PDF (6.0 MB) - GEA Group

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THE INTERNATIONAL MAGAZINE OF THE GEA GROUP ISSUE 07 NOVEMBER 2008 

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InnovatIon In actIon 

gea tablet process boosts 

pharma industry 

FooD FoR tHoUgHt 

food processing faces up to 

the future 

tHe stag RIses 

german liqueur takes on 

the world 

aRt In engIneeRIng 

FEATURE STORY 

Milk – something for everyone 

how the global dairy industry 

has kept pace with increasing 

demand for milk and its 

associated products 

HoW to Do It 

mining for copper 

Q&a 

protecting flora 

for eternity 

takIng stock 

paper industry leads 

recycling drive 

Last WoRD 

global news from gea 

DIggIng Deep 

satisfying the clamor 

for copper 

It’s sHoWtIme 

getting the best from 

exhibitions 

DaY In tHe LIFe 

gea westfaliasurge’s french 

connection 

GENERATE MAGAZINE ISSUE 07 1

2 

In the fast movIng and tIghtly 

controlled pharmaceutIcal Industry, 

the drIve Is always on to brIng more 

new products to the market and brIng 

them quIcker. an InnovatIve pIece of 

engIneerIng technology could play 

a key role In makIng thIs happen.

harmaceutical manufacturing is complex, 

tightly controlled and highly regulated. 

and it has to be because, with people’s 

health at stake, there can be no margin 

for error. 

like many other manufacturing industries, 

drug companies are under increasing 

pressure to make more faster, while 

reducing costs and maintaining high quality 

standards. according to the us food and 

drug administration’s process analytical 

technology (pat) guidelines for 2004, 

pharmaceutical manufacturers could 

achieve all these goals by shifting to 

continuous processing. 

currently, ingredients for medicines tend 

to be produced in batches. batch processes 

are very often inefficient and cannot manage 

the variability of the incoming material 

characteristics in a proper way. therefore, 

batch processes often result in reduced 

reliability and poor yields. a statistically 

disputable sampling step, after every batch, 

decides whether the product of that batch 

can be released to the next production step. 

Making medicines 

batch processing has been a feature of 

making medicines since the very early days. 

drugs were made as and when required, 

first by extracting the active ingredients from 

plants by soaking them in water or alcohol to 

create a potion for the patient to drink. later, 

medicinal plants were dried and ground into 

powders. but the problem was how to make 

sure patients received an accurate dose 

of medication. 

the invention of tablets provided the solution. 

before industrialization in the 19th century, 

tablets were handmade by pharmacists. with 

the introduction of the pill machine – a brass 

plate with grooves – greater accuracy was 

assured. 

PIll gaIns 

ConsiGma is a small unit that 

can easily be installed in existing 

production rooms, avoiding the need 

for expensive building alterations. It 

has environmental advantages, too. 

Running the machines continuously 

uses energy more efficiently over a 

longer period. 

fast-forward to the 21st century and the 

difference in tablet-making couldn’t be 

more marked. drug manufacture is carried 

out on a massive scale, using sophisticated 

processes. a typical tablet press can produce 

from 250,000 to more than one million tablets 

an hour. 

nevertheless, as wim van der goten, 

sales director of gea collette, points out: 

“the production methods for solid dosage 

forms are rather conservative compared to 

other industries, like food and chemicals, 

where continuous processing has been 

the standard for many years now. but 

continuous processing can only be successful 

with the development of better production 

techniques to provide consistent quality and 

measurement tools that allow for full control 

of production quality, at every instant”. 

Quality innovation 

with this in mind, a team at gea collette 

developed an innovative way of manufacturing 

granules for tablet production – consigma. 

this is a continuous high shear granulation 

and drying system which embraces the six 

sigma manufacturing quality standard*. it 

incorporates quality control at every instant 

inside the process and ensures that the 

outcome is 100 per cent within specification. 

it offers major advantages says van der 

goten: “for example, a 300 kg batch process 

can only be controlled once, on end quality, 

while, with consigma, the batch is 

controlled 6,000 times in-line.” 

the project won the gea innovation award 

2008, presented at the company’s global 

management meeting in beijing. an appropriate 

location given that the chinese capital 

has been the focus of record-breaking 

excellence with the olympic games. in this 

case, ultimately, the pharmaceutical industry 

and patients could turn out to be the real 

winners. 

one machine can operate successfully on 

any quantity from small 500g r&d batches 

to full-scale production. there is no process 

scale-up, which drastically cuts development 

time and cost so that new medicines can be 

made available to patients much faster. 

the granules produced can be compressed 

better which makes the tablet presses run 

more efficiently. 

since consigma was launched in april 

2008, several companies have invested in 

the technology, including two of the top ten 

pharmaceutical manufacturers, one of 

which is using it for production of a blockbuster 

drug. 

the development of consigma began three 

years ago and pharmaceutical companies 

were involved from the outset as they helped 

determine the specifications for the new 

system. a multi-disciplinary team of process 

engineers, technologists, software and 

service engineers from gea collette worked 

on the project, assisted by r&d staff from 

gea pharma systems. 

and the continuous processing revolution 

doesn’t stop there. gea pharma systems has 

developed a continuous blender, while gea 

courtoy has developed an advanced on-line 

pat for its tablet presses. 

* six sigma is a disciplined, data-driven process and 

methodology for developing products. it focuses on 

improving processes and eliminating defects. 


4 

Ore 

copper is a naturally occurring mineral but 

is found most commonly in ore (rocks) such 

as chalcopyrite, bornite and malachite. The 

process starts with digging the ore from the 

ground in open pit mines across the world, 

mainly in north and South america. 

cruSHing 

The ore is taken in 300-tonne trucks to the 

crushing plant, where it is dumped into a 

primary crusher. The resulting discharge is 

then fed into two secondary crushers and 

broken down into coarse (oxide) ore and fine 

(sulfide) ore. Oxide ore (see 3a & 4a) and 

sulfide ore (see 3B and 4B) are turned into pure 

copper cathodes in two different ways. 

Mining copper 

The global mining market for 

minerals like copper, nickel 

and zinc has seen a boom in 

recent years due to increased 

demand for metallic and energy 

raw materials, particularly 

from China. With the world 

clamoring for pure copper, 

here’s a quick guide to the 

production process. 

Heap leacHing 

Oxide ore is transported to a heap leach 

pad, into which a series of pipes and hoses add 

diluted sulfuric acid. The dissolved copper flows 

to a pond. This can take several months. 

cOncenTraTing 

The sulfide ore is concentrated into a slurry 

that is 15 per cent copper and the waste is 

removed and recycled to produce a grey copper 

concentrate powder.

SOlvenT exTracTiOn/elecTrOwinning 

The leach solution containing the dissolved 

copper passes to the Solvent extraction (Sx) 

plant. as its name suggests, this part of the 

process concentrates and purifies the dissolved 

copper by adding a chemical reagent to the 

Sx tanks, which binds with and extracts the 

copper. The copper is then transferred to an 

electrowinning plant where a current is passed 

from an inert anode through the liquid leach 

solution so that the metal is extracted and 

deposited in an electroplating process onto 

the cathode. The result is high-grade 

copper cathodes. 

