption filter is no longer necessary has enabled operators 

to achieve savings of several thousand Euros; the savings 

were rounded off by new components such as a plate heat 

exchanger, the new E40 control unit and a new oil monitor. 

Rated capacities of 

400 to 5000 litres per hour 

However, GEA Westfalia Separator Group was not satisfied 

with the above. The engineers again tested the various 

requirements such as performance, ease of operation, 

functionality, simplicity, retrofitting capability and safety. 

54 

the BilgeMaster ® -e 

5000 cleandesign 

With Wst 50 has 

had iMo type 

approVal and 

us Coast guard 

approVal 

sinCe 2010.

This has resulted in a modular concept which rounds off the 

bottom end of the range of ratings, with the new separator 

WSE 5, which can be used for nominal capacities above 400 litres 

per hour instead of the previous figure of 750 litres per hour. 

In addition, the top end of the range has also been extended 

with the largest machine WSE 50. It offers 25 percent more 

performance than the previously used WSD 35, namely 5000 

instead of 4000 litres per hour, in conjunction with the same 

size, same weight and same power consumption. Between the 

largest and the smallest system, there are now two sizes, 

namely the WSE 10 with 1200 litres per hour and WSE 20 

with 2500 litres per hour. Whereas the Bilge Master ® -E 5000 

cleandesign with the WSE 50 has had IMO type approval and 

the US Coast Guard approval since 2010, type approval for the 

other three models was obtained in the autumn of 2011. 

Greater flexibility for installation 

The new modular concept has a much smaller footprint, which 

is also achieved by means of a changed positioning of the 

switching cabinet, which can also be set up separately as a 

stand-alone module. In addition, the new series provides 

weight savings of up to 300 kilograms. This means that the 

flexibility for installing the modules in the limited space 

available on board a ship has been considerably improved. At 


the same time, the operating elements are now much more 

accessible for the operators, and the BilgeMaster ® -E 400 to 

5000 cleandesign systems have thus become much more userfriendly. 

Upgradable as safetyMaster and 

CombiMaster ® without any conversion 

The system can be combined with an adsorption filter without 

any need for conversion if the user wishes to attain a residual 

oil content of less than 5 ppm. In addition, the basic module is 

upgradable as SafetyMaster and CombiMaster ® without any 

need for conversion. The integrated SafetyMaster provides additional 

safety against unintended overboard discharging and, 

when locked, also provides protection against manipulation. 

Features which go far beyond the statutory requirements. A 

data recorder provides all information regarding the status 

of the bilgewater treatment system, including the respective 

position of the vessel and the volume of water discharged 

overboard during the past 18 months. 

New simplified 

CombiMaster ® concept 

The Combi Master ® can be used for processing the bilgewater 

as well as for dewatering the sludge and thus reducing 

the volume of sludge. The separated oil is stored in a buffer 

tank, and can be used as heating oil. In this operating mode, 

the water is not permitted to be discharged over board, 

and instead is pumped into the bilge tank. Whereas an 

additional pump heater module was provided in the previous 

Combi Master ® concept, the current solution requires only a 

much smaller metering pump which is used for conveying 

sludge to the normal feed pump. Accordingly, it is no longer 

necessary to shut down and convert the Bilge Master ® ; on the 

contrary, it is necessary only to simply switch over to 

CombiMaster ® operation. The CombiMaster ® continues to be 

a Bilge Master ® with type approval, and can also dewater 

sludge without any significant additional effort. 

The new module and Combi Master ® concept of the Bilge 

Master ® -E 400 to 5000 cleandesign systems in conjunction 

with the SafetyMaster provides marine operators with an 

extended range of capacities and applications, and guarantees 

safe and user-friendly operation. 

Dr. Klaus-Rainer Witte 

Head of Process Development 

Development and Design 


Phone +49 2522 77-2979 

klaus-rainer.witte@geagroup.com 

55


56

sourCe 

of youth 

hype surrounding 

CoConut Water 

in the usa 


57

The pop icon Rihanna is one of a number 

of rock stars who have confessed to 

being fans of the Vita Coco brand, 

including Madonna and the frontman 

of the Red hot Chili Peppers, Anthony 

Kiedis, both of whom are already 

investors in Vita Coco. 

They have chosen natural coconut water, which is an excellent 

regulator of fluid balance, as their favourite beverage. This 

means that the success story of the trend beverage coconut 

water is now entering the next round. The quality of production 

in many cases is the responsibility of separators from 

GEA Westfalia Separator Group, which, specifically among 

coconut processors in South East Asia, are installed as part of 

the core process and reliably ensure that the coconut water is 

defatted to a minimum residual oil content. 

Coconut water is currently the subject of hype in the USA. 

It is the non plus ultra after nights spent partying and is 

suitable as a rapid restorative following sports activities; 

recommended by advocates who are to be found mainly in 

chic beach clubs and fitness studios. The FAO (Food and 

Agriculture Organisation) has the following to say about this 

trend beverage: “Coconut water is a natural isotonic beverage, 

with an electrolytic ratio which is the same as that encountered 

in human blood. Coconut water is the liquid of life”. The 

positive effect has been known for a long time. In the Second 

World War, it was used as a physiological infusion serum 

because it is so similar to human plasma; in previous centuries, 

seafarers used coconuts to keep drinking water fresh. Coconut 

water has also been used in Ayurvedic medicine for centuries. 

