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Green Growth

Dairy & Food Production

Processing • Hygiene • Analysis

Ingredients • Packaging • Transportation

Denmark - June 2012

Green Growth

“Green Growth” is the major theme running through Danish Dairy & Food Industry

… worldwide this year.

Political leaders throughout the world work hard to get a grip on the global

economic crises through adherence to tight budgets and savings. However, a

further step out of the crises is Green Growth. By developing new green technologies

it is possible to grow e.g. the dairy and food production to help feed

our planets expanding population in an environmentally responsible way.

Thus, this issue of Danish Dairy & Food Industry includes editorials with various

perspectives on the theme of Green Growth: Developing more efficient

production processes, reduction of CO 2 emissions, increased control of wastes

and other emissions, use of alternative energies such as biogas, wind and water,

energy savings, water recycling and re-heating, use of green packaging and

new optimized ingredient types and analyzes as well as energy-saving hygiene

concepts and environmentally friendly transport systems. The Danish dairy

industry has developed - or is ready to bloom with several green initiatives and

technologies for a more sustainable production - if only the political framework

and economic incentives are present.

A large number of dairy supplier companies, educational and research institutions

participate in Danish Dairy & Food Industry, which this year is introduced

by the Danish Agricultural Minister Mette Gjerskov along with one of

the world’s leading dairy companies, Arla Foods.

Besides studying this magazine our readers are offered the opportunity to

meet representatives from the Danish dairy and food industry at large international

exhibitions in 2012 as for example: World Food Moscow 17-20 September,

GIDA in Istanbul 20-23 September, InterMopro in Düsseldorf 23-25

September, World Dairy Expo in Madison 2-6 October, InterFood in Delhi 4-6

October, SIAL in Paris 21-25 October, World Food Kazakhstan 30 October - 2

November, World Food Ukraine 31 October - 2 November, IDF World Dairy

Summit in Cape Town 3-9 November, FoodTech and the Danish Dairy/Food

Contests in Herning 13-15 November, and Health & Natural Ingredients Europe

in Frankfurt 13-15 November.

The Danish Dairy Managers Association and the Danish Dairy Engineers

Association own and publish Danish Dairy & Food Industry ... worldwide. We

have published the magazine since 1976 and this issue is the 22 nd in succession

informing you about Danish dairy and food industry.

Danish Dairy & Food Industry ... worldwide is distributed in more than 120

countries in 9.000 copies. Further, the magazine is available at our homepage:

www.ddfi.dk or www.maelkeritidende.dk. Our experience tells us that

about 100.000 dairy, food and marketing specialist worldwide study this journal

every year.

You are always welcome to contact us for further information. ■

Anne-Sofi Christiansen

Chief Editor

Anna Marie Thøgersen


The cover shows a lure. This instrument

dates from the Danish Bronze

Age (about 600 B. C.). It has only been

found in Denmark and the former Danish

territories. Today it forms part of

the Danish Quality sign known as the

“Lure-brand”, used on dairy products.

Background picture by Colourbox.

Circulation: 9.000 copies

Readership: Leading personnel in the

dairy and food industry in more than

120 countries as well as employees at

Danish embassies and consulategenerals,

Government advisers and

representatives of marketing councils.

The editorial staff of

Danish Dairy & Food

Industry ... worldwide:

Chief Editor, M. Sc.

Anne-Sofi Christiansen

Editor, M. A.

Anna Marie Thøgersen

Litographed by:

Gitte Kristiansen,

Jorn Thomsen A/S, Elbo

Kolding, Denmark

Printed by:

Jorn Thomsen Elbo A/S

Kolding, Denmark

Editorial office

and distribution:

Danish Dairy & Food

Industry ... worldwide

Munkehatten 28

5220 Odense SØ


Tel.: +45 66 12 40 25

Fax: +45 66 14 40 26




ISSN 0904-4310

22 June 2012

Reprint permission to interest

publications providing their credit

and tear sheets to the publisher.

Index to


43 Akzo Nobel

49 Alectia

33 Alfa Laval

19 Arla Foods

5 Au2mate

25 Chr. Hansen

11 Dairy Fruit

41 DSM

14 DSS Silkeborg

27 Ecolab

9 Elopak

45 FH Scandinox

- Plants for Sale

31 GEA Niro

54 International Dairy Books

47 Jorgensen Engineering

23 Keofitt

29 KOLD College


48 LP Kolding

53 MCH Herning,

Food Tech, November

30 Novadan

37 Palsgaard

17 Scan-Vibro


35 Tetra Pak

13 Tetra Pak Scanima

2 Trepko

34 University of Copenhagen,

Department of Food


42 Akzo Nobel: Sustainable

Salt Solution, by Anna Marie


50 Alectia: Sustainability, by

Karin Elsebeth Hansen

32 Alfa Laval: Energy Efficient

Pumping, by Bo Knudsen

8 Arla Foods: Arla

Aylesbury UK - The most

Environmentally Advanced

Dairy Plant, by Anna Marie


22 Au2mate: Control System

Upgraded Successfully, by Jan

Baastrup Jensen

18 Chr. Hansen: New Yoghurt

Cultures with WOW Effect, by

Helle Rexen

10 Dairy Fruit: Green Growth,

by Crispin Gell

40 DSM: Green and Sustainable

Dairy Production, by Ole Lund


15 DSS Silkeborg: Green

Technology for a Green

Industry, by Freddie D.


28 Ecolab: New MIP Range, by

Thomas M. Buehler

26 GEA Process Engineering:

Dairy Drying Technology

Scaled for the Future, by

Carsten Juhl Jessen

52 International Dairy Books:

New Butter Book

47 Jorgensen Engineering:

Complete Packaging Handling

Systems for Infant Formulas,

by Anna Marie Thøgersen

48 LP Kolding: Optimized

Hygienic Designs, by Mogens


30 Novadan: Green Cleaning &

Hygiene Concepts, by Torben



36 Palsgaard: A Case in Point,

by Lisa Dreyer Mortensen

16 Scan-Vibro: Going Green

with Vibration Technology, by

Lars Valentin Peters

20 SPX: Greener Solutions from

SPX Flow Technology, by Bent


24 Tetra Pak: Tetra Centri

AirTight Eco, by Frederik


12 Tetra Pak Scanima: Mixing

the Maximum Advantage, by

Jan F. Jensen

44 The 43rd Nordic Dairy

Congress 2012: Nordic Dairy

Industry - Future Perspectives,

by Kjetil Høvde

6 The Danish Ministry for

Food, Agriculute and

Fisheries: A Green Transition

of the Agro-Food Sector, by

Minister Mette Gjerskov

38 Trepko: Solutions Meeting

the Needs, by Agnieszka


34 University of Copenhagen,

Dairy Technology: Dairy

Technology in an Online


Au2mate at your service

Automation and Industrial IT worldwide

Au2mate’s know-how covers every dairy process from

raw material reception to packing including high value

added processes, OEE and MES solutions.

Please refer to our web page for further contact information

in Denmark, UK and Dubai.

Au2mate develops and supplies automation

solutions for the process industry world wide.

These solutions are prepared through team-

work and close partnerships with our customers,

and they cover the entire range from

complete automation projects to consultancy

services and advice.

NR. 22

Au2mate A/S - Dairy Automation and Industrial IT

Our expertise – your guarantee

We have many years of experience in the field

of process automation. We have developed a

structured work method, and with efficient

knowledge-sharing tools, we can guarantee

rapid delivery of top-quality solutions at

competitive prices.

Danish Dairy & Food Industry … worldwide 2012



A Green Transition of the

Agro-Food Sector

By Mette Gjerskov,

Minister for

Food, Agriculture

and Fisheries

(Photo by: Rune


Green Vision

The European agro-food sector is facing

hard times due both to increasing

costs and increased competition from

outside Europe. Meanwhile, the sector

is also facing demands from citizens

and politicians that the sector

should contribute to a sustainable environment

and to the upkeep of the

qualities of rural landscapes.

Thus, the “green vision” for the future

Common Agricultural Policy

must be to support and provide for

new green earnings in the agricultural

sector allowing the pursuit of

these objectives as well as the continued

production of a varied palette

of high quality foods. New earnings

where bio-based material (incl.

waste) are used in a resource efficient

way, e.g. biogas or the use of urea

from manure for glue, contribute to

solving the challenges ahead while

also providing the sector with new income


However, this requires a Green

Transition of the sector whereby the

intrinsic conflict between food production

and environmental protection

is solved - allowing each object

to be achieved without any detrimental

effect on the other.

This green vision will be on the

Danish agenda both during and after

the Danish EU presidency.

Targeted initiatives

New policy initiatives are required

for the agro-food sector to take the

Innovation is a central part of creating solutions to solve the future challenges of e.g.

climate change, biodiversity, renewable energy. (Photo: Colourbox).

greener path, and innovation is a central

part of this development towards

creating solutions to the future challenges

of e.g. climate change, biodiversity,

renewable energy.

We need new knowledge and new

technologies in order to improve productivity

and competitiveness in a

sustainable manner, i.e. without the

use of additional resources.

The European Innovation Partnership

on agriculture and other new

policy initiatives as the Bio-economy

Strategy will help achieve these goals.

Sustainability can provide


A new analysis carried out among

50 Danish food companies indicates

that 94 percent of the companies con-

sider environmental sustainability as

an important lever to enhance growth

and competitiveness. The analysis

was commissioned by the Ministry of

Food, Agriculture and Fisheries and

subsidized by GDDP (The Green Development

and Demonstration Program).

The program allocated DKK

103 million ultimo 2011 to 24 projects

from an assessment of what best

ensures the green transition of the

agro-food sector.

The analysis shows that the Danish

agro-food sector is at the forefront

when the Danish government talks

about green transition. ■

6 Danish Dairy & Food Industry … worldwide 2012 NR. 22

SuStainable CiP teChnologieS

from SPX


NR. 22

SPX SafeWater technology is a high-quality, skidmounted,

plug & produce solution designed for sustainable

production of sanitizer and cleaning agents for food &

beverage processing. The revolutionary CIP technology

is environmentally friendly, reduces costs associated with

expensive formulated cleaning agents and increases

operator safety. To learn more about how this groundbreaking

technology can revolutionize your CIP and

sanitation procedures visit www.apv.com/safewater

Danish Dairy & Food Industry … worldwide 2012 7

When finished in the summer 2013, the Arla Aylesbury UK plant will be second

to none in terms of efficiency and environmental standards.

The Most Environmentally Advanced Dairy Plant in the World

Arla Aylesbury

By Anna Marie Thøgersen, Editor

Exceptional environmental


The Aylesbury plant will be the first

zero carbon milk processing facility

in the world. - On our journey

to achieve this goal, we organized

a number of sustainable sessions

in conjunction with invited suppliers

in order to coordinate e.g. energy

and processing flows. In cooperation,

we have achieved some highly optimized

solutions to the benefit of the

environment, tells Arla UK’s Supply

Chain Director Lars Dalsgaard.

Thus, the suppliers came up with

solutions for machinery, pumps,

valves, pipes etc., and further the

necessary process capabilities in order

to minimize the use of power, water,

steam, cooling and other energy

resources. This remarkable collaboration

between the involved companies

resulted in solutions that contri-

Arla Aylesbury is going to be the largest

fresh milk dairy in the world, producing

all kinds of white milk including the

popular brand Cravendale.

bute to more than 50% of the target

to build a zero carbon facility with

zero waste. - That is quite outstanding,

underlines Lars Dalsgaard.

65,000 trees

The new 50.000 sqm fresh milk dairy

is now taking shape on the 300.000

sqm large plot, and the building site

is also going green in every way. -

65,000 trees will be planted! Further

we establish low-noise electrically

powered cooling as well as baffle

walls between the site lorry roads

Global Top-7 dairy giant, Arla

Foods is constructing the

company’s new 150 million

– Aylesbury milk plant just

40 miles North-West of London.

– Aylesbury will be the

most environmentally advanced

dairy plant in the World

– and moreover the largest

fresh milk plant on a global

scale. So tell Arla UK’s Supply

Chain Director Lars Dalsgaard

and Project Director

Jakob Nielsen. In late summer

2013, Arla Aylesbury is

ready for an annual production

of one billion litres of

fresh milk for the 11 million

Londoners and further 9 million

consumers in the South

East region of UK.

and the surroundings. Regarding our

neighbours in the Aylesbury region

we have established constructive dialogs

and developed various solutions,

e.g. of colour choices that makes the

factory blend into the landscape.

Even the traditionally shiny stainless

steel milk tanks will be in autumn

colours, tells Lars Dalsgaard.

Closer to Nature

Project Director Jakob Nielsen is the

anchorman of the coordination of the

giant Aylesbury construction. - Some

of the most significant environmental

improvements, we create within minimizing

water consumption, re-use of

water, rain water harvesting, building

own anaerobic digester, using less

packaging and alternative fuel for our

tanker trucks, tells Jakob Nielsen. Jakob

Nielsen elaborates:

Alternative power: Building of

a heat/power plant where some of the

energy comes from waste water residue,

and in the long term considerations

of establishing solar cells etc.

8 Danish Dairy & Food Industry … worldwide 2012 NR. 22

Minimized water consumption:

Generally, the required amount

of water to produce 1 litre of fresh

milk is 0,8 litre. The Aylesbury consumption

will be minimized to a new

industry standard, and represent


Less packaging: Use of plastics

for the fresh milk bottles will be reduced

up to 20%. Moreover, the aim

is to bring the recycling of plastics

up from the current 15% to 30%, and

eventually 50%.

Eco-driving: All drivers must

pass an eco-driving test, and this skill

typically lowers the fuel consumption

by 20%. On trial basis, some of

the lorries will run on natural gas. - If

this turns out successfully, the entire

transport fleet can be equipped with

gas tanks, and this would decrease

the CO 2 emissions by 25-30%, emphasizes

Jakob Nielsen. ■

NR. 22

Facts about Arla Aylesbury

• The first zero carbon milk processing facility in the world. The most advanced

construction techniques, process technologies and renewable

energy solutions.

• Up to 700 employees including drivers.

• Up to one billion litres of milk annually from British farmers.

• The plant will be able to supply 20 million residents in London and surroundings

with daily fresh milk.

Besides the up-coming Aylesbury milk plant scheduled for production

start in 2013, Arla UK owns and runs dairies in Ashby, Hatfield, Lockerbie,

Oakthorpe, Settle, Stourton, and Westbury.

Facts about Arla Foods

Turnover: 55 billion DKK

Milk: 9.200 million kg

Owners: 8.100 milk farmers in Denmark, Sweden and Germany

Employees: 17.400

Production and Sale: 33 countries

Great taste

comes in

great packages.