SMelTing/elecTrOlyTic refining 

The sulfide ore then goes through several 

melting stages to purify the copper. The sheets 

of pure copper are electrolytically refined 

in an electrolyte bath. copper ions migrate 

electrolytically from the anodes to starter 

sheets made from copper foil where they plate 

themselves on the cathodes, leaving similarly 

high-grade cathodes. 

GEA And thE mininG industry 

Separation is a key part of the mining production process so it’s no 

surprise that one of the leaders in the field, GEA Westfalia Separator 

has a presence in this growing market. It’s GEA Westfalia Separator 

Process business provides the mining industry with a range of 

products. Leading the way are separators and decanters that enable 

mining companies to guarantee continuous efficiency during the 

extraction process. 

Over the years, liquid extraction with acid has become the standard 

method for recovering metals like copper, nickel and zinc. However, 

crud (a layer of emulsion formed of aqueous and organic compounds, 

air and solids) is formed during the extraction process. Crud can 

have a negative impact on the extraction process and needs to be 

continuously removed, which is where GEA Westfalia’s separation 

technology comes in. A three-phase decanter process separates the 

emulsion into solids, water and solvent. The solids and water are 

disposed of and the solvent is recycled. Crud is continuously removed 

and the solvent recycled back to the extraction stage. GEA Westfalia 

has actually gone one stage better with its PLS (Pure Liquid Solution) 

clarification process that prevents crud forming by removing insoluble 

particles with nozzle-type separators. In addition, GEA Westfalia 

supplies a range of decanters and project management expertise for 

the mining industry. 

cOpper caTHOdeS 

The copper cathodes (99.9 per cent purity) are 

transported to mills or foundries, from where 

they are manufactured into finished products 

for use in the electrical engineering industry 

for wiring, as well as plumbing, roofing and the 

power, transport and communication industries. 

GENERATE MAGAZINE ISSUE 07 

5

oveR tHe past 10,000 YeaRs, bILLIons oF tonnes oF 

coppeR Have been extRacteD FRom tHe eaRtH anD tHe 

coppeR DeveLopment assocIatIon estImates tHat a 

LaRge peRcentage oF tHat Is stILL beIng UseD toDaY. 

geneRate Looks at HoW tHe WoRLD’s most RecYcLeD 

metaL contInUes to make a vItaL contRIbUtIon to 

eveRYDaY LIFe. 

6 

safE voyagE 

Christopher Columbus’ ships were among the 

first to have hulls sheathed with copper plate to 

protect the wood against barnacles and algae. 

sIzE mattErs 

The world’s largest statue is the 152-meter high 

copper Buddha on the Jiuhua Mountain in central 

China. It is more than three times taller than New 

York’s statue of Liberty and weighs 1,000 tonnes. 

id you know that the copper in your 

home, cookware, your car and even the 

coins in your pocket could date back to 

the egyptian pharaohs? 

this surprising claim from the copper 

development association is not nearly as 

far-fetched as it seems. the fact is that 

copper and its alloys, such as bronze and 

brass, can be melted down and re-used over 

and over again. 

copper has the world’s highest recycling 

rate for engineering metals. statistics from 

the international copper study group (icsg) 

show that, in 2005, 34 per cent of world 

copper consumption was recycled. the us 

alone recycles almost as much copper as 

it mines. 

this is just as well. demand for copper is 

soaring, particularly from china and india – 

in asia between 1960 and 2006 it rose from 

455,000 tonnes to eight million tonnes. 

in July this year the icsg predicted that 

copper mine output will rise by 5.2 per 

cent a year between 2008 and 2012, with 

annual production of 23 million tonnes, 

29 per cent higher than in 2007. 

more than 60 per cent of the world’s 

copper resources are found in chile, 

where gea westfalia separator 

process is the country’s leading 

supplier of centrifugal equipment 

for the copper mining sector. 

What’s In a namE? 

Copper was named after the Mediterranean 

island of Cyprus where it was mined 

extensively in Roman times. Cyprium or ‘metal 

of Cyprus’ was later shortened to cuprium, 

which became the Latin word for copper.

A versatile metal 

surprisingly, although copper has been used 

for 10,000 years, more than 95 per cent of 

the copper mined in that time was extracted 

after 1900. copper is truly a metal for the 

modern world. 

because copper doesn’t corrode and has 

heat and electricity conducting properties 

that are second to none, it is the metal 

of choice for a vast range of domestic 

and industrial applications. it’s also very 

attractive, making it ideal for musical 

instruments, decorative features on 

buildings and statues – the statue of 

liberty, for instance, is made from copper. 

here are just a few of copper’s many 

uses: wiring in buildings, power cables, 

electronics, telephone lines, plumbing, 

gas pipes, cookware, the magnetrons in 

microwave ovens and even the spray for 

killing mildew on garden plants. the average 

car has approximately two kilometers of 

copper cables and the metal is also used for 

the radiator, brakes and bearings. it’s also 

being used in new aircraft models and highspeed 

trains have between two and four 

tonnes of copper – twice as much as their 

traditional counterparts. 

copper doesn’t react with water, which 

is why you’ll find fittings made from 

copper nickel alloy on offshore oil and gas 

platforms, desalination plants and ships. 

Good health 

although copper is toxic in large doses, the 

world health organization’s international 

program on chemical safety reported in 

1996 that “there is greater risk of health 

effects from deficiency of copper intake than 

from excess of copper intake.” 

the fact is that people need copper. 

enzymes critical for bone growth and 

strength, maintaining the immune system 

and a healthy heart, the development of 

red and white blood cells, transporting and 

absorbing iron, brain development and for 

protecting against tissue damage are all 

dependent on copper. a lack of copper in 

the system puts the body at increased 

risk of developing high cholesterol and 

heart disease. 

copper-containing foods include beef, 

fish, oysters, chocolate, avocado and 

various vegetables, nuts and fruit. many 

people who suffer from arthritis and other 

joint conditions find it helpful to wear a 

bracelet made from copper which the skin 

gradually absorbs. 

another plus is that copper is biostatic, 

which means bacteria can’t grow on it. 

this makes it an ideal metal to have around 

hospitals for door handles, push panels and 

other surfaces to prevent the transfer of 

disease. medically, a complex of radioactive 

copper is used in imaging and also in 

radiation treatment for cancer. 

Future proof 

the use of copper has increased in 

line with technological developments 

and continues to be an essential 

component of innovation. 

microprocessors can operate 

faster and use less energy 

thanks to copper conductors 

in silicon chips. 

it’s worth remembering that high speed data 

transmission, including the internet, was 

achieved via existing copper telephone wires 

and you’ll find copper in mobile telephones, 

too. 

copper now has a role in environmentallyfriendly 

alternatives to oil and gas for heating 

homes. as the number one conductor of 

heat, it’s in demand for direct exchange 

geothermal heating systems. this is where 

heat stored in the ground is transferred by 

copper tubing into the home. 

with its continued versatility and huge 

worldwide demand to satisfy, copper’s 

future is assured – today’s copper could 

be recycled for tomorrow’s cutting-edge 

technology. 