In the tropics, coconut water has been a popular drink since 

time immemorial, drunk fresh with a straw from the nut or 

filled in bottles and cans. In some tropical countries, it is even 

used as a substitute for mother’s milk. 

Oil removal is essential 

Up to 800 millilitres, on average 300 millilitres, can be obtained 

from every nut from the trees which are up to 30 metres high. 

Coconut water is the clear liquid in young coconuts. When the 

fruit ripens, the water is gradually replaced by flesh and air; 

the still tender gel-like flesh gradually becomes firmer until it 

eventually dries out entirely. Coconut water is low in calories 

and is naturally virtually fat-free; it contains many A-, B- and 

C- vitamins, more electrolytes than most industrially produced 

sports beverages and has more potassium than bananas. It is 

cholosterol-free, promotes rehydration of the human body and 

removes heavy metals from the organism. However, the “juice 

of life” is also very sensitive, very quickly loses its taste and 

many of its nutrients when it has been opened. It is therefore 

essential to remove virtually all of the oil content in order to 

extend the shelf life of the product. 

58


3-phase separators used for 

separating the raW Water 

The main countries for cultivating coconut are Indonesia (around 20 million tonnes), the 

Philippines (around 15 million tonnes) and India (around 11 million tonnes), followed at a 

distance by Brazil, Sri Lanka, Thailand, Vietnam and many other countries in South East Asia, 

Central and South America, the South Seas and Africa. In these countries, the processors also 

have their base. Here the coconuts are shelled and chopped, the water is collected and then de-oiled. 

The self-cleaning skimming separators of the MSE series from GEA Westfalia Separator Group, 

which are familiar in milk-processing operations, are used for this purpose. The 3-phase 

separators separate the raw water into the three components fat-free coconut water, oil and 

solids. The oil content is generally reduced from the original level 0.25 to two percent – depending 

on the ripeness of the coconut – to a level of up to 0.01 percent. Users of this process with 

throughput capacities of 2500 to 8000 litres per hour can be found in the Philippines, Thailand, 

Indonesia and Vietnam. 

Extensive removal of bacteria is a side-effect of de-oiling 

A positive side-effect of the de-oiling process is removal of bacteria from the coconut water by 

the reduction of spores and bacteria which are discharged together with the solids. The MSE 

separators convince users as a result of their exceptionally good de-oiling properties with very 

high separation rates and very low residual oil contents of up to 0.01 percent. They are easy to 

operate, are reliable and keep operational expenditure (OPEX) low. Oil separation is also possible 

at low temperatures of between two and six degrees Celsius. Below ten degrees Celsius, most of 

the components containing oil in the coconut water turn into wax and accumulate with the 

solids on the periphery of the separator bowl. The oil returns to the liquid state above the 

product temperature of 20 degrees Celsius. 

After de-oiling, the coconut water is pasteurised, cooled and stored, and either mixed with other 

components such as aronia, pomegranate or mango, sterilised and packaged under aseptic 

conditions. Or the water is pre-concentrated in a reverse osmosis installation, then vacuumevaporated 

up to 60 degrees Brix and subsequently filled into 1000 litre containers as concentrate, 

freeze-dried and shipped. 

Sven Jadzinski 

Regional Sales Manager (SEA) 

GEA Westfalia Separator (S.E.A) Pte. Ltd. 

(Singapore) 

Phone +65 62836824 

sven.jadzinski@geagroup.com 

Market With a proMising future 

For instance to America, where the current hype started a few years ago. The market for coconut water in 

America is estimated to be approximately USD 60 million, still extremely small compared with the entire American 

beverage market, but with such a promising future that the two major soft drink groups Coca-Cola and Pepsi- 

Cola are already establishing a position in this field. Pepsi is already extending its portfolio in the direction of 

“healthy beverages”, and has taken over the largest coconut water producer in Brazil; Coca-Cola has acquired an 

interest in another coconut water producer. However, the Vita Coco brand, which was established in 2003, is still 

the market leader, with an approximately 60 percent share of the market and USD 40 million in 2010. The 

company has refused takeover offers from the two major groups running into millions, and intends to continue 

to operate on its own. Madonna has invested USD 1.5 million in the brand and used her world tour 2009 as an 

opportunity for marketing her new favourite drink. On the other hand, the second largest US brand O.N.E. of an 

agile young entrepreneur has concluded a distribution agreement with Pepsi-Cola. Zico, the number three in the 

market, is positioning itself independently as a source of youth. 

59

Born to run 

If you expect highest performance and maximum availability in all fields of application, opt for 

GEA Westfalia Separator ecoforce. This new decanter saves energy, water and operating costs, 

but not at the expense of robustness and endurance. High separating efficiency and throughput 

capacities have never before been available as reliably and sustainably. ecoforce is not just a, 

but the decanter of a new generation. 

GEA Westfalia Separator Group GmbH 

Werner-Habig-Straße 1, 59302 Oelde, Germany 

Phone: +49 2522 77-0, Fax: +49 2522 77-2488 

www.westfalia-separator.com 

engineering for a better world 

B_WS-12-03-0026 EN · Printed in Germany · Printed on chlorine-free paper 

Westfalia ® , Westfalia Separator ® , Separator‘s Digest ® , BilgeMaster ® , CombiMaster ® and SludgeMaster ® are registered trademarks of GEA Mechanical Equipment GmbH. 

GE-90-01-006

Separator's Digest 2012/1 - GEA Westfalia Separator Group

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