The Diamond ® Curve ® gable-top carton from Elopak.

Our innovative carton design features an exclusive shape

that increases visual impact on crowded store shelves.

And our variety of sizes and caps help satisfy changing

consumer desires. At Elopak, we have the perfect

packaging solution for your premium liquid foods.

1006038_ELO_Anz_DairyDK_158x114mm.indd 1 10.06.10 15:31

Danish Dairy & Food Industry … worldwide 2012 9

Green Growth

By Crispin Gell,

Sales Director,

Dairy Fruit


Food production and transportation

of products invariably effect the environment,

thus Dairy Fruit focus on

reducing these effects whenever possible,

and we constantly seek to minimize

the environmental impact of our

operations. At every level we pay attention

to find cost effective ways.

Within our manufacturing facilities

our aim is to reduce our water consumption

by 50%, and we have recently

installed a brand new CIP system

to one of the process lines. The

results are very encouraging, as they

show significant reductions, and thus

we will very soon complete additional

cleaning installations on all production


The nitrogen gas we use to pressurise

our steel containers was originally

purchased and delivered to site,

but now we have built our own nitrogen

plant, enabling us to reduce costs

as well as huge reduction on transportation.

“Green Growth” … what does it conjure up? To me it could be

my football club Plymouth Argyle aspiring to great things (long

term dream), but in the world of the food industry it equates

to; Clean Label, Natural, Organic, Healthy, and of course being

more environmentally friendly. How does Dairy Fruit adapt to

this growing theme? In a number of key ways: Environment,

Market, Product and Supply!

The next project just started, is recovery

of heat generated from our

production facilities which we will recycle

for heating of the company offices

and laboratories throughout the



All together, demands from our customers

and the consumers are: Clean

label, Natural, Organic, and Healthy

products. These issues are the keys to

green growth and we develop products

to match the ranges by co-operating

with both customers and suppliers,

and we strive to meet the

consumer’s needs and desires.

Recent consumer surveys indicate

in general strongly increased interests

in products holding green credentials

and as few additives as possible.

In addition, research shows that

consumers want clear and simple

messages, direct and to the point, no

confusion and no misunderstanding.


The consumers wish regarding “Going

Green” implies their expectations

for clean and environmentallyfriendly

foods to eat. Not the easiest

of tasks when it still has to taste and

even look good!

Recently and in collaboration with

a major international customer, we

were asked to develop products to

meet the natural and free-from-criteria.

The products should be clean

label, free of additives and flavourings.

That was a challenge, but the

task was solved successfully - judged

by the ongoing sales. The consumer

perceive various types of products as

“made at home”- ingredients such as;

Fruit, sugar, water and possibly corn

flour, as they all can be found in the

kitchen at home.

Not only did we use our innovation

skills to develop these preparations,

we also used our brand new packaging

concept; a container featuring

an agitator. The preparations (without

stabilizers) are pumped directly

into the container, and at our customers

facility they just need to connect

a motor to the container, which

in turn gently agitates the prep into a

uniformed suspended format readyfor-use.


It is essential that our customers

trust Dairy Fruit, as well as our suppliers

and our products. By acting responsibly,

communicating openly

and maintaining an ongoing dialogue

we all-together can work closely and


Going Green and using/sourcing

local raw materials is not always possible.

Actually, it gives our purchasing

team major challenges as you

can’t source fruits such as mango, banana

or pineapple in Northern Europe!

Though, we always try to purchase

the best local raw materials available

- when it is possible.

10 Danish Dairy & Food Industry … worldwide 2012 NR. 22

When cooperating with our suppliers,

we successively consider the environmental

aspect and impact both within

actual production as well as transportation

of goods. By now, Dairy Fruit

has implemented the group CSR

policy, and suppliers must demon-

NR. 22

Nature’s Taste

Dairy Fruit A/S offers our customers Nature’s Taste, by

developing and offering healthy and good tasting products.

We believe in looking forward, using our technical and

innovation skills.

Dairy Fruit’s expertise:

• Clean label

• Health and quality

• Environmentally awareness

• Organic

• Nature guides our innovation

• Joint working partnerships ... The driving force behind today’s

new developments

• 30 years experience of providing custom solutions, using our

team of experts to inspire creation

• Working together we can design your next product based on …

… Nature’s Taste

strate that they are socially responsible

within their own organizations as

well as their partners and suppliers.

As the consumers are increasingly

aware of environmental issues and at

the same time seek “green” products,

we at Dairy Fruit strengthen our efforts

to offer products which can adhere

to these requirements, and yet

provide the taste and expectations for

healthy and natural foods. We work

very closely with our customers and

suppliers to grow our position of being

Northern Europe’s leading supplier

of fruit and savoury preparations

to the dairy and food industry.

Dairy Fruit looks forward to being

your natural choice. ■



Phone: +45 66 13 13 70 • WWW.DAIRY-FRUIT.COM

Danish Dairy & Food Industry … worldwide 2012 11

Mixing the Maximum


Tetra Pak Scanima packs a whole lot of processes into one versatile machine.

By Jan F. Jensen,




Tetra Pak Scanima

Green technology was still a niche

concept when Tetra Pak Scanima

started to produce the first batch

mixers back in the late 1980s. Today

if you ask the company about how it

can help food manufacturers reduce

the carbon footprint of their processes,

the answer is: we always have.

A market leader in mixer technology,

Tetra Pak Scanima is the com-

Tetra Almix is the ultimate modular

system for fast, repeatable mixing

processes, suitable for a vast range of

dairy, beverage, cheese, ice cream and

prepared food products.

About Tetra Pak Scanima

Tetra Pak Scanima is a leading

manufacturer of high-shear mixing

solutions for a wide range of

demanding applications within

food, beverage and cosmetics.

Based in Denmark, the company

is part of the Tetra Pak group.

pany behind the Tetra Almix. To anyone

who has experienced it, the Tetra

Almix is the ultimate modular system

for fast, repeatable mixing processes,

suitable for a vast range of dairy, beverage,

cheese, ice cream and prepared

food products. Energy efficiency,

minimum product waste and

a safe working environment are all

built into the original design.

Fast and energy efficient

A good mixing process is fundamental

to everything else that happens

down the processing line. At Tetra

Pak Scanima, the heart of their machines

is the bottom-mounted turbo

mixer unit. Add your ingredients,

and the high-speed rotor and perfo-

rated stator will ensure they are thoroughly

mixed within seconds. Even

powder ingredients that are notoriously

difficult to wet, such as pectin

and xanthan gum, are rapidly dissolved,

ensuring maximum functionality

in the finished product. In fruit

preparations for ice cream, for example,

manufacturers have found they

can reduce their pectin dosage by up

to 30% simply because solubility is

improved. No conventional mixing

system can match the Tetra Almix for

energy-efficient dispersion.

High shear is critical whether dissolving

or dispersing solids, homogenising

liquids, or blending oil and water-based

ingredients into a smooth

emulsion. In this area, the Tetra Al-

12 Danish Dairy & Food Industry … worldwide 2012 NR. 22

mix is outstanding. Another unique

feature is its ability to switch from

high-shear mixing to gentle blending,

enabled by the patented dynamic

shear system. It is here that the mixer’s

supreme versatility lies - and,

along with it, a further opportunity to

reduce the food manufacturer’s environmental


High yield, minimum waste

Thanks to the dynamic shear system,

operators can adjust the shear rate at

any point during the mixing process.

What this means is that the stator

can be moved in or out of the rotor

stream. So, whether adding herbs to

dressings, inclusions to ice cream mix

or fruit pieces to desserts, larger particles

and chunks stay intact. On top

of that, the machine can be equipped

to take care of deaeration, cooling

and heat treatment. The big advantage

for the manufacturer is that

many processes can be performed

in one machine. Without the need

to transfer food mixes from one ma-

NR. 22

Tetra Almix ®

Scanima Technology by Tetra Pak


Tetra Almix is designed to meet your needs for mixing solutions

– liquids with liquids or liquids with powders.

Imagine a production line matched to your specifi c food products.

Imagine that it maximizes your effi ciency, output and environmental

performance, all in one.

You don’t have to imagine. Tetra Victenso production solutions for

soups & sauces, desserts, fruit preparations, tomato products and

baby food, enable you to achieve all this today. Longer running hours.

More effi cient heat transfer. Greater fl exibility. Uncompromising food

safety. With maximum output for your investment.

The Tetra Almix offers the ability to perform high and low shear

mixing, agitation, dearation, powder handling and heat treatment

in one single unit and in one single tank.


chine to another, the number of processing

steps is reduced. Product loss

is limited to the absolute minimum,

giving manufacturers optimum yield

with the tiniest raw material waste.

Clean, safe and hygienic

Apart from being easy to operate, the

Tetra Almix rewards operators with a

cleaner, dust-free environment on the

factory floor. Via an optional vacuum

system, ingredients can be sucked

into the mixing vessel below the liquid

surface. This sub-surface entry

both prevents loss of powder ingredients

into the air and ensures instant

wetting, contributing to the rapid dispersion

process. It is also during vacuum

mixing that deaeration takes

place, limiting the air and foaming

problems that may have a negative

impact on product quality further

down the processing line.

Of course, the most important part

of quality assurance is food safety.

With this priority in mind, the mixers

are designed to apply just the

Visit www.tetrapak.com or www.tetrapakscanima.com

Tetra Pak, , PROTECTS WHAT’S GOOD and Tetra Victenso

are trademarks belonging to the Tetra Pak Group.

right treatment for each food application.

All Tetra Almix solutions are

prepared for CIP as standard. That

way manufacturers need never be

in doubt that the food products they

produce are perfectly safe to eat.

International customer


Installing the right mixer solution for

a specific application calls for professional

advice. As part of the Tetra Pak

group, Tetra Scanima has product development

centres around the world,

where qualified staffs are ready to

give customers all the assistance they

need. Customers can see the batch

mixers in action, run their own application

tests and may even hire a

mixer to see how it works in their

own production plant.

Once experienced, the Tetra Almix

is rarely forgotten. Once installed, the

robust design ensures a long life of

reliable performance with minimum

running and maintenance costs. ■

Victenso_halfpH_11185.indd 1 09-11-23 18.02.31

Danish Dairy & Food Industry … worldwide 2012 13



DSS Silkeborg AS

Bergsøesvej 17

DK-8600 Silkeborg

Tel. +45 8720 0840

Hotline +45 7070 1661

14 Danish Dairy & Food Industry … worldwide 2012 info@dss.euNR.



GREEN GREEN technology technology for a GREEN GREEN industry industry


Our skilled experts

are always 100%

dedicated, supplying

the best possible


GREEN technology for a

GREEN industry

Innovative membrane filtration solutions for sustainable dairy production

Just before the turn of the century,

the problem of human contribution

to global warming was addressed officially,

when the world’s largest industrialized

countries agreed to reduce

greenhouse gas emissions to stop the

rapid progression of global warming.

Environmentalists, scientists, and international

organizations had long

been fighting to make the world take

preventive action; and encouraged by

consumers, green thinking and environmental

awareness has now become

a natural part of new investment

schemes in the food and dairy

industry, particularly in the western


As an environmentally responsible

company, DSS Silkeborg was at

NR. 22

By Freddie D.

Lauridsen, Area

Sales Manager,

DSS Silkeborg

the forefront with a dedicated green

strategy to reduce energy and water

consumption of dairy membrane

plants, setting a target of a 25% reduction

on the environmental load of

any given DSS membrane filtration

plant. The target was to be met within

5 years, by including the GREEN concept

in all our membrane technology

solutions. New thinking and extensive

scrutiny of our plant engineering

has produced noticeable savings in

energy consumption that contribute

positively to the green image of the

dairy industry in the areas with the

largest environmental impact: power,

cooling, heating, and water consumption.

Reduced power consumption

An example of the many green initiatives

we have taken is the introduction

of the “ESA” Energy Saving ATD,

a patented technology for membrane

plants that reduces power consumption

with up to 30%, while maintaining

the output of the plant. A typical,

Example - Green Flush

An existing membrane plant without the Green Flush solution has a flushing

capacity of 100 m 3 /h and requires a flushing time of 10 minutes. The total

water consumption of a flush is 16.7 m 3 . The overall cleaning procedure typically

needs 4 flushes, meaning a total spent volume of water of 66.8 m 3 and

40 minutes for a cleaning cycle.

A similar-sized DSS membrane plant equipped with the Green Flush solution

requires 13 m 3 per flush. Altogether, the Green Flush solution requires

only 52 m 3 of water, and in addition, reduces the time needed for flushing.

The savings, therefore, total 14.8 m 3 of water and 8 to 10 minutes per

cleaning. A Green Flush plant which is cleaned 300 times a year saves 4,440

m 3 of water per year and between 40 and 50 hours of cleaning time, which

can instead be used for production.

Hence, by embracing new, green technology it is possible to grow the

world’s dairy production and help feed the planet in an environmentally responsible

and economically viable way.

large-scale membrane plant uses 260

kW/h equalling 6,000 kWh/day, 325

production days equals 1,925,000

kWh per year. And 30% reduction

equals 585,000 kWh/year. Recalculated

into carbon dioxide, this is just

above 250 tons of CO 2 emission per

year. Furthermore, savings in the

power uptake mean less heat generation,

and the subsequent savings in

cooling equal around 60 tons of CO 2

- totalling 300 tons/year. Not surprisingly,

the “ESA” is a huge success

in a great number of DSS membrane

plants around the world.

Water reuse/savings

The dairy industry is traditionally a

heavy user of water, so water-saving

measures are an extremely important

part of a green strategy. Membrane

filtration technology is ideal

for recovery of water from products

and product streams, procuring water

of exceptional purity that can be

recycled for reuse in a variety of processes.

This reuse of water is already

widely practiced worldwide in dairy

factories with DSS Reverse Osmosis

installations; they reduce net demand

on water supply systems and

thus overall water consumption - and

they cut costly effluent discharge. Undoubtedly,

this technology will be developed

much further in the coming


Another initiative supporting green

growth is our recently introduced

“Green Flush” solution, which reduces

water consumption by more

than 25% compared to traditional

membrane plants. A membrane plant

typically requires large volumes of

water over a short period of time for

effective flushing. ■

Danish Dairy & Food Industry … worldwide 2012 15

Going Green with

Vibration Technology

By Lars Valentin

Peters, Business


Manager, M.Sc.

Dairy Science,

Scan-Vibro A/S

For a long time, environmentallyfriendly

food production has been an

important issue of the food industry

and is more relevant than ever. Scan-

Vibro A/S has for several years, often

together with our customers, worked

with optimization of the overall environment

profile of our equipment.