©alimentarium 

8 

tHeRe can neveR Have 

been a tIme WHen FooD 

Was not pRocesseD In 

some WaY. sInce ancIent 

man DIscoveReD tHat meat 

LasteD LongeR IF DRIeD 

In tHe sUn oR tasteD 

betteR IF cookeD, FooD 

pRocessIng Has been a 

vItaL paRt oF oUR LIves. 

Packaging of soup 

at the Maggi factory 

about 1900.

ost early food processing techniques 

concerned preservation. sun drying, 

salting, fermentation, pickling and the 

preparation of conserves (jams and jellies) 

were all motivated by a desire to extend the 

shelf lives of otherwise perishable foods. 

these foods were largely used by those who 

did not have access to a regular supply of 

fresh provisions – sailors and soldiers mainly 

– who for centuries owed their survival to 

preserved foods. 

many of the advances in food processing, as 

with most technology, have been born out of 

conflict. french soldiers in the napoleonic 

wars were the first to try out food preserved 

in cans, ironically a process invented by 

an englishman, peter durand in 1810. 

subsequent wars increased the popularity 

of canning, especially during the first world 

war where cans were uniquely able to survive 

the ravages of trench warfare. even today, 

preservation techniques such as freezedrying 

and vacuum packing owe much of 

their success to the need to provide armies 

with daily rations, and to space exploration. 

Convenience food 

as society has developed, the motivation 

for food processing has changed. now it’s 

no longer sufficient simply to slow down 

the process of decomposition, now people 

want convenience, novelty and excitement 

from their food. it’s much easier to choose a 

packet of your favorite fries from the freezer 

than to make your own, even if you would 

know how and had the time. the modern 

kitchen in the developed world is packed full 

of processed food – even staple items such as 

bread, butter and cheese. 

its very success has led food processors 

on to the next stage of development for 

the industry. beyond preservation, more 

than convenience, novelty and excitement, 

the modern consumer now demands 

taste and nutritional excellence as well. 

food processing can lower the nutritional 

value of foods. processed foods tend to 

include additives, such as flavorings and 

texture enhancing agents, which may have 

no nutritive value or even be unhealthy. 

processed foods also tend to have more 

calories. 

so the challenge now for food processors 

is to produce exciting, novel foods that 

are healthy, packed with vitamins, fiber 

and minerals, contain the minimum of fat, 

preservatives and artificial colorings, have 

a long shelf life, and taste great, too. as 

if that’s not difficult enough, modern food 

processing factories need to operate under 

extremely hygienic or even aseptic conditions 

and use the minimum of energy and natural 

resources. no easy job. 

throughout the last century gea companies 

have played their part in providing the 

equipment food and drink processing 

companies need. gea niro for the spray 

drying of powders to make products such 

as baby foods, soups and instant coffee; and 

for freeze-drying equipment to preserve 

the natural flavor and nutritional value of 

fruits and vegetables. gea procomac for 

aseptic bottling lines with minimal power 

consumption; gea westfalia separator has 

the technology to extract bacteria from 

milk through centrifugal separation before 

bottling, thereby significantly extending its 

shelf life without affecting its taste; gea 

wiegand for evaporation technology, gea 

grasso for refrigeration; gea niro soavi for 

homogenizers that create our smooth, easyspread 

dairy products; and gea tuchenhagen 

to link everything together to create 

innovative, efficient systems. all of these are 

just examples of how gea companies serve 

this continuously growing market. 

Global growth 

as global development, particularly in china 

and india, gathers pace, so the demand for 

processed food grows, too. according to 

the indian food and beverages forecast 

published by the bahrat book bureau, 

between now and 2011 higher incomes in 

india will encourage more indians to shop in 

supermarkets; and changing lifestyles should 

lead to rapid demand for value-added milkbased 

products such as processed cheese, 

butter and ice cream. 

coffee consumption, too, is expected to grow 

by ten per cent a year. the chinese, as the 

country’s 1.3 billion people become richer, 

are demanding higher-quality products, more 

processed food, more meat and more dairy 

products. they are also becoming much more 

discerning consumers, potentially causing 

shortages and higher prices elsewhere in the 

world, but certainly creating opportunities for 

those companies involved in food production. 

the opportunities for food producers are 

immense and are likely to continue as 

from kItchEn to factory 

The history of industrial food processing is the 

subject of a special exhibition at the Alimentarium 

Food Museum at Vevey on the shores of Lake 

Geneva in Switzerland. 

Called ‘De La Cuisine A L’Usine’ the exhibition 

showcases four landmark products – powdered 

soup, condensed milk, milk chocolate and coffee 

substitute – and their development at the 

beginning of the 20th century. It runs until the end 

of January 2009. 

The Alimentarium Food Museum, which opened 

in 1985, has a range of permanent displays 

and activities, including the history of cooking 

techniques, nutrition and demonstrations from 

professional chefs. 

an IntErEstIng fact 

The can opener was not invented until 30 years 

after the can. Napoleon’s soldiers were required 

to open their canned meals using bayonets or by 

hitting them with rocks. 


©alimentarium 

long as the raw materials remain plentiful. 

opportunities for equipment suppliers also 

seem boundless. yet strong competition will 

always ensure that only excellence, in both 

product and service, is rewarded. 

9

milk is widely regarded as nature’s 

miracle food – and it’s easy to see 

why. apart from being packed full 

of essential protein, vitamins and 

minerals, it is arguably the most 

versatile food on the planet. 

Julie Mitchell looks at a global 

phenomenon that shows no signs 

of slowing. 

photography: will thom 

styling: sabrina Jard

othing cappuccino coffee, an indulgent 

cake oozing with cream, a cool glass of 

milkshake on a summer’s day, butter 

melting tantalizingly on hot toast, a crusty 

bread roll crammed with delicious, nuttyflavored 

cheddar cheese. there’s no doubt 

that dairy products regularly feature in 

the daily diet in most parts of the world. 

the uses of milk are legion. as a drink, 

flavored with fruit or chocolate or added 

to hot drinks. you can process it into a 

variety of milk types. skim the cream off 

the top for myriad culinary uses or churn 

it into butter. curdle milk and you get 

cheese – the varieties run into thousands. 

whey, the by-product of cheese-making, 

which used to be discarded as waste, is 

today a valuable raw ingredient for the 

food industry. and even when milk turns 

sour you can still enjoy it as yogurt. 

such is the cultural impact of dairy products 

that they have inspired many well-known 

phrases. people in the us refer to an 

important person as ‘a big cheese’, while 

the french expression ‘en faire tout un 

fromage’ means to make a big deal of 

something. similarly, ‘to milk’ is associated 

with making the most of a situation, for 

example, “he milked it for all it was worth”. 

12 

the uses of milk are legion: skim 

the cream off the top for myriad 

culinary uses or churn it into butter. 

curdle milk and you get cheese – 

the varieties run into thousands. 

how Milking developed 

there’s no conclusive evidence to pinpoint 

when humans started to drink milk 

from animals, although it is generally 

accepted to date from when man learned 

to domesticate goats and sheep in the 

middle east around 8000 bc. it’s also 

known that people were herding cattle 

in parts of turkey as early as 7000 bc. 

the ancient egyptians enjoyed dairy 

products. murals on some of their tombs 

show cheese being made. and there was 

also a cosmetic value – cleopatra famously 

bathed in ass’s milk to improve her skin. the 

greeks, too, were into cheese. one of their 

most famous sons, homer, immortalized 

it in his epic poem, the odyssey, where 

he describes the cyclops making cheese 

from sheep and goat’s milk. but it were the 

romans who are credited with establishing 

uniform cheese-making techniques in 

europe. they also introduced them to 

other parts of their empire where cheesemaking 

had previously been unknown. 

eventually, dairy products were on the menu 

throughout europe as well as parts of asia 

and africa. then, during the age of discovery 

in the 15th-17th centuries, europeans 

spread the word to the far-flung corners of 

the globe when they took domestic cows 

and dairy production to their colonies. 

today, more people drink milk from cows 

than from any other animal. according to the 

international dairy federation’s world dairy 

situation 2007¹ cow milk represents 84 per 

cent of world output – 551 million tonnes in 

2007. interestingly, the report also reveals 

that, in india and pakistan, buffalo milk 

production is growing faster than cow milk 

production. sheep and goat milk production 

is estimated at 21 million tonnes worldwide. 

other animal milk sources include camels, 

yaks, reindeer and horses. people in central 

asia are partial to drinking fermented mare’s 

milk, which they call kumis, while in sweden 

and russia there are moose dairies. 

because milking is a labor intensive process 

– between three and five minutes per cow – 

up until relatively recently dairy production 

could only be achieved on a small scale. 

milking had to be done by hand – the farmer 

or milkmaid sitting beside the animal with a 

bucket. but when electricity was discovered 

in the mid-19th century the race was on to 

transform milking from an art to a science. 

after 50 years of trial and error the 

first pulsator was introduced in 1895, 

paving the way for the modern pulsator 

machines. another key development 

around this time was the milk pipeline, 

which replaced the cumbersome task of 

carrying pails of milk to collection tanks. 

but the real breakthrough came in 1929 when 

the first rotary milking parlor was installed on 

the walker-gordon dairy farm in plainsboro, 

new Jersey in the us. called the ‘rotolactor’, 

it could milk 50 cows at a time. it remained in 

use until the 1960s when it was superseded 

by more sophisticated rotary milking parlors. 

advances in milking technology, not least 

rotary parlors capable of milking more than 

100 cows an hour, have enabled dairy farms 

throughout the western world to become 

huge corporations with thousands of cows. 

and the trend is spreading to new markets 

such as china, iran, pakistan and turkey. 

during the 20th century mechanization, food 

processing technology and refrigeration 

have made a huge variety of dairy products 

readily available around the world. 

1/2 bulletin of the idf n°423/2007 – the world dairy 

situation 2007, international dairy federation, 

diamant building – 80, boulevard auguste reyers, 

1030 brussels – belgium, www.fil-idf.org

Estimated volume of cow milk delivered 

to processing facilities in 2007. 

PastEurIzEd by heating it to 

74°C for 15-20 seconds 

WholE mIlk has a fat content 

of 3.5 to four per cent. 

sEmI-skImmEd milk has a lower 

fat content, 1.5 to 1.7 per cent, 

while skimmed milk is virtually 

fat free 

uht (ultra heat treated) milk is 

heated to at least 135°C and 

packaged in sterile containers. 

EvaPoratEd mIlk is heated at 

temperatures between 60°– 65°C 

then sterilized in sealed cans for 

ten minutes 

mIlk PoWdEr 

Milk is heat-treated and preconcentrated, 

then homogenized 

and fed into a spray dryer where the 

water is removed. 

saFe to DRInk 

the milk collection revolution has gone 

hand-in-hand with advances in food 

production. today “the share of milk 

production which is delivered to dairies for 

processing is growing faster than in previous 

years,” says the World Dairy situation 2007 

bulletin². “an estimated volume of 371 

million tonnes of cow milk was delivered 

to processing facilities, which is 65 million 

tonnes more than ten years ago.” 

milk is first pasteurized by heating it to 

74°c for 15-20 seconds to kill potentially 

harmful bacteria, without damaging the 

nutritional value or taste, then rapidly cooled 

and refrigerated to preserve its shelf life. 

Whole milk, which has a fat content of 3.5-4 

per cent, is usually homogenized to spread 

the fat evenly through the milk and prevent 

cream forming on the top. semi-skimmed 

milk has a lower fat content, 1.5 – 1.7 per 

cent, while skimmed milk is virtually fat 

free. Unfortunately, reducing the fat content 

lowers the levels of vitamin a and D but, on 

the positive side, reduced fat milks contain 

slightly more calcium by volume. 

Ultra heat treated (UHt) milk is heated 

to at least 135°c and packaged in sterile 

containers. as a result it can be stored 

for several months and, until it’s opened, 

doesn’t need to be kept in the refrigerator. 

sterilized milk, which goes through a 

more severe heat treatment, will last even 

longer but has a lower nutritional value 

and the taste is affected. other durable 

liquid varieties are evaporated milk, heated 

at temperatures between 60°–65°c then 

sterilized in sealed cans for ten minutes, 

and condensed milk from which most of the 

water has been removed and sugar added. 

the longest-lasting format is milk powder. 

milk is heat treated and pre-concentrated, 

then homogenized and fed into a spray 

dryer where the water is removed. With the 

exception of some vitamins, whole milk and 

skimmed milk powders retain the nutritional 

value of their liquid forms. milk powders 

can be reconstituted with water and then 

treated the same way as fresh milk. they 

are used extensively in food manufacturing, 

particularly in cakes, biscuits and sweets and 

also form the basis for baby milk formula. 

> 


Estimated value of worldwide 

dairy products market by 2010. 

a gRoWIng maRket 

by 2010 the worldwide dairy products 

market is predicted to be worth more 

than usd 305 billion, according to a 

report published this year by global 

industry analysts (gia). several factors 

are expected to fuel this growth, including 

more emphasis on value-added products, 

changing eating habits, increasing 

demand for organic products, packaging 

innovations and marketing of niche brands. 

gia found that europe, the us and the 

asia pacific region now account for more 

than 70 per cent of the dairy market but 

that, by 2010, asia pacific will be the 

fastest growing regional market. this is 

attributed to changing dietary aspirations 

in line with new-found wealth. the report 

14 

usa 

BIggEst mIlk ProducErs 

grEatEst dEmand 

futurE ExPandIng markEts 

usa 

europe, the us and asia 

pacific account for more 

than 70 per cent of the 

dairy market but by 2010 asia 

pacific will be the fastest 

growing regional market 

latIn 

amErIca 

also argues that yogurt will be the most 

profitable sector, particularly in china. 

higher demand for dairy products is 

expected to come from latin america and 

the caribbean, while western europe will 

continue to lead the dairy consumption 

league table – it currently accounts for 

42 per cent of the global market. 

the biggest milk producer by far is the us, 

followed by india and russia. as mentioned, 

most farms in the developed world are run 

to industrial capacity. but, thanks to the 

latest processing technology, countries like 

pakistan are being encouraged to develop 

their dairy industries for the export market. 

pakistan is actually the world’s fourth 

largest milk producer but, interestingly, its 

livestock is widely distributed among rural 

households. new state-of-the-art processing 

plants, like nestle’s at kabirwala, have the 

capacity to process up to three million liters 

of milk per day to international standards. 