“Green” design concept

The design of our SRS 10 Vibration

Sifter in the CIP-able version

(showed in figure 1) has been developed

by close evaluation of its process

function in combination with the

overall environmental impact. By the

overall environmental impact we do

not only understand the energy consumption

of the vibration motors

used, but also the evaluation of:

Figure 1: SRS 10 with Intregrated CIP.

Scan-Vibro A/S is an expert and global partner within

vibration technology. Custom-designed sifters, conveyors and

feeders are built - and in operation at many food plants all

over the world. Our company offers multifunctional vibration

equipment for: Sorting, spreading, draining, conveying,

cooling, heating …

• Hygienic design, with a minimum

of product build-up (less waste

during cleaning)

• Overall lifetime of the machine

couponed (low maintenance)

• Self-draining (less energy to be

used during dry-out)

• Low noise impact

• Secure a minimum product waste

to the production environment.

A Scan-Vibro SRS 10 has an excellent

sustainability, with a reuse of up

to 98%.

Today Scan-Vibro A/S is the only

manufacturer of vibration sifters for

milk powders, where the screen mesh

can be left in the machine during

CIP-cleaning. This provides the following


• No powder waste to environment

• No risk of bacteriological or other

re-contamination during the re-installation

of the mesh screen

• Manpower savings

• Overall reduction of the cleaning

cost etc.

The SRS 10 Vibration Sifter design is

future-proofed, as it is based on the

different standards and guidelines

for machinery to be used in the food

industry like EHEDG, USDA, 3A,

NZFSA (NZCP6). As a member of

the EHEDG organization, Scan-Vibro

A/S takes active part in the improvement

of machinery to be used in the

food industry.

To us a green profile of a vibration

machine, means looking at the

overall environmental impact of our

equipment and company!

World’s no. 1 spray dryer


When GEA Process Engineering

gained the order to build the world’s

largest dairy spray dryer in New Zealand,

Scan Vibro A/S was selected as

sub-supplier for vibration sifters and

powder transport systems.

The output from the dryer will be

30 tons of milk powder per hour.

This enormous amount of powder

will be handled by two SRS 10 Vibration

Sifters with a total sieving area of

12.5 m 2 , each handling 15 tons of milk

powder per hour. With these high

powder amounts, machine reliability

16 Danish Dairy & Food Industry … worldwide 2012 NR. 22

ecomes a key-factor, and again our

core product, the SRS 10 Vibration

Sifter has proven its value.

Another important feature of the

SRS 10 Sifter is its very gentle product

handling combined with high

sifter function. This is for instance vital

during the manufacturing of agglomerated

milk powder, where no

or only minor degradation of the agglomerate

powder is wanted!

Further, Scan-Vibro is also supplying

the NZ-project with vibration

conveyors type TRS (figure 2)

which are designed for use in numerous

areas of food production, where a

closed sanitary and gentle conveying

is required.

Features of vibration conveyor type


• High-sanitary tubular design - CIP

on request - standard or tailormade

to suit your job

• Length from 500 mm to 12 meters

in one unit

NR. 22

Figure 2: TRS with 4 powder inlets. TRS - Hygienic design.

• Equipped with 2 vibration motors

- mounted either below or above

the tube

• Equipped with removable covers

for easy access

• Designed to meet the current requirements

for effective and gentle


The TRS also comes as a reverse,

2-way vibration conveyor TRS-R,

where the powder is transported either

one - or the other way. The benefit

of the TRS-R conveyor includes

e.g. a very limited building height and

food print combined with competitive


Scan-Vibro A/S

Scan-Vibro’s superior technological

solution is based on knowledge and

the employees’ year-long high technical

experience. The staffs count 65

highly skilled engineers, smiths, CAD

draughtsmen and other technicians.

Processing and Handling

Vibration Equipment

Vibration sifters, conveyors and feeders for the

dairy and food industry - World-wide!

Based on our wide range of standardised products and our

expertise and know-how in products and processes we develop

tailor-made and innovative solutions in close cooperation with

our customers. For a general view please visit our website.

Sørup Kirkevej 74 • 5700 Svendborg • Denmark • Phone: +45 62 21 16 20

Fax: +45 62 22 37 30 • vav@scan-vibro.com • www.scan-vibro.com

The company is engaged in long

lasting and innovative relationships

with large international plant-

and engineering companies. When

it comes to collaboration with these

companies, Scan-Vibro contributes as

a subcontractor within the field of vibration

technology expertise. However,

Scan-Vibro also works alone,

when customers worldwide learn

about the company’s expertise and

want to either replace or expand their

plants with new types of vibration


Scan-Vibro A/S, was founded in

1949, operates two production facilities

and serves customers worldwide.

Sanitary sifter type

SRS CIP 1540

Sanitary reversible conveyor type TRS-R

Danish Dairy & Food Industry … worldwide 2012 17

By Helle Rexen,


Consultant, Chr.

Hansen A/S

For the third year in a row global

bioscience company Chr. Hansen

launches a series of new YoFlex ® and

probiotic nu-trish ® yogurt cultures in

spring 2012.

This time the focus of Chr. Hansen’s

well-oiled innovation machine

has been on developing cultures with

second-to-none taste and texturing

properties, among other things - but

not solely - to perform well in low fat


More than 20 million tons of yogurt

is consumed every year corresponding

to each person on earth eating

up to four kg a year. So far less

than 20% of this volume is low fat yogurt

even though low fat represents a

major part of new product launches

over the past five years.

Taste is king … and back to


“If the amount of yogurt with reduced

fat has not grown any faster it is because

the quality simply has not been

good enough. Consumers refuse to

accept a poor taste or a thin, watery

mouthfeel, no matter how healthy the

product may be,” explains Morten

New Yogurt

Cultures with

WOW Effect!

Chr. Hansen sets out to change the low fat dairy landscape

with new Creamy and Premium cultures.

Boesen, Marketing Manager, Fermented

Milk Cultures, Chr. Hansen.

“Another predominant market

trend, “back to nature”, has further

made it complicated for yogurt producers.

The natural trend is driving

product development towards using

an absolute minimum of ingredients,

which for yogurt means milk, cultures

and possibly fruit - that is, no stabilizers,

thickeners and flavors added to

compensate for the lack of fat. So far

high quality yogurt has been contradictory

to healthy and fat reduced -

but not anymore! Chr. Hansen’s new

cultures can do the trick and unite

them,” promises Boesen.

Three-in-one … with extras!

The new portfolio of seven cultures,

three of them with the well-documented

BB-12 ® probiotic strain for

improved gut health, enables dairies

worldwide to deliver on all three parameters

at the same time: Exquisite

taste, healthy and clean label.

“The Creamy and Premium cultures

developed over the past two years provide

the creaminess, texture and good

taste normally provided by fat and additives,

so there is no longer any excuse

for not producing delicious,

clean, natural yogurt with optimal nutritional

properties,” Boesen says.

Go for it … or go Greek!

At the other end of the scale indulgence

is seen as a mega trend in the

dairy industry, and with Chr. Hansen’s

new cultures consumers can get

a true WOW feeling from luxury, dessert-like,

yet healthy, yogurt. Another

well-suited application is Greek yogurt,

one of the fastest moving segments

in the market.

Texture building blocks

Chr. Hansen’s strong international

development organization in combination

with its competence level

within selection and characterization

of lactic acid bacteria and composing

of unique cultures has been the

backbone in the development of the

new range. The development work

involved the screening of thousands

of strains for texture building blocks

and flavour compounds.

“Using exopolysaccharides (EPS)

we chose strains that would boost the

viscosity and gel firmness of low-tomedium

fat yogurts to counter the

thin, watery mouthfeel consumers’

associate with standard fat reduced

versions. We identified the most

promising candidates and then mixed

them in different combinations using

robot-based handling of mini scale

yogurts which enabled a fast evaluation

of a very large number of products,

supported by sensory panel

testing,” concludes Ditte Marie Folkenberg,

Senior Department Manager

and project manager of this development

project. ■

18 Danish Dairy & Food Industry … worldwide 2012 NR. 22


NR. 22

We strive to make

natural products


to everyone

Danish Dairy & Food Industry … worldwide 2012 19

Greener Solutions from

SPX Flow Technology

- SafeWater from SPX cleans up naturally

By Bent


Director Global

Marketing, Food

& Beverage, SPX,

Silkeborg, Denmark,



Implement greener process

The dairy, food and beverage industry

is looking for green solutions that

combine bottom line improvements

with social responsibility. SPX works

with customers to develop solutions

that require less energy, reduce environmental

impact and minimize water

consumption and waste. Many

of our solutions focus on optimizing

energy efficiency, helping to reduce

costs and resource usage, resulting in

not just a “greener” solution but also

a more economical one.

SPX has engaged in a significant

numbers of projects in recent years

with built in sustainability solutions

that makes a difference to our customers

bottom line and green profile.

• Next generation Tubular UHT,

with extended run time, > 30 % energy

savings and less product loss.

• GoldStream White Water recovery

process for zero milk waste and

water savings through recycling.

• Next generation Nexus Margarine

System using CO 2 refrigeration resulting

in 18% power saving and

68% heat saving.

• The APV Cavitator technology for

scale free heating and superior

mixing & dispersion resulting in increased

production efficiency and

longer up-time.

• Cold ProFrac technology resulting

in 40% operational cost saving and

added value to cheese and ingredients

products and processing.

• LeanCreme technology adding new

functional properties to cheese,

dairy drinks and food ingredients

by enhancement of best from nature

whey proteins.

• Evaporator solution for optimized

energy recovery resulting in reduced

down time and 30% reduction

of energy, water and CIP cost.

• SPX Microfiltration process for

bacteria removal in milk whilst

minimising the loss of retentate

thus reducing membrane surface

area and power consumption.

The SPX SafeWater


Conventional CIP and sanitiser solutions

have been used for decades

without major improvements of bottom

line sustainability, CO 2 emissions

and green image.

APV SafeWater is a new technology

revolutionising sanitation and

CIP procedures in the dairy, food and

beverage industries.

The fundamentals of using natural

drinking water with just a bit of salt

added and applying an electrical current

to produce a natural disinfectant

that is very similar to the chemical

process used by the human body to

fight infection has elevated the status

of natural disinfection as an environmentally

friendly solution.

When sodium chloride is subjected

to electrolysis with a dividing

membrane between the electrodes,

two separate solutions are produced.

These are primarily hypochlorous acid

(HOCl) and sodium hydroxide at the

anode and cathode respectively (Fig.1).

Fig. 1: APV SafeWater Flat Plate cell with a

membrane separating the cathode from the anode.

20 Danish Dairy & Food Industry … worldwide 2012 NR. 22

SafeWater - Natural and safe

The hypochlorous acid (HOCL) produced

by the SPX SafeWater process

sanitises process equipment rapidly

and effectively.

SPX has performed a number of

process equipment disinfection tests

that confirm the disinfection efficiency

SafeWater HOCl on process

equipment. Analyses confirm a significant

reduction of bacteria on stainless

steel surfaces and in the final

rinse water.

In addition to producing a powerful

and natural sanitiser, the Safe-

Water generator (Fig. 2 - plate configuration),

a proprietary licensed

technology, can also produce large

amounts of “ready-to-use” caustic

electrolyte which is a highly efficient

NR. 22

Fig. 2: The APV SafeWater plate system.

cleaning agent that replaces conventional

caustic cleaning solutions.

The disposal of APV FX SafeWater

after use is environmentally friendly

because the fluids are quickly neutralised

upon contact with organic

materials on the way to or at the

waste-water treatment plant.

SafeWater has significant


APV FX SafeWater has significant potential

benefits for the dairy, food and

beverage processors including: providing

a replacement for sanitisers

and chemical detergents; improved

microbial efficiency; destruction of

pathogens and biofilm and safety for

the people using it. In some cases

there can also be a reduction in CIP

time and water usage especially in the

beverage industry.

Dairy ingredients and cheese

plants can generate large amounts of

“cow water” in the form of RO polisher

permeate from membrane processing

of whey and milk and from

evaporator condensate. The polished

“cow water” might in several cases

fulfil the water volume requirement

and result in zero water intake. SPX

SafeWater HOCL can be used as an

effective sanitiser for this recovered

water before reuse.

Water reclaim and recycling is high

on the agenda in the dairy, food and

beverage industries and SPX Safe-

Water technology is a perfect match

to ensure high quality and safe water

streams. ■

Danish Dairy & Food Industry … worldwide 2012 21

Control System Upgraded Successfully

Au2mate performs successful upgrading of control system at Arla Foods amba Holstebro

Cream Cheese. As result of the upgrade, Holstebro has since 2008 reduced its costs for energy

(electricity, steam and ice water) by over 20%, plus costs for water and chemicals by over 30%.

By Jan Baastrup

Jensen, Technical

Division Director,

Au2mate A/S


Arla Foods amba Holstebro Cream

Cheese annually produces 58,000

tons of cream cheese in various flavours.

Approx. 3,500 plant components

are connected to the control

system. The former control system

was established in 1989, and the reason

for replacing the control system

was the main problem in obtaining

spare parts and limited availability of

engineering resources.

Technical solution

Success criteria for the technical solution

were to get an open system that

Holstebro itself can maintain and enlarge,

a future-proof investment, plus

encapsulating the knowledge and experience

in the dairy. Furthermore, it

should be constructed in accordance

with Arla Foods Standards / ISA S88

/ ISA S95, and built for data collection

and traceability through integration

to the Arla Foods IT reporting

system & SAP.

Scope of supply

• 8 pcs. Siemens S7-414 PLC’s

• 1 pc. Wonderware Intouch overview

station, large screen located in

the process area

• 14 pcs. Wonderware Intouch stations

distributed in the respective

control rooms and the process area

• 3 pcs. redundant Wonderware IAS


• 1 pc. Siemens programming station

• ISA S88 structured Siemens software


• Wonderware Intouch SCADA application

• Data collection for the ISA S95

structured database

Project process

The project was initiated early 2009

and extends over 3 years. It is carried

out as a step by step upgrade /

expansion, conducted over a total of

12 stages, thus the commissioning is

implemented with minimum interruptions.

The project is completed in

close cooperation with Holstebro’s

technical personnel and operators.

Improved profit for Arla


As result of the upgrade Holstebro

has since 2008 reduced its costs for

electricity, steam and ice water by

over 20%, plus costs for water and

chemicals by over 30%. Additionally,

the maintenance costs for the

control system are reduced and its

flexibility and integration possibilities

are increased. As a natural part

of the upgrade Holstebro has implemented

a good deal of optimization

and expansions of the process plant.

Today there is better traceability and

22 Danish Dairy & Food Industry … worldwide 2012 NR. 22

far better reporting capabilities than


Dairy Automation and

Industrial IT

Au2mate develops and supplies automation

solutions for the dairy and

process industry world wide. These

solutions are prepared through teamwork

and close partnerships with our

customers. The solutions cover the

entire range from complete automation

projects for entire factories, as

well as for individual process sections

to consultancy services and advice.

Our know-how covers every dairy

process from raw material reception

to packing.

We hold years of experience in the

field of process automation. We have

developed a structured work method,

and with efficient knowledge-sharing

tools, we can guarantee rapid delivery

of top-quality solutions at competitive


NR. 22

4 quick facts about Au2mate A/S

1. Founded in 2001 by Carsten G. Jensen & Klaus Dam, both with multiple

years of experience within dairy automation.

2. Has 42 employees at offices in Silkeborg, Dubai and in the UK, and

holds more than 400 man years of experience in dairy automation.

3. Project-oriented, has delivered more than 900 projects, PLC, SCADA,

MIS / MES and ERP integration to dairies throughout the world including

Nordic countries, Europe, Middle East and Africa, America and


4. Delivers solutions based on open standard platforms and internationally

recognized methods for software development and project management.

Why buy at Au2mate?

When you buy an automation solution

at Au2mate you do not only get

a control system, you buy the opportunity

to optimize your process plant

simultaneously. Au2mates staff has

many years of process knowledge

and can provide your process plant

the latest knowledge and optimiza-

tion. Your company may also be able

to reduce costs with several percentage

like Arla Foods amba Holstebro

Cream Cheese achieved. ■

Danish Dairy & Food Industry … worldwide 2012 23

Tetra Centri

AirTight Eco

World’s first hermetic direct driven dairy

separator cuts energy consumption up to 35%.

By Frederik



Director, Tetra Pak

Processing North


Tetra Pak, the world leader in food

processing and packaging solutions,

have recently launched the Tetra

Centri AirTight Eco separator, the

world’s first hermetically sealed direct

driven dairy separator.

Suitable for all dairy customers

with high capacity production, the

Tetra Centri AirTight Eco separator

reduces energy consumption of

an overall separation system by up to

35% compared to conventional paring

disc separators and doubles production

time between major services

compared to belt driven separators.

Lars Jacobsson, Managing Director,

Tetra Pak Processing Components

points out: “This new

generation separator is a further development

in our proven Tetra Centri

AirTight range of separators. Using

a number of breakthrough innovations

to deliver higher operational

efficiency and lower environmental

impact than ever before, the Tetra

About Tetra Pak

Tetra Pak is the world’s leading food processing

and packaging solutions company. Working

closely with our customers and suppliers,

we provide safe, innovative and environmentally

sound products that each day meet

the needs of hundreds of millions of people

around the world. With over 20,000 employees

and operations in more than 150 countries,

we believe in responsible industry leadership

and a sustainable approach to business.


reflects our vision to make food safe and available,

everywhere. More information about

Tetra Pak is available at www.tetrapak.com

Centri AirTight Eco separator will enable

our customers to cut costs and

meet the growing environmental demands

on their operations.”

Green innovations

The new Tetra Centri AirTight Eco

separator introduces three innovations:

the eDrive system, the eMotion

system and the eCon control system.

The gearless eDrive is a patented

new direct drive system in which the

motor is connected to the separator

spindle directly and incorporated into

the separator bowl without a gear.

That increases up-time and reduces

costs compared to belt driven separators.

With fewer moving parts and

less wear and tear, the mechanical

simplicity of the eDrive extends production

time between major services

from 8,000 hours to up to 16,000

hours. It also uses 90% less lubrication

oil than previous systems.

The patented eMotion system reduces

friction inside the separator,

enabling reduced energy loss and

thus reducing the energy consumption

of the separator itself by over

50%. That translates to an up to 35%

reduction in the energy consumption

of an overall separation system

compared to conventional paring disc

separators. Added benefits are the reduction

of noise levels by three dB(A)

and the reduction of machine surface

temperature. The eCon system is a

full control system, which handles all

of the separator’s support functions,

such as cooling, lubrication, and discharge.

This enables dairies to simplify

and improve monitoring, status

reporting and reliability of the systems

and decreases the number of

unplanned stops.


Unique to the Tetra Centri AirTight

range of separators are the hermetic

seals at the inlet and outlet, which

prevent the intake and exposure of

the product to destructive air. In the

Tetra Centri AirTight Eco separator,

the product is fed smoothly into

the separator bowl from the bottom

through the new eDrive, which ensures

that the size of fat globules and

particles is maintained. This is why

the separability of fat and impurities

and concentration of cream in the

Tetra Centri AirTight Eco separator is

more efficient than in any alternative

design on the market.

Backed by Tetra Pak performance

guarantees, the Tetra Centri AirTight

Eco separator provides dairy customers

with a guaranteed production outcome

that is pre-defined according to

contractual agreements on parameters,

such as energy consumption and

running times. ■

NR. 22

New yogurt cultures

with WOW effect

Chr. Hansen’s groundbreaking Creamy and Premium from the

YoFlex® and probiotic nu-trish® yogurt culture range create:

- Low fat yogurts that taste like full fat

- Healthy probiotic products with creaminess and

a lot of texture

- Pure and natural products without unnecessary additives

- Indulgent desserts low in fat and calories

- Available with BB-12® for added value

NR. 22

Chr. Hansen (UK) Ltd / 2 Tealgate,

Hungerford RG17 0YT - UK


Chr. Hansen A/S

Bøge Allé 10-12

2970 Hørsholm




Danish Dairy & Food Industry … worldwide 2012 25

Dairy Drying Technology

Scaled for the Future

By Carsten Juhl

Jessen, Deputy

Division Manager,

GEA Process

Engineering A/S,

Food & Dairy


Energy optimisation

Energy recovery can lead to significant

savings. A GEA Niro evaporation

and spray drying plant equipped with

extensive heat recovery systems can

save as much as 20% energy for the

same output. Similar savings can

be realised by retrofitting older


Practical limits to how much energy

can be recovered and reused in

an efficient way drive recent development

towards reducing the energy

consumption through optimised design

and by operating the plant more

efficiently. The results have been significant;

increasing capacity, less energy

use and generally lower operational

expenditures (OPEX) and CO 2


Within the evaporation technology,

optimised heat treatment systems resulting

in prevention of thermofilic

bacteria, and concentration to higher

solids content in the concentrate reduce

energy consumption. Protein

standardisation through lactose addition

and correct fine-tuning of spray

drying process conditions enables

higher solids content in spray dryer

feed with a significant reduction in

energy consumption as the result.

Worldwide milk production is growing rapidly to satisfy the

increasing demand for dairy products. At the same time,

the dairy industry and producers of formulated nutritional

products are challenged by factors like rising energy costs,

a demand for sustainable production and an increased

focus on food safety. GEA Process Engineering - one of the

leading suppliers of process technology - unite the company’s

deep-rooted insights into food and dairy processing with

technological edge to supply process lines that fulfil the

demand for food safety, product quality, efficiency and

sustainable production.

In formulated nutritional plants,

the impact of fluctuating ambient

conditions has led to integration of

process air dehumidification systems

which are integrated into the plant

energy recovery systems. The use of

controlled process air conditions enables

a tight control of drying parameters

whereby total energy consumption

is reduced.

Process development

The GEA Niro plants are constantly

developed to remain state-of-the-art.

Among the latest examples are the

optimised air dispersers and spray

drying chambers. By using the most

advanced Computational Fluid Dynamics

(CFD) simulation models,

the capacity of one type of GEA Niro

spray dryer has been increased by

30%. Furthermore, a focus on continuously

improving all plant components

according to 3A and EHEDG

standards, provide dairy and nutritional

companies plants of improved

and documented hygienic designs.

By improving the efficiency of the

spray dryers, a significant reduction

in energy consumption is accomplished.

The design of the GEA Niro

air disperser secures long production

runs with minimum deposits inside

the spray dryer and thus less frequent

CIP required. Furthermore, lower energy

consumption is realised due to

efficiently automated start-up/shut

down and through optimised process

conditions and faster achievement

of product specifications. Adjustable

nozzle lances enables round

the clock operation for long periods,

and nozzles can be inspected using

the GEA Niro SPRAYEYE monitoring


Making them BIG

In recent years, the size of a typical

spray drying plant has more than

doubled. There are clear operational

advantages of the increased plant

sizes; economies of scale and the ability

to process high quality powders

at low operational expenses clearly

stimulate the development.

As the spray drying plant is the

largest single unit operation of a

complete powder plant, the entire

production line is optimised according

to the spray dryer and to minimise

its downtime. Building requirements,

plant maintenance, round

the clock operation, advanced in-line

product analysis and lower QA cost

26 Danish Dairy & Food Industry … worldwide 2012 NR. 22

NR. 22

Engineering for

a better world!

Complete GEA

Powder Plants for

the dairy industry.

About GEA Process Engineering

GEA Process Engineering develops, designs and markets production plant

equipment and processes for the dairy, brewery, food, pharmaceutical and

chemical industries. With sales close to EUR 1.6 billion in 2011 and more

than 5,000 employees working in more than 40 countries, GEA Process Engineering

is recognised as a world leader within liquid processing, concentration,

industrial drying, powder processing & handling, emission control, solid

dosage forms & sterile products and aseptic packaging. GEA Process Engineering

is a business segment of GEA Group, headquartered in Germany.

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Synergies delivering sustainability

The new Mip products have a unique patent pending

composition. Active ingredients were selected and

systematically optimized for synergistic cleaning

performance resulting in lower use concentrations

and minimal environmental impact.

The Mip range is universally applicable in cleaning in

place (CIP) across all food and beverage industries.

all contributes to lowering operational

cost. In most cases the result

is a 9-10% reduced OPEX. With optimised

utilisation of up- and downstream

equipment and less building

requirements, total cost of ownership

(TCO) calculations shows in excess of

10% lower cost. Capitalised over a 10year

period, this leads to multi-million

euro savings.

Several large projects in different

parts of the world confirm this trend.

Most major dairy and formulated nutritionals

projects are in capacities of

10-15 t/h. However, GEA Process Engineering

has recently been awarded

the contract to supply what is to be

the world’s largest milk powder plant

- a complete milk powder line from

milk reception to powder bagging

including the world’s largest dairy

spray dryer to Fonterra in New Zealand.

The plant will have the capacity

of 30 t/h whole milk powder, equivalent

to 4.4 million kg whole milk/

day. ■

Features include:

y Hot and cold surface application

y Excellent water hardness compatibility

y Efficient cleaning of burnt on soil

y Single phase CIP

y Low effluent load

For further information, please ask your local Ecolab representative or visit our local websites at www.ecolab.com.

© 2012 Ecolab Inc. All rights reserved.

Danish Dairy & Food Industry … worldwide 2012 27

Ecolab’s new Generation of Formulated Alkaline Cleaners

New MIP Range

By Dr. Thomas M.

Buehler, Marketing

Director Flow

EMEA, Ecolab

Europe GmbH,



CIP cleaners’ requirements

Cleaning in Place (CIP) procedures

rely on water based cleaning solutions.

The cleaning medium needs to

come in contact with the soil and it

is a standard prerequisite for achieving

hygienic conditions in closed processing

environment that all parts of

the plant including gaps and crevices

need to be wetted with the cleaning


Properties of the cleaning medium

need to support physicochemical effects

and reactions such as:

• Separation, dissolution and removal

of soluble and insoluble soil

from surface

• Keeping insoluble soil particles in

stable dispersion in the soil

In addition, CIP solutions need to

comply with practical conditions in a

dairy production plant. The requirements

include aspects such as:

• Water hardness compatibility

• Quick soaking and/or dissolving

properties towards product specific


• Reduced foaming properties to ensure

effective operation, cleaning

and reuse conditions

• Compatibility with all materials of

a plant

• Good rinsability for low rinsing requirement

• Good ecologically compatibility

The complete set of requirements

mentioned above cannot be met by

a single chemical product and hence

Ecolab has developed a new range of caustic cleaners for the

dairy, food and beverage industries. This article describes

some of the background behind formulated caustic cleaners,

important results in cleaning performance and other key

criteria of the new MIP range.

formulated products are in use in

most CIP applications today.

In dairies, the main residue in the

plant comprises heat denatured protein

and milk fat. For this reason

most plants use caustic based CIP

cleaners in the main cleaning step.

Caustic soda as the main alkalinity

source offers very good dissolving

and breakup properties of dairy proteins

particularly also in heat denatured

state. In addition, alkalinity as-

Graph 1: Synergistic effect of cleaning compounds.

Graph 2: Dairy soil removal of pure caustic solution,

older and new Mip commercial product in comparison.

sists in emulsifying and dissolving of

fatty or oily soils.

Chelating and sequestering compounds

prevent insoluble mineral

salt formation in cleaning solutions.

These compounds are effective on

heat-polymerized and carbonized

food residues on surfaces in bringing

soil deposits into dispersion and suspension.

Surfactants are a group of chemicals

that reduce the surface tension.

28 Danish Dairy & Food Industry … worldwide 2012 NR. 22

Hence they are effective in penetrating

and dispersing deposits from surfaces

and also act as emulsifiers for

fatty or oily food ingredients. This

product group is selected specifically

to exhibit anti-foaming properties

in combination with foam active soil

compounds such as proteins.

The synergistic combination of

the different groups of ingredients

described above improves cleaning

performance defined here as soil

removal over time. This effect is depicted

in Graph 1.

The effect can also be seen in

Graph 2. It shows the removal of a

standardized dairy soil after a defined

cleaning interval in a dip test. In order

to be able to compare the caustic

concentrations, NaOH concentration

in the pure solution and the formulated

products was kept constant. Deionized

water is used as a reference

point for all trials to trace any mechanical

effects exerted on the product

through dipping.

NR. 22

The high standard of Danish dairy and food technology

is recognised and appreaciated worldwide. Kold college

has played an important part in developing and maintaining

this exellence. Our international activities focus

on the integration of food education and are based on

our fundamental concept “from soil to table” .

The new MIP range

Based on comprehensive screening

methods, modern raw materials were

evaluated and statistically optimized

for cleaning behavior and staining

residues and have been formulated to

produce best in class products with

respect to safety and environmental

impact. As a result of this Europewide

development and application

study, Ecolab has devised ten completely

new formulations covering all

cleaning requirements of alkaline CIP

cleaners. The new MIP products have

a unique, patent pending composition.

In addition to the usual product

and safety data sheets all products

have been prepared for new CLP labels,

ecological certificate and compatibility

statement for anaerobic

waste water treatment plants.