> 

WEstErn 

EuroPE 

PakIstan 

IndIa 

russIa 

asIa 

PacIfIc 

asIa 

PacIfIc 

mIlkIng succEss 

Movie star Sir Sean Connery began his working life as 

a milkman at the Corstorphine Dairy in Scotland before 

turning to acting. 

chEEsE off thE mEnu for mIcE 

In 2006 researchers at Manchester Metropolitan 

University in the UK made an amazing discovery that 

debunks the long-held belief that mice like cheese. Their 

study showed that mice are attracted to sweet, sugary 

foods, preferring to tuck in to fruit and grains rather 

than the Cheddar on the mousetrap.

the unique teXture and flavor of the different 

cheeses depends on the milk used – usually from 

cows, buffalo, goats or sheep – the animal’s diet, 

the curdling technique, butterfat content, 

processing and length of aging. 

crEam and ButtEr 

Without homogenization the fat content of milk will, 

when left to stand, rise to the surface and float on 

the top. Before mechanization this cream would 

simply be skimmed from the surface. Today, the 

process is speeded up using centrifugal separators. 

There are several grades of cream available 

– the higher the fat content, the thicker the 

cream. Thick cream, known as double cream in 

the UK and heavy cream in the US, is favored 

for cooking as it is less likely to separate 

when heated than the lower fat type. 

Cream is a key ingredient for many cakes and 

desserts, not least ice cream, as well as sauces 

both sweet and savory. It can also be fermented 

with bacterial cultures to create sour cream 

and crème fraîche. Central and Eastern Europe 

have a similar product called smetana. 

Churning cream produces butter, another worldwide 

dairy staple. Butter can be salted or unsalted and 

the color varies according to the breed of cow and 

its diet. Clarified butter, made by separating the 

milk solids and water from the butterfat through 

gentle heating, is favored for frying because it can 

be heated to higher temperatures than ordinary 

butter. India has its own version, known as ghee, 

which is a regular ingredient in recipes. Moroccan 

smen is clarified butter mixed with spices. 

Tibetan households have butter made from 

yak milk. Tsampa, the national dish, consists 

of barley flour mixed with yak butter. Another 

favorite is tea with rancid yak butter and salt. 

chEEsE 

US television host Clifton Fadiman summed up 

the feeling of cheese-lovers everywhere when he 

described cheese as, “milk’s great leap towards 

immortality”. No other food has quite captured 

the imagination, or the palate, like cheese. 

There are literally thousands of cheeses from the 

familiar Cheddar, Brie, Gouda, Emmental and 

Gorgonzola to the less well-known Kadchgall 

from Afghanistan and Daralagjazsky from 

Russia. Many cheeses are allowed to develop 

molds which create distinctive blue veins, or 

have colorings and flavorings added, for example 

Wensleydale with cranberries or the fiery Afuega 

‘I Pitu with chilies. And for the brave there is 

Casu Marzu from Sardinia with live maggots. 

The method of making cheese is basically the same, 

whatever the type. Rennet, a starter bacteria, or acid 

such as vinegar, are added to the milk to curdle it 

so that the solid curds are separated from the liquid 

whey. The curd is then pressed into a mold and the 

whey is usually transformed into a powder for use in 

the food, animal feed and pharmaceutical industries. 

The unique texture and flavor of the different cheeses 

depends on the milk used – usually from cows, 

buffalo, goats or sheep – the animal’s diet, the 

curdling technique, butterfat content, processing 

and length of aging. Some cheeses are heated to 

between 35° and 55°C to remove more moisture, 

giving them a harder texture, while others are made 

by washing the curd in warm water to create a milder 

flavor. There is also a range of cheeses, such as 

cottage cheese or Romanian Cas, which require little 

yogurt and fromagE fraIs 

For centuries, people living in the Balkans, 

Turkey, Asia and the Middle East have sworn by 

the restorative powers of yogurt. It was generally 

believed that yogurt helped to prolong life and cure 

gastrointestinal conditions. Although yogurt is a 

Turkish word it’s not certain who actually invented it. 

However, yogurt is probably the oldest method 

of preserving milk. It is made by adding specific 

bacteria to milk and fermenting it under 

controlled temperatures. The bacteria eat the 

lactose (milk sugar) and release lactic acid 

which thickens the milk protein while preventing 

harmful bacteria getting into the product. 

Yogurt is available in whole, reduced fat and non-fat 

varieties, either in its natural sour state or sweetened 

and mixed with fruits, nuts and syrup. Some types, 

such as Greek yogurt, are strained through a cloth or 

paper filter to give a thicker consistency. Across the 

Middle East, Central Asia and India yogurt is popular 

as the basis for drinks, such as kefir and lassi. 

Another dairy product which resembles yogurt is 

fromage frais. It is actually made from curdled 

milk, like cheese, except that curds are stirred 

to prevent them from solidifying. Pure fromage 

frais is fat free but there are versions with cream 

added. It can be enjoyed the same way as yogurt 

or added to desserts and savory dishes. 


What’s good aBout a glass? 

vitamin B12 = red blood cells 

calcium = strong bones and teeth 

16 

carbohydrates = energy 

magnesium = muscle function 

Phosphorus = release energy 

Potassium = nerve function 

Protein = growth and repair 

riboflavin = healthy skin 

zinc = immune system 

DaIRY anD HeaLtH 

are dairy products good for you? for 

milkmaids it would seem that the answer 

is yes. historically, milkmaids, who 

milked the cows and prepared cream, 

butter and cheese, have been presented 

as fair, fecund and in fine health. 

perhaps easy access to dairy products 

meant they were getting enough to eat at 

a time when many working people were 

malnourished. their skin was certainly in 

better condition: working with dairy cattle 

exposed them to cowpox, a less serious 

form of the human version, smallpox. 

contracting cowpox made them immune 

to smallpox, which meant milkmaids did 

not have the pockmarked complexion 

common to smallpox survivors. 

in the 19th century kumis, made from 

mare’s milk, was considered to be a panacea 

for all ills, so much so that kumis resorts 

sprang up in the south east of russia. 

even now the antioxidant content of mare’s 

milk makes it much sought after in the 

cosmetics industry for use in skin creams. 

in today’s health-conscious, diet-obsessed 

world the jury is still out on how good or 

bad dairy products are for human health. 

certainly dairy products, especially the full 

fat varieties, can be fattening and doctors 

recommend that people with high cholesterol 

or heart conditions should avoid them. 

also some people lose the ability to digest 

lactose, becoming lactose intolerant. 

on the plus side a glass of milk contains: 

vitamin b12 for red blood cells, calcium for 

strong bones and teeth, carbohydrates for 

energy, magnesium for muscle function, 

phosphorus to release energy, potassium 

for nerve function, protein for growth 

and repair, riboflavin for healthy skin and 

zinc to protect the immune system. 

numerous studies have been carried out into 

the effects of regular milk consumption. it’s 

been suggested that drinking low fat milk 

reduces the risk of hypertension, coronary 

heart disease, colorectal cancer and obesity. 

in recent years there’s been an upsurge 

in demand for probiotic milk drinks and 

yogurts from health-conscious consumers. 