Results from practice

From more than 40 field trials conducted

in different industries and

countries our application managers

have gained the confidence that the

new MIP range offers excellent performance

and the ruggedness they require

in practice. In all applications

the new products achieved equal or

better cleaning results, generally at

lower use concentrations. The new

range is now implemented all across


In a large dairy site in Denmark,

Ecolab application specialists have

replaced P3-mip SP against Mip SMA

for general dairy CIP applications.

The results show that cleaning performance

could be maintained or

even improved while use concentration

was reduced and environmental

conditions could be improved. CIP effluent

COD-levels could be reduced

by over 45%. Due to lower use concentrations

and optimized formulation,

salt load in effluent could be

reduced by near 50% against the existing

effluent. In addition, the new

product is now EDTA-free. ■

Kold College offers tailor-made courses for the global

dairy sector and food industry.

We houses the only dairy college in Scandinavia: The

Dairy Training Centre of Denmark, which specialises

in courses in dairy technology • laboratory techniques

• maintenance of dairy equipment • environmental

engineering • energy saving • quality control

management • the operation of dairy plants.

Our mission is to continue the expand of our international courses and contacts. Please contact us for futher information.

landbrugsvej 55, dK-5260 odense s • t: +45 63 13 20 43 • Cvr-nr:86572028

KoldCollege.dK • KoldCollege@KoldCollege.dK

Danish Dairy & Food Industry … worldwide 2012 29

Green Cleaning &

Hygiene Concepts

By Torben Jensen,

Key Account

Manager, Novadan

Green profile

Increasing requirements from customers,

authorities and consumers

constantly force food producers to be

one step ahead on the ”Green Profile”.

However, they must use their

common sense, as a green profile may

imply additional costs and thus less

competitive power compared to producers

who do not choose this profile.

Though, choosing a green profile

within cleaning and hygiene can be

profitable in most areas, for example

CIP, foam cleaning, disinfection,

wastewater and employees’ safety.

Years of green experience

Certain unwanted substances are typically

nitrates, phosphorus, EDTA,

NTA and (base/acid) pH which need

to be controlled. Hazard labeling has

a lot to do with that, because dead

fish, highly corrosive and flammable

are not really accepted among food

producers anymore.

Novadan has many years of experience

in this area, due to the fact that

about 10 years ago, Novadan was the

first company in the industry to focus

on and subsequently launch cleaning

agents and disinfectants without

EDTA, NTA, phosphorus, nitrates

and chlorine. Novadan took

this initiative as the industry already

then started to demand effective and

environmentally friendly products

for cleaning of sensitive processing

equipment as alternatives to the environmentally

harmful products.

These years, chlorine /sodium hypochlorite

has been brought into focus

because many local authorities do

not want chlorine-containing chemicals

in the wastewater. The Danish

Environmental Protection Agency

also has chlorine on their list of substances

to be phased out.

No compromises

All these parameters and requirements

along with the wish for the

least possible product waste (waste

milk) and optimized water/energy/

chemistry consumption put large demands

on Novadan as a complete

supplier of cleaning solutions.

No colon bacteria, no germs, yeast,

mould, no flavor defects, no ap-

products for cleaning and

disinfection processes

Innovators in Cleaning

(Photo Colourbox)

pearance defects, no unwanted substances

in the wastewater are all requirements/parameters

where wrong

guidance counts. So even though a

green profile is wanted, there are no

compromises in the area.

In relation to the increased environmental

requirements, Novadan

has continuously developed new

cleaning agents and disinfectants for

e.g. aseptic filling machines, crate

washers, surface cleaning, CIP etc.

where hygienic demands are essential.

Novadan has successfully implemented

these cleaning agents, developed

specifically to be gentler to the

environment as well as optimizing

the consumption of energy and water.

If you want to know more about

these solutions, contact Novadan already

today. ■

Cleaning processes for fillings

Environmentally friendly products

No corrosion of light metals

Effective disinfectants

Effective surface products

Effective CIP products

Novadan ApS

Platinvej 21, DK-6000 Kolding

Tlf.: +45 7634 8400

Mælkeritidende_annonce 2012_GB.indd 1 23-04-2012 13:31:06

30 Danish Dairy & Food Industry … worldwide 2012 NR. 22



Plants for

the Dairy


NR. 22

Few industries are as demanding as the dairy industry when it comes to

powder processing. That’s why we’ve learned how to blend experience with

innovation to offer complete solutions that deliver to the strictest standards.

A GEA Niro plant provides everything you need, from reception, storage and

evaporation to spray drying, powder handling and packaging – with the

efficiency and reliability you can expect from a single supplier. For a partner

that knows powder, talk to GEA Niro.

GEA Niro

Gladsaxevej 305, PO Box 45, DK-2860 Soeborg, Denmark

Tel: +45 39 54 54 54, Fax: +45 39 54 58 00

foda@niro.dk, www.niro.com

engineering for a better world

GEA Process Engineering

Danish Dairy & Food Industry … worldwide 2012 31

Save energy and reduce emissions with

Energy Efficient Pumping

By Bo Knudsen,

Market Manager


Alfa Laval A/S

Pump optimization

Pump optimization is highly relevant

in today’s competitive business climate.

With the right pumps, you can

reduce total cost of ownership, raise

system performance and enhance

your plant’s environmental profile.

By optimizing pump selection, it is

possible to reduce energy consumption

and realize savings of up to 50%

(Source: British Pump Manufacturing

Association (BPMA), 2009 study,


Price or total life cycle costs?

There are several factors to consider

when selecting a pump for a given

duty. Choosing a high-quality, energy-efficient

pump with close tol-

Typical Centrifugal Pump Life Cycle Cost

Maintenance 3%

Initial purchase

price 6%

Energy 91%

Figure 1: Typical Centrifugal Pump Life Cycle Costs.

erances, optimized internal design

and robust construction is generally

a wiser approach than going with a

low-cost pump (figure 1). Some other

considerations for pump selection:

• Careful calculation of the duty

point and pump selection in order

to optimize the system.

• Working with suppliers that have a

broad pump offering and expertise

in choosing the right pump for the

right process and duty

• Best Efficiency Point (BEP) as the

selection criteria for the pump (see


Choose the Best Efficiency


The Best Efficiency Point (BEP) is the

point at which a pump operates at

the optimal head and flow rate to deliver

the highest possible efficiency

for a particular duty (figure 2). The

closer the Best Efficiency Point is to

the duty point required, the higher

the pump efficiency. Computerized

programs, such as the Alfa Laval CAS

design and selection tool, can help

Figure 2: Best Efficiency Point.

select the right pump for the task at


Optimize to economize

The principles of efficient pump operation

apply to both new and existing

systems. Because systems change

over time and even minor changes

impact efficiency, it is important to

evaluate and modify systems continuously.

During installation, newly designed

systems may require modifications

in the pipe layout due to on-site restrictions.

After installation, the actual

flow and pressure may therefore

differ from the design flow and pressure.

Or the viscosities of the final

products may differ from those predicted.

By auditing existing systems, using

pump performance characteristics,

and pressure gauges, flow meters

and amp draw meters, it is possible to

evaluate and adjust pump operation.

Modifications like these may restore

pump efficiency:

32 Danish Dairy & Food Industry … worldwide 2012 NR. 22












Best Efficiency Point (BEP)

Duty point


Pump curve

50 100 150 200 250 300 350 400 450












• Change to a pump operating at the


• Add a variable frequency drive,

which will contribute reduced energy


• Change the diameter of the pump


Other modifications, such as changing

the pipe layout to reduce system

pressure losses or removing the control

valves, can also improve pump


Payback for such modifications,

which contribute to energy savings

and reduced emissions, most often

takes less than a year.

Saving energy and reducing


Take, for example, a recent system

audit at a major Danish dairy.

Alfa Laval proposed the replacement

of two pumps, each with a 100

kW motor, with two Alfa Laval LKH

pumps equipped with variable speed

NR. 22

About Alfa Laval

Alfa Laval is a leading global provider

of specialized products and

engineered solutions that help

customers’ heat, cool, separate

and transport products such as oil,

water, chemicals, beverages, foodstuffs,

starch and pharmaceuticals.

Alfa Laval’s worldwide organization

of 16,000 employees works

closely with customers in 100

countries. Listed on the NASDAQ

OMX Nordic Exchange, Alfa Laval

posted sales of approximately 3.2

BEUR in 2011.

drives and a rated power of 75 kW

per pump. The new pumps will pay

for themselves in less than a year

through 36,000+ EUR in annual energy

savings and reduce annual car-

bon emissions reductions by 100,000


CIP energy and water


Optimizing cleaning-in-place (CIP)

pumps also contributes to energy

savings and environmental benefits.

Replacing conventional static spray

balls with high-efficiency rotary jet

head tank cleaning machines and operating

CIP pumps at the BEP will

deliver electrical energy savings of

between 60 and 80%, or roughly 3

to 10% of total CIP cost per tank, depending

on the tank size.

Why optimize?

Pumps consume 1340 terawatt hours

(TWh) or 10% of the total worldwide

energy production. Pump optimization

therefore makes good business

and environmental sense. ■


to economize

So where is all your energy going?

The surprising fact is that pumps

account for as much as 50% of

consumption in some processes.

Pump optimization for maximum

efficiency in each process is key,

it could cut your bill considerably.

321828_DK_AD_158x114mm.indd 1 13/04/12 09.28

Danish Dairy & Food Industry … worldwide 2012 33

Department of Food Science

Faculty oF Science

univerSity oF copenhagen

Dairy Technology - in an Online Classroom

Take a course that provides you with all the basic

knowledge on dairy technology - and take it anywhere

in the world!

University of Copenhagen offer the e-learning course

“Introduction to Dairy Technology” and all you

need to attend is access to the internet and a webcam.


The course will cover:

• Milk production and biosynthesis

• Basic dairy chemistry

• Microbiology of raw milk and dairy products

• Quality assurance of raw material and product

• Processing of dairy products: Fluid milk products,

Fermented milks, Cheese, Butter and Powder

• Cleaning and hygiene

The course is based on a series of e-learning modules

integrating literature studies, exercises relating to

theory and case studies. More information about the

course at: http://www.courseinfo.life.ku.dk/Kurser/



We have designed the course to fit students with a

background equivalent to a B. Sc. in Food Science.

The course equals 7.5 ECTS credits and it is possible

to attend as an exchange student, credit student or as

part of a continuing education plan.

Successful completion of the course is based on a final

written exam as well as on finishing each e-learning

module, i.e. participation in online discussions, questionnaires,

fulfilment of individual assignments and

group work.


The teachers are from the Department of Food Science,

Faculty of Science, University of Copenhagen.

They are all experienced researchers with a comprehensive

knowledge of the science and practice of

dairy technology.

About the Department of Food Science

The Department of Food Science, Faculty of Science,

University of Copenhagen performs research and conducts

teaching at the highest academic level in the area

of food science. More at http://www.en.ifv.life.ku.dk/

(Photo: Anders Clausen)


The course is offered once a year and next time will be

in September 2012. The course will start on Monday 3 rd

September and end on Friday 10 th November 2012.

How to attend?

For information on how you become an e-learning

student, tuition fee and the possibilities for continuing

education please take a look on the faculty homepage

under education: http://www.life.ku.dk/english.aspx

Other questions, please contact the course responsible,

Professor Richard Ipsen at ri@life.ku.dk

34 Danish Dairy & Food Industry … worldwide 2012 NR. 22

NR. 22


Our latest development – the new Tetra Centri AirTight Eco separator

– takes sound performance to a new level. Offering reduced energy

consumption in your overall separation system by up to 35%, a unique

new feature enables you to save even more money, while also saving

the environment.

Tetra Centri AirTight separators are already known for providing

excellent product quality, superior separation efficiency and

unmatched production flexibility.

The new Tetra Centri AirTight Eco separator also provides

embedded separator controls that assure optimal performance.

And a new direct drive that boosts effi ciency even further,

while lowering your costs.

There’s more. It’s designed for simplicity of installation,

start-up, operation, cleaning and maintenance. Oh yes, it

cuts noise levels too.

You’re welcome to visit us

at www.tetrapak.com

– or get in touch directly:


Tetra Pak, , PROTECTS WHAT’S GOOD, Tetra Centri and AirTight

are trademarks belonging to the Tetra Pak Group.

Danish Dairy & Food Industry … worldwide 2012 35

A Case in Point

- Working with Sustainability as a Key Ingredient

By Lisa Drejer



Palsgaard A/S

Consumer awareness

Consumers are increasingly interested

in high-quality, nutritious and

responsibly produced dairy products.

Having a focus on corporate, environmental

and social responsibility

across the supply chain highlights the

dairy industry’s long-standing commitment

to health as well as making

good business sense. Palsgaard explains

how working with corporate

social responsibility has become part

of the daily routines with

the company.

Natural ingredients

Palsgaard develops and manufactures

emulsifiers, stabilizers, blends

thereof as well as integrated ingredients

for the dairy, ice cream, bakery,

confectionery, margarine and fine

food industries. All our products are

based exclusively on raw materials of

vegetable origin and/or other natural

components. We are working with

industry partners to share advances

in production practices and technology

and have incorporated a variety

of measures to achieve this as high

quality application service is the most

important relation we want with our


Corporate Social


Palsgaard has formalized its responsible

approach in a set of principles

and aims comprised in our

recent award-win-

ning CSR report (available for downloading

at www.palsgaard.com). We

have pledged to become CO2 neutral

by 2020, to minimize wastewater,

refuse and packaging as well as

improve the working environment

and employees’ skills. We are also

very involved in developing supplier

management. Our CSR-strategy includes

action plans on initiatives for

working against corruption and cartels

as well, and we want to increase

the share of RSPO-certified palm oil

in our products to 100% by 2015.

Palsgaard has just been RSPO Supply

Chain certified (Mass Balance model)

and will thus be able to trade RSPO

certified products.

The raw materials used in

Palsgaard’s products comprise

mostly different kinds of vegetable

oils, gums, starches and glycerine.

Many of the initial stages in these

raw material value chains originate

in countries where there is a risk that

the standards for environmental and

working practices are not fully implemented.

This includes the supply

of palm oil, where there is

some concern about working

conditions and the impact

on climate and biodiversity.

Jakob Thøisen,

Palsgaard’s CEO,

notes: “By keeping

an implemented

supplier management

system including

set standards for quality

and ethical behaviour

we have a basis to maintain

ongoing improve-

Palsgaard has just been RSPO Supply Chain

Certified (Mass Balance model) and is now able to

supply emulsifiers based on certified palm oil.

36 Danish Dairy & Food Industry … worldwide 2012 NR. 22

ments and optimizations within our

supplier relations. We are members

of the RSPO, Green Palm and Sedex

as well as a member of UN Global

Compact and have similar ethical expectations

of our suppliers.”

Ingredient considerations

The ingredients manufactured by

Palsgaard are primarily used to give

food products the desired consistency,

stability and to ensure that they

remain fresh.

Some consumers, however, are

generally sceptical to food additives,

which are commonly referred to as

E-numbers. The E-number system is

the European Union’s internationally-recognized

classification system

for food additives. The classification

system ensures that a specific ingredient

complies with identification

and purity requirements on which

the scientific toxicological assessment

of the ingredient as content in an ordinary

food product is based.

NR. 22

At Palsgaard, we see our food ingredient

products as playing a positive

role in matters of topical interest

to consumers, e.g. low-fat products

such as ice cream and yoghurt, and

other fat reduced consumer products.

Emulsifiers are also used in the improvement

of food waste reduction.

We believe that food additives should

be the subject of more nuanced debate

and we encourage a dialogue

with decision-makers and consumer

organizations on issues of this nature.

Processing and people

Our goal to achieve CO 2 neutrality

was based on well-established

practices. These include optimizing

and improving efficiency in production

processes to create a balance

between costs, quality and the

environment. In 2005, we built the

largest privately-owned strawfired

heating plants in Denmark and have

converted all our boilers from heating

oil to natural gas. This, and our

other energy consumption optimiza-

Emulsifiers and stabilizers for dairy

Visit www.palsgaard.com

to find out how we can help you

in your product development.

tion plans, earned Palsgaard the Danish

environmental award Wise m 2 in


To create sustainable products, it

is also worth investing in the people

producing them as well as the local

community. While this is often seen

in dairy farming, it is also highly relevant

to the dairy ingredients sector.

Thøisen explains: “We invest in varied

sectors including wind farming,

real estate, forestry, research, farming

and the local community. Our

consideration for our employees also

manifests itself in our remarkably

low employee turnover rate.”

In the dairy sector, as in the wider

food ingredients industry, responsible

know-how and dedication

are the best way to achieve continued

success. Thøisen concludes: “To

Palsgaard the dedication to strategic

CSR means competitive advantages

and enables us to market our

responsible profile in a verifiable

way. ■

Enhanced emulsion stability, mouth-feel,

texture and viscosity. Improved stability,

whippability, foam structure and water

retention... Palsgaard’s emulsifier &

stabilizer systems help you achieve it all.

Our technical teams around the world

are experts in emulsifiers and stabilizers

for various dairy products and know how

to create products matching local tastes

and preferences.

Palsgaard A/S

DK-7130 Juelsminde, Denmark

Phone +45 76 82 76 82


Danish Dairy & Food Industry … worldwide 2012 37

Solutions Meeting the Needs

The TREPKO Innovations

By Agnieszka

Libner, MSc,

President &

Managing Director,

TREPKO Sp. z o.o.,


Areas of innovations

TREPKO has been present in the

packaging machinery market for

decades now, mainly thanks to the

customer-based innovative approach.

Especially in the recent years,

TREPKO participated in an accelerating

pace of innovations in the food

industry. Although the new solutions

arise from a truly close co-operation

with our customers, we have also witnessed

how our proposals inspire

food producers for further development.

The recent years have been especially

fruitful in three areas of innovations:

• Comprehensive solutions to cover

all the steps of the packaging process

• New products to respond to the

growing needs of our customers

• Customised innovations to follow

even the most sophisticated ideas.

Thanks to a vast area of expertise

TREPKO offers solutions for the

whole packaging process – from a

single, unit container to a pallet. Integration

of different machinery types

in one line is aimed at smooth performance

of all the packaging functions

but also taking advantage of synergy

effect. Since all the components of a

packaging line are designed, made

and integrated by the TREPKO specialists,

they are prepared to work as

a system with little manpower and

supervision required. On the other

hand, our expertise allows us to adapt

lines’ layouts to customers’ local conditions.

New machineries

To compliment the existing range

of machinery TREPKO introduced

new products in our range. Based on

many years of experience within the

brick forming & wrapping technology,

a new generation of these machines

is developed. The first machinery

type 822 packs 250 g brick with

capacity of 250 bricks per minute giving

an output increased by 35% compared

to the previous generation. A

number of these machines have been

successfully installed.

Another new product by TREPKO

extends the range of packaging types

within the TREPKO’s offer. The new

900 Series represents a range of

Form-Fill-Seal technology for the individual

mini-portions. The machines

cover an output range of 80-200

packs per minute and can be supplied

with a wide range of depositing

systems. Thus a variety of different

products, including processed cheese,

butter or other spreadable fats, can

be packed into small containers.

Keeping up with the development

pace of new technologies has also

been a major factor in the TREP-

KO’s new products. A perfect example

of such development is a new palletizing

robot that includes a brand

new upgrade of the control system.

Thanks to a new interface the functions

of this unit can be controlled

from an iPad ® or tablet. New algorithms

furthermore enable optimised

movements and automatic generating

of proposals for the optimal pack


Customised solutions

Apart from new products, a major

part of the TREPKO’s new solu-

tions results from realisation of innovative

projects. A strong technical

background supported by an openminded

approach and state-of-theart

production facilities ensure that

even the most sophisticated ideas are

implemented in the packaging machinery

delivered by TREPKO. Thus,

new trends in the dairy and packaging

technology can easily be found

also in the TREPKO’s standard products

in the form of customised solutions.

Each year brings another set of

examples of such innovations.

One of them is a versatile model

of a brick forming and wrapping machine

- PMG 5, which opens up the

possibility of packing bricks within

the wide range of 250-2000 g. The

solution offers a possibility to form

both traditional and oval shape with

a limited change-over time. On the

other hand - in its brick forming and

wrapping range, TREPKO has also

built a twin PMG 4 machine for packaging

of 10-15 g bricks, integrated

with a semi-automatic stacking unit.

Interesting new solutions are also

offered within the cup filling and

closing range. One of them is implementing

a new closing type in the

form of pre-cut foils dispensed from

a daisy-chain. A special foil from reel

dispenser can be installed on any

TREPKO cup filling & closing machine.

Hygiene and safety

TREPKO has always been dedicated

to the packaging hygiene and safety

issues. In every step of the packaging

process preservation of the product

safety can be additionally enhanced.

Therefore, in the range of optional

equipment a great number of different

hygienic solutions can be found.

They include both cleaning an empty

container, sterilisation methods, fill-

38 Danish Dairy & Food Industry … worldwide 2012 NR. 22

TREPKO 900 Series’ machine.

Deionization of cups on a TREPKO 200

Series’ machine.

ing in modified atmosphere as well

as control means for checking a final

packaging. Safety and shelf life of the

product rely strongly on the continuous

efficiency of these systems, so

a great attention is paid to the selection,

design and application of these

systems. Variety of the offered solutions

allows both to reach the Ultra-

Clean standard or simply to optimise

the packaging hygiene within a certain

economical budget.

NR. 22

An example of brick formed on a

TREPKO PMG 5 machine.

TREPKO Conference & Exhibition Hall.

New Exhibition &

Conference Centre

Facts speak louder than just declarations.

At TREPKO we understand

that an investment process requires

a practical insight into the machine’s

operation, so we make it possible for

our customers to participate in a testdrive

at our newly opened Exhibition

& Conference Centre based in

Gniezno, Poland. In the near future,

a permanent exhibition of packaging

15 g bricks from a TREPKO PMG 4


machines with a possibility of testing

them will be opened for our customers.

Special courses for the technical

staff focusing on running and maintenance

of the TREPKO machines will

soon take place. We are also looking

forward to meeting our customers at

the 3rd edition of the TREPKO Conference

& Exhibition, which will be

held in spring 2013. ■

Danish Dairy & Food Industry … worldwide 2012 39

Green and Sustainable

Dairy Production

By Ole Lund Svendsen, DSM

Nutritional Products Europe Ltd,

Regional Marketing Manager, Animal

Nutrition and Health, EMEA

Ruminants and global warming

Global warming is linked to the emissions of greenhouse

gases such as CO 2 , CH 4 and N 2 O.

72% of these emissions are CO 2 notably coming from

means of transport. Methane (CH 4 ), however, is also seen

as a key gas to reduce because its Global Warming Potential

is much stronger than CO 2 . Moreover, the impact of

its reduction is quicker to observe than for CO 2 due to a

shorter life cycle in the atmosphere. Even though ruminants

only contribute to 2% of global greenhouse gases

emissions, there is an interest in reducing their methane


Ruminants and the carbon cycle

Ruminants eat plant-based food that is pre-digested by

microorganisms in their rumen, then regurgitating the

semi-digested mass and chewing it again. This process is

called “ruminating”. The rumen is like a fermentation vessel,

with a wide variety of bacteria which produce energy

for living and performance (milk and meat). During this

essential process, also methane is produced and expelled

through the mouth of the ruminant. This is a waste of energy

for the animal and it contributes to global warming.

DSM is working much focused on the optimization of

the efficiency and longevity of dairy cows in order to decrease

methane and other related emissions from dairy

production units.

Who is DSM?

DSM is the world’s leading supplier of nutritional ingredient

and solutions for the dairy industry. From Optimum

Vitamin Nutrition (OVN) TM ingredient solutions for Animal

Nutrition, to award-winning Enzyme and Culture solutions

for Dairy Foods production to unparalleled valueadded

nutritional ingredients that enrich and enhance

Dairy Foods for Human Nutrition, DSM is at the forefront

DSM has recently initiated a research project focusing on

reduction of methane emissions by changing the diet of the

dairy cow including a new feed ingredient solution.

and deeply involved in developing healthy and sustainable

solutions for the dairy industry world-wide.

Traditional dairy nutrition

The beginning and very important part of the dairy value

chain starts at the dairy farm. Starting with the feed ingredients

and the premix, the OVN concept is one of the

most cost-effective strategies one as a dairy farmer can

implement to ensure optimum lifetime performance in

the dairy herd. The OVN concept is what is used in practice

since years. For instance, the vitamins β-carotene

(pro-vitamin A), E, as well as biotin are of prime importance

in the nutrition of dairy cows. They play a key role

in the prevention of the three main reasons for culling

in modern dairy herds. Reproductive disorders (concept

β-carotene), mastitis (concept vitamin E) and lameness

(concept biotin) accounts for 65% of culls in high yielding

dairy herds. OVN supplementation ensures that the animal’s

diet is fortified with these vitamins at levels required

to achieve optimum productivity, health and well-being.

Looking beyond tradition

Looking into the future development the research and development

activities at DSM Nutritional Products are focusing

on identifying and developing new solutions to

40 Danish Dairy & Food Industry … worldwide 2012 NR. 22

the animal and feed industry which goes beyond traditional

nutrition. Animal nutrition, being part of the “Food

Chain”, has to consider the consumers demand for safe

and high-quality products of animal origin, environmental

aspects and animal welfare. It is our challenge to contribute

with our solutions to these needs. Currently the

main focus of our research is set on these topics.

As to a better improvement of feed utilisation and environmental

aspects, we are currently promoting our

CRINA ® Ruminants solution which is a blend of essential

oils. This solution is aiming at releasing the full potential

of the rumen by helping and sustaining a healthy balance

in the rumen which in return is optimizing protein

and energy utilisation of the feed benefitting the animal’s

production of milk and meat instead of being excreted in

the manure.

DSM is also currently looking at enzyme ingredient solutions

which when fed to the dairy cows in return can

break-down feed raw material fibers more efficiently; e.g.

more rapid hydrolysation of starch rich diets which more

and more is what is fed to the modern high yielding cow

of today. Our RONOZYME ® RumiStar ® concept is currently

awaiting EU approval which is expected towards

the beginning of 2013.

Methane emission

One of the big topics of the climate debate is methane and

this debate is often linked to dairy cows. Via their rumen,

dairy cows produce methane which has a Global Warming

Potential 25 times higher than CO 2 .

More recently, DSM initiated a research project which

objectives are to directly reduce methane emissions by

influencing the fermentation process. The approach is

change the diet of the dairy cow including a new feed ingredient

solution that will encourage the bacteria in the

rumen to produce less methane but make more energy

available for production. We are currently collaborating

with main stakeholders in the ruminant science community

of the world and selected industry partner to speed

up the development work and get faster to the market

which desperately needs such innovative solution. To be

continued… ■

NR. 22

I want a

brighter world.

What will we want in the future? Who can tell?

We may not value what we value today. But we will

certainly expect a happier, healthier, safer world.

At DSM we believe Bright Science can take us there.

It’s our name for an approach that brings together

ideas, sustainable solutions and innovation from

across Life Sciences and Materials Sciences.

And it could make allour lives brighter.


Danish Dairy & Food Industry … worldwide 2012 41

Sustainable Salt


A few years ago, Akzo Nobel Salt DK calculated that two of

Arla Foods’ dairies could gain considerable advantage by

changing type of salt in the production of butters respectively

cream cheeses. To solve the issue, Akzo Nobel Salt came up

with a sustainable solution in more than one way …

By Anna Marie Thøgersen, Editor


- A few years ago, we found that the

two Arla Foods Holstebro plants producing

butter respectively cream

cheese could reach some economical

benefits by using other salt types.

Of course, the plant managers would

eventually have reached the same

result. But, plant managers are extremely

busy, and one of our key

tasks as business affiliate is to provide

our customers with honest information,

improved solutions and services,

underlines Claus Smedegaard,

Business Development Manager at

Akzo Nobel Salt.

The salt issue

At Arla Foods Holstebro butter factory

it is of extreme importance to

produce the world renowned Danish

Lurpak butter under the utmost

standards and amongst several quality

parameters the factory uses Akzo

Nobels butter salt for the butter

brine. Though, this type of salt was

used for other purposes not required,

and further all types of salt were delivered

in sachets and big bags. The

nearby Arla Foods cream cheese factory

likewise received the required

amount of salt products in this type

of packaging.

To solve the issue, Akzo Nobel Salt

came up with a technical solution

which resulted in construction and

installation of a 60 cubic meter salt

silo with capacity of 70 tonnes of salt.

Less driving, packaging and


This solution holds several environmentally-friendly

advantages - both

externally and internally. Today,

the necessary salt amount of app.

30 tonnes delivered by truck is decreased

to just every second week.

Larger quantities of salt per delivery

mean less driving - and less CO 2

emissions. The salt silo solution implies

no more purchases and disposals

of big bags and other packaging.

About Akzo Nobel

Akzo Nobel Salt Specialities is part of the global coating and chemical

Group Akzo Nobel, headquartered in Amsterdam, and a Global Fortune

500 company. Akzo Nobel operates in more than 80 countries and employs

app. 55,000 people around the world.

Akzo Nobel Salt Specialities is one of the world’s major suppliers of salt.

The salt is used in a variety of applications within e.g. food processing,

pharmaceuticals, water softening, and agriculture.