probiotics contain bacteria that can 

counteract harmful bacteria in the intestines. 

tRenDs In tHe DaIRY InDUstRY 

because fresh milk has a relatively short 

shelf life it used to be delivered directly 

to households. the milkman and his daily 

round are still alive and well in the uk 

and in rural india it’s delivered in a metal 

container attached to a bicycle. but, in 

many countries, modern food distribution, 

refrigeration and lifestyles have taken away 

the need for home delivery and now most 

people buy their milk from the shops. 

over the years the packaging has changed 

from the glass bottle to the wax-coated paper 

carton and the plastic container. now, with 

the environmental lobby seeking to cut down 

on plastic, the next stage of the packing 

evolution looks set to be recyclable bags. 

a major growth area for dairy is flavored 

milk as concerns about wellbeing and 

obesity prompt consumers to ditch 

carbonated sugary drinks in favor of 

healthier options. chocolate, strawberry 

and banana are the most popular. 

goat’s milk is also experiencing a 

renaissance. in europe the market is 

increasing by ten per cent a year, prompting 

farmers to increase herd sizes. 

like other food producers dairy farmers are 

feeling the effects of increased animal feed 

and fuel costs, which are driving up prices. 

but the long-term outlook is healthy: with 

the enhanced demand for new products 

such as milk-based drinks, probiotics and 

niche cheeses, the world’s appetite for dairy 

products shows no signs of abating. 

PErfEct snack 

Log on to www.cheddarometer.com to find the recipe 

for the perfect cheese sandwich. The site contains 

a mathematical formula devised by scientists at 

Bristol University in the UK, which calculates the ideal 

thickness of the bread and cheese, plus the required 

amount of salad, mayonnaise or pickle. 

cokE not ‘thE rEal thIng’ In oz 

More flavored milk is drunk in South Australia than 

anywhere else in the world. Farmers Union Iced Coffee, 

a coffee-milk-mix drink, is a far bigger hit there than 

coke.

Milking and processing excellence 

The globalization of the dairy industry could not have 

been achieved without milking machines, cutting-edge 

processing technology and refrigeration. And new 

developments in all these areas will continue to play a 

critical role in helping farmers and dairy companies to 

meet the challenges of the future. 

One of the leaders in this field is the GEA Group, which 

has a long and impressive history of supplying innovation 

and engineering know-how throughout the dairy chain. 

Given that GEA technology is involved in approximately 

one quarter of all milk produced worldwide it’s highly 

likely that the dairy products in your refrigerator will 

have had some contact with the company’s milking or 

processing equipment. 

Since 1926 WestfaliaSurge – part of GEA Farm 

Technologies – has been setting the trends in milk 

collection technology, with a comprehensive range of 

equipment for all stages of the milking process. In 

particular, the market-leading WestfaliaSurge AutoRotor 

can milk more than 100 cows an hour. And now the 

company has now taken the milking revolution further 

again with the T!TAN milking robot, which enables cows 

to be milked when they choose and is suitable for farms 

of virtually all typical sizes. 

GEA’s Process Engineering Division supplies everything 

from stand-alone installations to complete plants for 

processing dairy products including milk and whey 

powders. The division supplies turnkey plants for some 

of the world’s biggest dairy operations. GEA Process 

Engineering company Ahlborn was founded in 1856 and 

became part of the GEA Group in 1979. Today, it is part 

of the newly named GEA TDS GmbH company, which also 

includes Tuchenhagen Dairy Systems, a leader in the 

dairy, fruit juice and food processing industries. 

The companies of the GEA Process Equipment division 

support adherence to strict hygiene regulations for 

companies from the brewing, beverages, dairy and 

foodstuff industries, as well as the pharmaceutical, 

biotechnology, cosmetics and health care industries 

with a range of homogenizers, valves and plate heat 

exchangers. The diverse processes for handling liquid 

foodstuffs require many heating up and cooling steps. 

GEA Ecoflex plate heat exchangers meet these demands 

with a wide range of plates for all applications. A high 

level of productivity, cost-efficient operations and reliable 

product consistency characterize process components 

from GEA Tuchenhagen. Process valves, valve blocks, 

in-line measurement and control equipment, cleaning 

devices, CIP units and pumps manufactured by the 

company from Büchen, Germany, meet the demanding 

hygienic and sterile requirements of these industries. 

High pressure homogenization is essential for improving 

the stability and shelf life of dairy products. GEA Niro 

Soavi offers a full range of homogenizers and pumps 

covering all dairy industry requirements, from pilot 

to large scale fully automated units. Compared to 

conventional homogenizing valves, the company’s 

patented NanoValve achieves optimal performance 

at low pressure and is ideal for processing milk, cream, 

yogurt, cheese, baby food, ice cream, whey and butter. 

The company GEA Niro offers pilot plants for test 

processing and manufacturing product samples. And its 

Test Center for Food and Chemical Products in Denmark 

offers a world-leading resource for food and chemical 

companies to try out a range of extraction, evaporation 

and drying technologies. 

Separation equipment is central to the processing system 

within modern dairies. This is also a field in which GEA 

– with its company GEA Westfalia Separator Process – 

excels. The centrifugal separators remove bacteria and 

they are crucial to a wide variety of dairy processes. 

Applications range from single-stage/two-stage bacterial 

clarification to the special bacterial clarification used 

for drinking milk as well as the variable bacterial 

clarification of cheese milk, treating concentrated whey 

and pre-treatment of milk powder. Westfalia is the 

market leader in centrifugal separators for fresh cheese. 

The FAGE dairy, the largest operation of its kind in Greece, 

chose machines from GEA Westfalia Separator Process 

for its main plant in Athens as well as for a new dairy in 

the US. 

Another innovation from Westfalia’s Dairy Technology 

Business Unit is PROCOOL – which enables dairies 

to switch from cold to warm milk separation, using 

the same machine, providing more flexibility and 

cheaper running costs. Westfalia also produces turnkey 

process lines for the variety of soft cheese products 

that have been developed in the trend towards more 

health-conscious diets (including cream cheese, quark, 

Thermoquark and Baker’s Cheese). There is a high level 

of automation in the process lines. In addition Westfalia 

supplies all elements of the process lines for the butter 

industry, including the buttermilking machine, tanks, 

pasteurization unit and associated pipework. 

Like most fresh foods, dairy products need to be kept 

cold. GEA Refrigeration is one of the world’s leaders in 

industrial refrigeration. The division provides stateof-the-art 

refrigeration technology, which can be used 

during the whole process, from the delivery of the fresh 

milk to the factory through all stages of production and 

storage. 

Finally, clean air at the right temperature is essential to 

providing the hygienic conditions needed for processing 

and storing dairy products. Leading air treatment experts 

of the GEA Air Treatment Division broke new ground 

by providing a climate control system at the Müritz- 

Milch cheese dairy in Waren, Germany, based on the 

dehumidifiers normally used for indoor swimming pools. 

To counteract the effects of the salty air from the brine 

bath – central to the cheese-making process – GEA 

Happel Klimatechnik supplied equipment made from 

corrosion-resistant steel. 