Arla Foods about the


Project Manager at Arla Foods

butter factory, Michael Jensen is

indeed very satisfied with the solution

provided by Akzo Nobel

Salt. - Today, we receive a broader

range of specific salt products at

total lower costs, and we now use

the former 30 square meter storage

room for other purposes. Further,

we avoid heavy handling and

disposal of no less than 32.000

pieces of 25 kg salt bags, and not

least the employees avoid salt dust

nuisances. All together, the solution

provides us with yearly savings

of 10-15%. (Photo shows Project

Manager Michael Jensen on

top of the salt silo).

Further, the working environment

has improved for the involved employees

- both at Arla Foods in Holstebro

and Akzo Nobel Salt in Mariager

- as they no longer have to

manually pack/unpack and otherwise

handle the heavy big bags.

Strengthens Technical


As Akzo Nobel Salt DK wants to

strengthen this type of technical services,

the company has recently recruited

a highly skilled engineer, Mi-

42 Danish Dairy & Food Industry … worldwide 2012 NR. 22

Market Development & Technical Service Manager, Mikael

Saaby Tofts primary task is to strengthen Akzo Nobel Salt’s

technical service to the benefit of the customers.

kael Saaby Toft. He is by now the

technical interpreter and liaison between

Akzo Nobel Salt and the company’s

dairy and food customers. -

Besides the day-to-day technical and

product related counselling, my ambition

is to learn, transfer and be

ahead of possible technical solutions

to the confidential benefit of our cus-

NR. 22

Suprasel salt is the professional

solution for the food industry when

you need salt of high quality and

a high level of food safety in your


Akzo Nobel Salt is the leading European

producer of salt for the food industry in Europe

• Akzo Nobel Salt is the largest European

producer of vacuum salt with plants in

Denmark and Holland

• We have the highest quality standards and

we deliver according to: On Time In Full to

food manufacturers all over Europe

• We are certified with ISO 9001, ISO

22000 (HACCP) and GMP (pharma)

tomers, underlines Mikael Saaby


Akzo Nobel Salt Denmark

Akzo Nobel Salt Denmark is one out

of Akzo Nobel’s three salt factories

situated in respectively Mariager,

Denmark, and two in The Netherlands.

Salt for the food industry

Akzo Nobel Salt A/S · Tlf.: +45 9668 7888 · Mail:mariager@akzonobel.com

The Danish factory processes vacuum

salt, based on salt fetched from

the company’s own salt dome just a

few miles west of the refinery. This

dome contains 30 billion tonnes of

salt, of which 600.000 tonnes is retrieved

every year. And when will the

salt dome be empty? Not within the

next 16.000 years! ■

Danish Dairy & Food Industry … worldwide 2012 43

The 43 rd Nordic Dairy Congress in Norway June 2013

Nordic Dairy Industry

- Future Perspectives

The Nordic Dairy Council welcomes you at the 43 rd Nordic Dairy Congress to be held in

Norway, June 6-8 2013. The congress takes place in Lofoten at Thon Hotel Lofoten in the

centre of Svolvær close to the picturesque harbour. Lofoten is located north of the polar circle,

and thus by attending you can enjoy the midnight sun. The theme of the 2013 technical

program is “Nordic Dairy Industry - Future Perspectives”. All lectures will be given in English.

By Kjetil Høvde, President of the

Nordic Dairy

Council 2010-13, M.Sc. Dairy Science

and Dairy Manager, TINE

Future Foods

Welcome to every third year organized and in order the

43 rd Nordic Dairy Congress to be held at Thon Hotel Lofoten,

in Svolvær June 6-8 in 2013.

The theme of the congress will be “Nordic Dairy industry

- Future Perspectives”, and the program offers an extensive

view of the latest technological and future developments

and innovations within the world-renowned

Nordic dairy industry. The programme includes six sessions

within two days:

Responsible food sessions

• Future challenges in the Nordic dairy industry

• Product quality

• Nutrition and health

Future products and possibilities sessions

• Future products and possibilities

• New product technology

• New product properties

The sessions include approximately 15 presentations performed

by highly specialized key-note speakers. Please

visit our homepage for more information. The program is

continuously updated and is available at www.dairycongress.no


The Nordic Dairy Congress addresses all dairy people

working within the fields of product/process technology

and development, quality, primary production, dairy production

and marketing. Moreover, the congresses are attended

by participants from related areas as packaging,

detergent, culture, ingredients and bio-science industries

and as well as from dairy schools, research institutes and


Approximately 2-300 dairy people from all over the

world attend the congresses every third year.

Nordic Dairy Council

The Nordic Dairy Council (Nordisk Mejeriteknisk Råd

- NMR) is responsible for the continuity, coordination,

arrangement, quality and high expert level of the congresses.

The Nordic Dairy Congress takes place every

third year and the practical arrangements alternate between

each of the Nordic countries.

Enjoy the midnight sun

In addition to an interesting technical program, you will

experience the magnificent arctic summer and Norwegian

nature at its best. Lofoten is located north of the Polar

Circle and from May to the end of July there is daylight all

day and night long. We also hope for nice weather so we

are able to enjoy the midnight sun. The social program of

the congress will give you an opportunity to experience

the special nature of Lofoten and cultural highlights.

As president of NMR and the congress period 2010-13 I

am happy to warmly welcome you all at the 43 rd Nordic

Dairy Congress, June 2013 in Norway. ■

44 Danish Dairy & Food Industry … worldwide 2012 NR. 22


Responsible Food

1: Future challenges in the Nordic dairy industry

At this opening debate, representatives from each of the

Nordic countries give short introductions within the following

themes: Volumes vs. specialties, Diet advice/authorities

requirement/nutrition, Industry structure,

Consumers demand and request, Education/branch qualifications,

Challenges in production technology, Availability

of raw milk/logistics/environmental requirements.

2: Product quality

What is quality? Which quality requirements, will consumers

make in the future, and how does the Nordic dairy

industry meet these demands? Focus on future challenges

within quality management in the value chain from raw

milk to consumer.

3: Nutrition and health

Which nutrition requirements do the surroundings have

to dairy products and how can we meet these challenges?

Focus on product content and how to combine know-how

and technology to meet these demands.

Future products and


4: Future products and possibilities

This session will e.g. focus on The New Nordic Food

movement and possibilities for the Nordic dairy industry,

influence of dairy products in the new Nordic Diet, possibilities

in the value chain and Nordic differentiation.

5: New product technology

The application of new technology to develop tailor made

new products. The session addresses topics within new

possibilities of different milk types as raw materials, innovative

technologies and processes, and new possibilities in

packaging and logistics.

6: New product properties

How to surprise the consumer and retailer with new and

innovative Nordic products with added value?

Focus on e.g. technological possibilities in fermentation,

functional properties, and Nordic Ingredients.


Approximately 300 dairy people attended the 42 nd Nordic

Dairy Congress, held in Finland, June 2010.

NR. 22



Complete consumer`s fresh milk dairy plant.

Manufacturer: TETRA PAK. 30 million liter milk per year.

Extremely good condition. Consisting of:

• Milk reception. 3 lines in

• 2 x pasteurizing lines. 20.000 l/h and 12.500 l/h

Incl. separators, homogenizers, pasteurizers, etc.

• Stainless steel storage tanks, buffer tanks, cream tanks

• 1 x CIP Plant. 5 tank system. 7 lines

• 1 x Automation system. Incl. operating panels

• 3 x Tetra Pak filling lines:

Tetra Rex 8 for filling 0,25/0,33/0,5/1,0 liter cartons

Tetra Rex 7 for filling 0,25/0,33/0,75/1,0 liter cartons

Tetra Rex 6 for filling 1,5 liter cartons

• Container fillers

• Container washing machine

• Carton crushing machine

• Huge number of belonging pumps, valves, instruments

• Utilities, i.e ammonia compressors, air compressors etc.


The plants will be sold ”in as it is working condition”

ex. works “Tine Høgset Dairy” Norway.

Inspection & Sale Now!

Visit our Web page for more information.

Responsible for sale, customer registration and




(Sales- & Engineering Department)

Phone: +45 75343434 • Fax: +45 86944800

DK-8464 Galten/Aarhus

fhs@fhscandinox.com • www.fhscandinox.com

Danish Dairy & Food Industry … worldwide 2012 45

Complete Packaging Handling Systems for


By Anna Marie Thøgersen, Editor

Infant formula packaging

Infant formula is a growing segment

within the global market for canned

products, and most of the major milk

powder producers are fully aware of

the Danish company Jorgensen Engineering’s

packaging handling competences

for these products.

- To fulfill customers’ and end-consumers’

high quality demands on infant

formulas - as well as on other

foods, we successively optimize the

technologies behind our complete

handling lines. This includes e.g. robotic

technologies to the benefit of

optimized production as well as handling

the milk products at the highest

possible hygienic level. Our knowhow

and high focus on sterilization

of the cans and lids before filling ensures

a quality product with a long

shelf life, explains Jesper Johansen,

Jorgensen Engineering is one of the global leaders within projecting,

constructing and building of complete packaging handling

solutions for foods and pharmaceuticals. One of the business

areas is packaging systems for infant formula products,

and in co-operation with a major player within milk powders,

Jorgensen has just recently constructed an advanced robotic

system for placing portioning scoops in canned infant formulas.

marketing manager at Jorgensen Engineering.

For the time being Jorgensen’s

technical staff is working around the

clock to finish a new robotic solution

for a global player within infant formula.

As extras this solution features

robots for inserting up to 350 scoops

in cans per minute and vision systems

checking correct insertions.

Leak tester detects micro leaks

- Recently, we have also launched an

innovative can leak tester measuring

on nano-level, which makes the

method extremely accurate and ensures

that the milk powders’ shelf life

is maintained, continues Jesper Johansen.

He underlines, that the leak

tester is fully automatic and designed

to be integrated into any production



and gentle







in front of a

can handling


The system uses inactive helium

gas as tracer in the full cans in a nondestructive

test. The inert gas is present

in the containers as a result of

the milk powder production and

packaging process. The cans are exposed

to a strong vacuum, and the

equipment utilises the unique ability

of helium to penetrate even the

smallest cracks and flaws. If helium

is detected outside the can, a leak signal

is given for further inspection and

localisation of the leak. The system is

also capable of testing empty cans.

Powder packaging lines

Lines for infant formulas feature various

customized technological solutions,

but in general a complete packaging

handling system for infant

formulas features: Automatic de-palletizing,

jet air cleaning and feeding

of empty cans, scoop inserting, filling,

check weighing, clinching, end handling,

air evacuation and gas flushing,

seaming, labeling, plastic lid overcapping,

code reading, wrap around

case packaging, case coding, palletizing,

and line control SCADA.

Whatever line, flexibility is a key

word when it comes to changing between

can sizes, and the equipment

meets the highest standards of hygiene

and easy cleaning.

Jorgensen solutions

Jorgensen is an international specialist

within projecting and building of

46 Danish Dairy & Food Industry … worldwide 2012 NR. 22

Complete robotic system for scoop insertion as delivered to one of the largest European dairy companies. In

close co-operation with the customer, Jorgensen Engineering has constructed a complete powder line including

robotic technology and a SCADA control system, which communicates with the management control system.

complete packaging lines to various

business segments as human food,

infant formula, milk powder, condensed

milk as well as pet food and

pharmaceuticals. The lines are built

to handle different packages made of

tin, aluminum, glass and plastic.

The company has almost 80 years

of experience within systems for retort

handling, conveying, de-palletizing

& palletizing, cleaning & sterilizing,

infant formula/milk powder and

SCM handling, and fruit & vegetables

handling. Further layout and degree

NR. 22

of automation are fully tailored to

meet the customers’ requirements.

Jorgensen Group

Jorgensen has supplied processing

equipment and know-how to customers

all over the world for almost 80

years. Jorgensen Engineering a/s is a

privately owned company founded in

1933, and is the holding company in

the Jorgensen group. During the years

the group has grown to its present size

with 250 dedicated employees in eight

compagies in Denmark, Netherlands,




Close-up photo

shows one

of the robots

picking scoops

for placing in

the cans on the


Germany, Switzerland and Australia.

The Jorgensen Group consists of:

• Jorgensen Engineering: Packaging

handling systems

• Tripax Engineering: Food processing


• brüel international: Crate washing

& handling systems

Today Jorgensen Engineering is

considered to be one of the leaders

within several of its business areas

offering customized packaging handling

systems. ■

With a little help…

…from Jorgensen

Together with the market

leaders in the food industry

we continuously optimize and

develop packaging handling

systems for infant formula,

baby food and milk powder.

Our strengths are:

engineering, innovation and


And to keep promises.

Jorgensen Engineering a/s

M.P. Allerups Vej 20 • DK-5220 Odense SØ

Tel.: +45 63 13 22 11 •� www.jorgensen.dk

Danish Dairy & Food Industry … worldwide 2012 47

Optimizing Hygienic Designs

By Mogens Andreasen, Managing Director, LP Kolding

LP Kolding features 48 years of experience

in design and construction

of stainless steel tanks and processing

plants. When designing new or

upgrading existing facilities for optimized

production, LP Kolding focuses

on hygienic designs. Recently

we have completed a delivery of preheater

units for process optimization

of whey protein concentrate at Arla

Foods Denmark Protein plant.

Customer dialogues

LP Kolding is a specialist within designing,

planning, construction, documentation

and installation of stainless

steel tanks and process equipment.

The company always cooperates with

customers, from concept to the desired

installation is completed, installed

and ready for production.

Based on positive dialogues to provide

optimal design, our business

concept is custom tailored solutions.

LP Kolding’s expertise is founded on

the company’s employees who possess

the necessary high skills ranging

from design knowledge to technical

handling of materials during construction

and assembly.

Tanks • Units • Plants •

Special Stainless Alloys

• Engineering

• Project Planning

• Construction

• Documentation

• Assembly

Tanks and complete plants

LP Kolding has decades of experience

within designing and constructing

steel tanks without pressure, as well

as pressure tanks in stainless steel.

We custom-design PED approved

pressure tanks, thus fulfilling current

EU standards for safety in operation,

material design, manufacturing process

and continuous tests.

LP Kolding possess special expertise

in manufacturing pressure vessels

for the following purposes: Fermenters,

mixing tanks, inoculum

tanks, process tanks, tube heat exchangers,

sterile tanks, air tanks, vacuum

tanks, and pressure cookers.

We clarify the required needs for

the processing tanks regarding e.g.

design, pipe work, heating/cooling

jacket, various applications, and

measuring equipment. Further, we

ensure all requirements regarding

strength, insulation and cladding depending

on tank location. Moreover,

we are experts within final assembly

and subsequent documentation.

During the years, LP Kolding has

constructed units for: Fermentation,

evaporation, powder pumps, drying

chambers, butter churns, pressure filters,

and complete units - ready to install

in the dairy plant.

Optimized hygienic design

for WPC

Recently, we have constructed preheater

units for whey powder concentration

at the new evaporator at Arla

Denmark Protein in Videbæk. The

task included high priority on an optimized

hygienic design on the WPC

pre-heater units. Thus, we e.g. focused

on optimizing piping for elimination

of dead-legs and on optimum

CIP cleaning. Also continuous quality

control of surface roughness and the

welding quality has been in focus.

Global Company

The LP Kolding staff count 24 highly

competent employees, and the company

contributes as subcontractor as

well as independent business partner

within our field of expertise: Designing

and building hygienic process

equipment and tanks for customers -

around the world. ■

Stainless Steel Solutions

Complete 1000 liter Butter Churn on frame

LP Kolding A/S • Egtvedvej 2 • 6000 Kolding • Denmark • Phone: +45 75 52 41 77 • lp@lp-kolding.dk • www.lp-kolding.dk

48 Danish Dairy & Food Industry … worldwide 2012 NR. 22

ALECTIA has delivered planning and building consultancy on ARLA Food’s impressive powder plant

in Vimmerby, Denmark

Future-proof solutions

With more than 60 years of experience, ALECTIA is a leading advisor to the

international dairy and food industry.

We deliver cross-disciplinary solutions combining function, design and

economy with long-term development. ALECTIA offers advice during the

entire project implementation - from the very first ideas until our client has

a fully operational plant, designed to meet future requirements.

Our consultancy includes everything from building projects, water supply

and waste water treatment, health and safety, logistics and process optimization

to business and strategic development.

Visit us at www.alectia.com

NR. 22

Danish Dairy & Food Industry … worldwide 2012 49


By Karin Elsebeth

Hansen, Senior




Sustainability is high on the agenda

of many industries, governments and

organizations. Focus is not “only” on

how to ensure high quality, safe products,

a good working environment,

and how to reduce the environmental

impact of the factory.

Now focus is increasingly concentrating

on how the business performs

as a whole, and how it operates from

principles concerning people, planet

and profit - and how a positive development

is ensured in the long term

indicating that sustainability is a

long-term strategic process for which

individual solutions are needed.

For the food and dairy industry

there are a number of common elements

that are relevant to focus on.

The “People, Planet, Profit” concept

is therefore expanded with “Product”

and examples of focus areas are given

in the fact box.

Within the dairy industry, some

companies have come a long way

in developing policies within these

“People, Planet, Profit and Product”

- An Integrated Approach for Improving Performance on

People, Planet, Profit and Product

areas and have turned these into essential

elements of their overall business

strategy, often by combining

health and safety, environment, food

safety and social responsibility in

core business objectives and strategies.

Getting started

A sustainability policy and strategy

is not developed overnight, but is

based on the values of the company,

its market and ideas along the path

to where the company wishes to be in

the future.

People: At a strategic level you

need to have skilled and competent

employees and to retain them,

by providing a safe working environment,

continuous education and

training and being able to attract

new employees through collaboration

with local educational institutions.

For this you need targets on incidents,

accidents and absence, but

also on employee turnover and training

days per year.

Planet: Efficient usage of resources

can be obtained in many

ways either through objectives and

ALECTIA has facilitated sustainability workshops with international clients prior to

large capital projects such as planning and design of green-field manufacturing sites.

targets on energy and CO 2 reductions,

allocation for environmental investments

within the annual CAPEX investment

pool or through calculation

of carbon or water footprint of products

manufactured at the production

facility. Design of the manufacturing

building should also be taken

into consideration both concerning

climate as well as building materials.

Further, proactive collaboration

with suppliers of process equipment

and ingredients should be part of the

sustainability strategy. For example




• Competent staff, including

training and retention of skills

• Safe and healthy workplace

which prevents illness and attrition

• Provide working conditions

such as leisure facilities, childcare

and medical support


• Minimize the usage of non-renewable


• Reduce the environmental impact

of the business

• Utilisation of existing resources

– raw materials and equipment

• Building design and materials


• Capacity of the existing plant

• Efficiency of utilities

• Focus on and reduction of wastage

• Supply chain efficiency


• Product safety

• Good ingredients

• Sound and sufficient packaging

50 Danish Dairy & Food Industry … worldwide 2012 NR. 22

Five Divisions in ALECTIA

• Leadership, Health and Safety

• Water, Energy and Environment

• Building

• Process (Brew, Dairy, Food, Business Consult)

• International

purchase of a new homogenizer with

lower noise level and less energy usage

or supply of ingredients sourced

from sustainable manufacturers and


Profit: An efficient plant and supply

chain is an essential part of a sustainability

strategy. Production audits

and LEAN programs are some of

many methods to identify and optimise

the capacity of the production

equipment. Business structure analyses

may help optimizing supply chain

activities in general.

Product: For the food and dairy

industry efficient usage of raw materials

is a must, ensuring that healthy

and safe products are developed,

manufactured and distributed to customers

and consumers. Packaging

must be sound and sufficient both for

protecting the products throughout

their storage life and disposal/recycling

of the packaging material.

For all aspects it is important that initiatives

are not only initiated from

own interest of the company, but

also from being in dialogue with external

stakeholders, e.g. consumers,

customers, authorities and suppliers,

and to jointly work towards longterm

sustainable solutions to the

benefit of People, Planet, Profit and


Managing a sustainability


To make a difference the sustainability

strategy must be transformed to

actions and results - it must become

operational at all levels within the organisation

so each division, business

unit or department can contribute

to and drive the overall strategy. For

each area specific indicators must be

NR. 22

ALECTIA 100 years

1912: The engineering company Birch &

Krogboe is founded

Since 2005 11 strategic acquisitions have

been completed

2005: Danbrew

2006: “Dansk Arbejdsmiljø” og “Byggeriets

Arbejdsmiljøcenter Danmark”

2007: JobLiv Danmark

2007: Watertech

2007: MA Project

2008: Penborn Technical Services Ltd

2009: Maersk Constructions

2009: Tano FoodCon Group


2011: Healthy Company

In 2008 the company name was changed to

ALECTIA. ALECTIA has 700 employees in

offices in Denmark and UK. In addition we

have agents worldwide and we also establish

temporary project offices in the countries

where we perform large capital projects

for our international clients.

agreed and targets must be set for actions

and initiatives.

ALECTIA can assist you in preparing

both a business specific sustainability

strategy and objectives - and

also in making the strategy operational

in the day to day work.

We have also facilitated sustainability

workshops with international

clients prior to large capital projects

such as planning and design of green-

The sustainability focus

has extended to how the

business performs as a

whole, and how it operates

from principles concerning

people, planet, profit, and


field manufacturing sites - ensuring

that these projects both represent the

sustainability policy of the business,

but more importantly also becomes

highly efficient production sites.

Our approach to sustainability is

based on the interdisciplinary character

from our five divisions as well

as extensive experience with clients

from the food and dairy industry. ■

Danish Dairy & Food Industry … worldwide 2012 51

New butter book from


International Dairy books is a publishing house providing a broad range of scientific dairy

literature. In September 2012 the affiliated web-shop www.dairybooks.dk launches a new book

about “butter and Related Products” by Adjunct Professor børge K. Mortensen.

About the author

Børge K. Mortensen graduated in

1966 as M.Sc. in Dairy Science and

Technology (Cand. Lact.), and was

in 1972 awarded with a Ph.D. degree

from the Royal Veterinary and Agricultural

University in Copenhagen.

Børge K. Mortensen was recruited as

Research Dairy Scientist at the Governmental

Research Institute for

Dairy Industry in Denmark where he

during more than 30 years had a remarkable

career and was Managing

Director 1982-1990, followed by an

appointment as Head of Research at

Arla Foods until 2005.

Further, Børge K. Mortensen has

e.g. been President of the Danish Society

of Dairy Technology, member

of the Danish National Committee of

the International Dairy Federation

(IDF), member and later president

of the Permanent IDF Commission B

Butter and Similar Products

In September this year, International Dairy Books will publish a new book

about “Butter and Related Products - Product characteristics, production

technology and quality aspects”. “Butter and Related Products” by Adjunct

Professor Børge K. Mortensen is based on several years of practical experience

within butter production and additionally more than 40 years of scientific

studies of butter technology and quality aspects.

The book is intended for students within dairy technology as well as butter

technologists who want more knowledge about the fundamental and scientific

aspects behind their profession. The book also addresses food scientists

working with topics related to butter and similar products who want to

know more about the practical technology of the industry in which their scientific

results might find application.

(Dairy Technology & Engineering),

and member of the board of the Danish

Dairy Research Foundation. Since

1997, Børge K. Mortensen has been

Adjunct Professor in Dairy Technology

at Copenhagen University.

International Dairy Books

International Dairy Books (owned by

Mælkeritidende I/S - Denmark) is a

publishing house providing scientific

literature and journals for professionals

within the dairy industry. The web

shop of the publishing house offers a

broad range of dairy books within the

subjects: Cheese, Dairy Technology,

Juice, Functional Foods, Microbiology,

Preserved Milk Products, Ultrafiltration

and Membrane Processes

etc. ■

More information about the web-shop on page 54 and on


52 Danish Dairy & Food Industry … worldwide 2012 NR. 22

NR. 22

13-15 November 2012

Including the worlds

biggest Dairy exhibition

with products from

Denmark, Norway,

Sweden, Iceland,

Germany, the Netherlands,

England, Canada,

USA and Brazil.

Danish Dairy & Food Industry … worldwide 2012 53

International Dairy Books

International Dairy Books (owned by Mælkeritidende I/S - Denmark) is a publishing house providing

scientific literature and journals for professionals within the dairy industry. The web shop of the

publishing house offers a broad range of dairy books within the subjects: Dairy Technology, Cheese, Juice,

Functional Foods, Microbiology, Preserved Milk Products, Ultrafiltration and Membrane Processes etc.

Amongst the most popular books in the web-shop you will find:

Dairy Processing Handbook”, “Handbook of Milk Powder Manufacture”,

“The Orange Book”, and “Spray Drying in Practice”.

Visit www.dairybooks to order

International Dairy Books • Munkehatten 28 • DK-5220 Odense SØ

Phone: +45 66 12 40 25 • Fax: +45 66 14 40 26 • info@dairybooks.dk

Danish Dairy & Food

Industry ... worldwide

Munkehatten 28

5220 Odense SØ • Denmark

Fax: +45 66 14 40 26



Please help us to keep up a

complete mailing list!

We continuously update our mailing list. In order to receive the journal on

a regular basis, we kindly ask you to inform us if you have changed your address

or it is incomplete.

Identification no.

Title and Name



Postal code



54 Danish Dairy & Food Industry … worldwide 2012 NR. 22

”Danish Dairy & Food Industry ... worldwide”

is distributed in the following countries:

Africa: Algeria, Belize, Benin,

Botswana, Burkina Faso, Cameroon,

Congo, Ethiopia, Gabon, Gambia,

Ghana, Guinea, Kenya, Lesotho,

Liberia, Libya, Madagascar,

Malawi, Mali, Morocco, Mauritius,

Mozambique, Niger, Nigeria,

Senegal, Sierra Leone, Somalia,

Sudan, Swaziland, South Africa,

Togo, Tunisia, Tanzania, Uganda,

Zambia and Zanzibar.

Asia: Bangladesh, Bhutan, Burma,

China, Cyprus, Hong Kong, India,

Indonesia, Japan, Laos, Malaysia,

Mongolia, Nepal, North Korea,

Philippines, Singapore, South Korea,

Sri Lanka, Taiwan, Thailand and


Australasia: Australia, Fiji and

New Zealand.

Are you looking for new

Markets for your Products

or Highly Skilled Dairy

Employees? Contact:

Seeking new markets or employees?

Are you looking for markets to launch your processing

equipment, innovative ingredients, packaging, analysis or

sanitary equipment?

Or are you looking for highly skilled dairy employees

with international experience such as dairymen, dairy

technicians or M.Sc. in Dairy Technology?

No matter what, you can always advertise in Mælkeritidende!

For more information please visit www.maelkeritidende.dk


“Mælkeritidende” and “Danish Dairy & Food Industry ...

worldwide” is owned and published by the Danish Dairy

Managers Association and the Danish Dairy Engineers


NR. 22

Europe: Austria, Belarus, Belgium,

Bosnia, Bulgaria, Croatia, Cyprus,

Denmark, Eire, Estonia, Faeroe

Islands, Finland, France, Germany,

Greece, Greenland, Holland,

Hungary, Iceland, Italy, Latvia,

Lithuania, Luxembourg, Malta,

Macedonia, Norway, Poland,

Portugal, Rumania, Russia, Serbia,

Slovakia, Slovenia, Spain, States

of CIS, Sweden, Switzerland, The

Czech Republic, Ukraine and United


North America: Bermuda, Canada,

Mexico, Panama and USA.

South America: Argentina,

Barbados, Bermuda, Bolivia, Brazil,

Chile, Columbia, Costa Rica, Cuba,

Ecuador, El Salvador, Guatemala,

Guyana, Haiti, Honduras, Jamaica,

Montserrat, Nicaragua, Paraguay,

Peru, Puerto Rico, Tobago, Trinidad,

Uruguay and Venezuela.

The Middle East: Afghanistan,

Bahrain, Egypt, Iran, Iraq, Israel,

Jordan, Kazakhstan, Kuwait,

Lebanon, Oman, Pakistan, Qatar,

Saudi Arabia, Syria, Turkey and


The topics of Mælkeritidende are scientific, technical,

and political information about the dairy industry and related

areas. Furthermore, Dairy R&D, dairy product information,

company profiles and exhibition information are

accepted by the journal.

Further information

If you want further information about Mælkeritidende

and Danish Dairy & Food Industry … worldwide, please

contact Chief Editor, M.Sc. in Dairy Technology, Anne-

Sofi Christiansen or Editor, M.A., Anna Marie Thøgersen.

Mælkeritidende and Danish Dairy & Food Industry,

Munkehatten 28, 5220 Odense SØ, Denmark. Phone: +45

66 12 40 25, Fax: +45 66 14 40 26, www.maelkeritidende.

dk - www.ddfi.dk - info@maelkeritidende.dk

Danish Dairy & Food Industry … worldwide 2012 55

The right gear for the job …

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Danmarksvej 11 · DK-9670 Løgstør

Tel. +45 9966 1000 · Fax +45 9966 1548

logstor@logstor.com · www.logstor.com

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19589 Annonce Dairy and Food Industry.indd 1 19/04/11 14.19

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