18 

millennium seed bank 

laboratory manager 

keith manger gave 

geneRAte a guided tour 

through the most 

bio-diverse building 

on earth. 

photography: James bell


19

An underground vault in 

the heart of the Sussex 

countryside in the south 

of England contains an 

international safety deposit 

box. It doesn’t hold money 

or gold but something 

far more valuable to the 

survival of the planet – 

seeds. The Millennium 

Seed Bank Project is the 

most ambitious worldwide 

conservation project 

ever. And, by the end of 

the decade, will have 

safeguarded 30,000 wild 

plant species – ten per cent 

of the world’s flora. 

20 

Q. why was the millennium seed bank 

established? 

A. It started in the 1960s when the royal 

botanic gardens, kew, in london, and 

other botanic gardens wanted to store 

and exchange seeds from plant species 

of particular horticultural interest. kew 

decided to expand the criteria to wild plants 

generally and particularly those facing 

extinction and those that are economically 

important in developing countries. In 1995 

we were granted eur 37.9 million from 

the millennium commission to support the 

development of a millennium seed bank 

(msb). with matching donations from a 

variety of organizations the project was 

able to move to purpose-built premises in 

august 2000. 

since then, the team has grown from 15 

to almost 70 people. they include expert 

botanists who collect the seeds plus 

technical staff responsible for cleaning 

and storing the seeds and also for testing 

their viability. 

the msb has formal partnerships with 

australia, botswana, burkina faso, chile, 

china, egypt, Jordan, kenya, lebanon, 

madagascar, malawi, mali, mexico, namibia, 

saudi arabia, south africa, tanzania and the 

us. we also collaborate with organizations 

from more than 50 countries, creating a 

global seed conservation network helping to 

deliver the aspirations of the convention on 

biological diversity and the global strategy 

for plant conservation. 

Q. how many seeds does the msb hold and 

from how many different species? 

A. we have the world’s largest wild plant 

seed bank, currently safeguarding more than 

1.2 billion seeds from 24,000 plant species. 

they come from all continents, including the 

only two species found in antarctica. virtually 

all of the uk’s flora is represented – making 

the uk the first country to conserve its entire 

flora in a seed bank. 

by 2009 we will have succeeded in our 

ambitious target of collecting seeds from 

ten per cent of the world’s plant species. we 

have concentrated on endangered, endemic 

(geographically specific) and economically 

important species. over the next ten years 

we are hoping to expand to 25 per cent of the 

world’s flora. 

Q. how are the seeds collected? 

A. expert teams collect the seeds when 

the plants are ready to release them. the 

collectors never take more than 20 per cent 

of the available seed on a given day so as 

not to compromise the growing population. 

they collect randomly to obtain a good 

representation of the genes. 

the majority of our seeds come via our 

formal international partners. where 

possible half of the seeds will be stored in 

suitable seed banks in the country of origin 

and the rest are sent by courier for safe 

long-term storage at the msb. 

for each species, we also collect location 

data using gps (global positioning system) 

co-ordinates, habitat information and photos. 

this is proving invaluable for monitoring wild 

plant populations, particularly in relation to 

climate change. 

Q. what conditions are required to 

conserve seeds? 

A. seeds need to be kept cold and dry. on 

arrival each batch is dried in a mechanical 

drying room at 15°c with 15 per cent 

relative humidity. the seeds are then 

cleaned and x-rayed to ensure their quality 

before being placed in hermetically sealed 

glass containers and stored in one of our 

underground cold rooms at -20°c. 

a computerized building management 

system accurately controls the temperature 

and humidity in the dry rooms, cold rooms, 

glasshouses, incubators and other critical 

areas. the cold rooms are served by a

scrolling compressor pack system which not 

only achieves optimum temperature control 

but is also extremely energy efficient. the 

system is water cooled and the waste hot 

water is recovered for domestic use. all 

critical areas of the building have inbuilt 

alarms and emergency systems including 

automatic generator back-up and round the 

clock security. 

Q. How long can the seeds survive 

in storage? 

A. Hundreds and, potentially, thousands of 

years. Recently, we were asked if we could 

test some seeds that had been discovered 

in a leather purse in the national archive 

at kew. the seeds had been collected in 

south africa by a Dutch merchant in 1803 

and had since been stored in less than ideal 

conditions. many of the seeds were dead 

but we managed to successfully germinate 

and grow seeds of a Leucospermum and 

an acacia. We are now waiting for them to 

flower so they can be formally identified. but 

this proves that many seeds can indeed be 

stored for centuries. 

every ten years we germinate a sample 

from each seed collection by growing them 

on agar, to check that they are still alive. 

many wild plants have evolved dormancy 

mechanisms so that seeds only germinate at 

a precise time in nature. consequently, we 

frequently have to apply special treatments 

to encourage the seeds to grow. 

although 91 per cent of seeds can be stored 

in cold rooms, the remaining nine per cent, 

which tend to have large, fleshy seeds, 

are desiccation intolerant or recalcitrant. 

this means they have to be kept moist and 

can only be stored short term or via cryopreservation 

and tissue culture techniques. 

Q. How and when will the seeds be released? 

A. Up to now we have been focusing on 

reaching our main target of collecting 24,000 

species, particularly endangered, endemic 

and economically important plants. but 

increasingly msb collections are being 

used in restoration, sustainable use and 

re-introduction projects around the world. 

However, the distribution of seed from the 

msb to third parties is governed by the 

terms and conditions of the access and 

benefit agreements that we have with our 

international partners. In most cases it is 

our partners who make most use of the 

collections and we provide an insurance 

policy by looking after the duplicate 

collection at the msb. 

an important tenet of the convention on 

biological Diversity is that benefits arising 

from genetic resources are shared fairly 

and equitably with the country of origin. 

Q. Has the msb helped to improve 

knowledge of plants and aid research? 

A. the msb works with other departments 

at kew including the Jodrell laboratory 

and Herbarium to better understand the 

chemical traits and taxonomy of plants. all 

aspects of the work of the msb produce 

data that helps to improve the knowledge of 

plants and their conservation. much of this 

knowledge is freely available via our website. 

members of our team share their skills 

and experience with our partners, including 

training. We make our laboratories available 

to research scientists from partner 

organizations. 

We involve schools with our work. For 

example, through a nationwide project Uk 

schools have been carrying out experiments 

on the longevity of seeds of Uk species. this 

is helping us to better predict the storage life 

and hence management of our collections. 

also we have developed a ‘mini seed bank’ 

kit which is available for schools and 

members of the public to collect and store 

seeds using the principles of seed banking. 

Q. How many species have been saved from 

extinction as a result of the work that you do? 

A. there are many examples of endangered 

plants having their seeds safely stored 

with subsequent reintroduction into their 

natural environment. We’ve recently been 

involved with a project in south africa where 

a species called cylindrophyllum Hallii 

thought to be extinct was re-discovered by 

our partners. We have successfully stored 

the seed and have been able to grow plants 

in our glasshouse for increasing the size of 

seed collection and for reintroduction in 

the wild. 

sEEd sElEctIon 

coco-dE-mEr 

(Lodoicea maldivica) 

The world’s largest seed, 

from the Seychelles. 

Banksia cone 

(Proteaceae) 

From Australia. 

conE of thE sugar PInE 

(Pinus lambertiana) 

The longest cone in the 

world, from the USA. 

lEgumE sEEd casE 

(Berlinia grandiflora) 

A large legume tree from 

Burkina Faso, West Africa. 

BaoBaB fruit 

(Adansonia digitata) 

The fruit of the upside down tree, 

found throughout Africa. 

vIsIt thE msB 

The MSB is housed in the Wellcome Trust Millennium 

Building adjacent to Wakehurst Place in West Sussex. 

Owned by the National Trust, Wakehurst Place is 

managed by the Royal Botanic Gardens, Kew. 

One of the aims of the MSB Project is to educate 

and involve the general public, which is why 70 per 

cent of the laboratories are on view. Visitors can 

watch the seeds being researched and processed 

and see a virtual tour of the seed vault. 

more information is available from 

www.kew.org/msbp or http://data.kew.org/sid/ 

thE rIght tEmPEraturE 

GEA Refrigeration is a world leader in industrial 

refrigeration equipment, systems and services. It 

offers customized solutions for the food, brewery, 

drinks, marine, chemical, pharmaceutical, and 

logistics industries. The company’s ammoniaoperated, 

high-performance and energy-efficient 

heat pumps are proving useful in commercial 

greenhouses – ensuring the right temperature 

without harming the environment. 

Increasingly, GEA Refrigeration is playing an 

important role in the ornamental plant sector where 

cool temperatures and conditioned relative humidity 

are required. 


22 

Books, cARs, coMputeRs, dRink, food, 

fuRnituRe, tRAvel, toys – whAteveR 

you’Re Buying oR selling, A tRAde 

show is the plAce to see And Be seen.

very year millions of people flock to 

many thousands of trade fairs and 

exhibitions held around the world. 

For visitors and exhibitors alike, these 

events are the perfect showcase for 

the latest products and services. 

companies can test new markets, make 

contact with others within their industry 

sector and, of course, keep tabs on 

what their competitors are doing. 

exhibitions and trade fairs, in their various 

guises, have been pulling in the crowds for 

hundreds of years. but everything changed 

with the great exhibition of the Works of 

Industry of all nations. Held in London in 

1851, it set the standard for years to come. 

not only was this the first international 

trade fair but also the first to have a 

purpose-built venue – crystal palace. the 

massive glass and iron exhibition hall was 

built in just nine months and provided 

93,000 square meters of exhibition space. 

During the six months it was open, six 

million people visited the great exhibition, 

marveling at the 100,000-plus products 

on display, including false teeth, flush 

toilets and even an early version of 

what was to become the fax machine. 

interactive experiences 

since then, exhibition halls and convention 

centers have sprung up around the world, 

catering for fairs on an ever grander 

scale. During the 20th century, new 

technology, including velcro, which enabled 

materials to be displayed more easily, vinyl 

graphics and the Internet have helped 

transform trade fairs from static events 

to hands-on, interactive experiences. 

In the 1960s two things happened that 

still influence today’s events. Firstly, the 

mccormick place convention center in 

chicago burned down, just hours before 

a major exhibition was due to open. this 

prompted the setting of strict fire safety 

rules. secondly, exhibitors won the right to 

appoint their own contractors. previously, 

they had to use a contractor appointed 

by the organizer to build their stand. 

For companies exhibiting at trade fairs the 

costs in time and resources are enormous. 

space has to be rented and displays 

designed and constructed. then there’s 

promotional literature to prepare, travel 

and accommodation to organize and, of 

course, basic services – such as electricity, 

cleaning, Internet connections and material 

handling – all have to be paid for. 

many companies do business in a number 

of different sectors, which can make 

attending all the relevant fairs a logistical 

headache. this is certainly the case for 

the gea group in 2009 when three major 

exhibitions – anuga Foodtec, acHema and 

Drinktec – are due to take place within a few 

months. participation at all three exhibitions 

represents a significant investment for 

gea in terms of time, effort and money 

from many different parts of the company. 

and the degree of difficulty involved is 

multiplied by the fact that three big events 

take place in a relatively short timespan. 

this is when the company’s years of 

experience of attending fairs around the 

world will really pay off. Jürgen Henke, 

who chairs gea’s exhibition committee, 

explains: “We normally start planning 

for an exhibition at least 18 months 

in advance. First we ask which of our 

companies want to participate and then 

we agree how much space to allocate 

and divide the costs. We have some great 

people from the different parts of the 

business who have to work really well 

together to pull off events of this size.” 

What it takes 

good communication between all the 

participating companies is essential. 

“all our divisions have representatives on 

the committee who are responsible for 

their part of the business,” says Henke. 

“We select project leaders for each of 

the big events who co-ordinate both our 

internal and external needs. this includes 

everything from inviting tenders for the 

stand construction to providing name 

badges for the sales people at the events 

– the list is long enough to fill a book.” 

the outlay may be huge but the cost of 

not taking part could, potentially, be so 

much greater. “a big show is a perfect 

sales and information platform,” adds 

Henke. “It also enables people to meet our 

engineers and components manufacturers 

together in one place and to learn first 

hand about our ‘engineering excellence’.” 

all the exhibitions have particular 

challenges but the acHema chemical 

engineering and process industries 

exhibition in Frankfurt is the busiest 

in terms of visitor numbers and gea 

representation. a total of 30 gea companies 

from different divisions attend this event. 

thus, the co-ordination and planning 

has to be meticulous, especially as the 

gea stand is normally packed to capacity 

with visitors. one thing’s for sure: in 

terms of exhibitions, 2009 looks like 

being anything but dull for gea. 

2009 

10-13 anuga foodtEc 

march colognE 

The world’s most important fair for food and drink 

technology. It attracts nearly 40,000 visitors from more 

than 150 countries. GEA, represented by 12 of its Group 

companies, will have a 1,000 square meter stand 

promoting its engineering expertise in the dairy, food 

and beverage industries. 

www.anugafoodtec.com 

11-15 

may 

The number one event for the chemical engineering 

and process industries, attracting 190,000 visitors. 

Some 4,000 exhibitors from 50 countries will be 

taking part. GEA Group will be the largest exhibitor 

with a 1,100 square meter stand and 30 companies 

represented to showcase the Group’s expertise and 

extensive product range for these industries. 

www.achema.de 

14-19 

sEPt 

Presents all the latest technology for manufacturing, 

filling, packaging and distributing all kinds of soft, 

alcoholic, hot and health drinks. GEA will have a major 

presence with a 1,500 square meter stand and 11 

companies in attendance. The stand will highlight 

the GEA Group’s processing and engineering expertise 

in brewery and beverage industries. 

www.drinktec.com 

achEma 

frankfurt 

drInktEc 

munIch 


n 1974 Sidney Frank, a New York State 

entrepreneur, was granted the exclusive 

United States import rights of a German 

liqueur that few Americans had ever heard 

of: Jägermeister. Frank had a reputation as 

an outstanding brand builder in the field 

of spirits and liqueurs, and he confidently 

predicted he could market this herbal 

aperitif across North America. His friends 

thought he was crazy when he imported 

a few hundred cases of Jägermeister for 

parties and set up promotional events 

hosted by a band of attractive models 

that he called the “Jägerettes”. But his 

ingenuity made Frank a fortune and turned 

the brand into the third largest-selling 

imported liqueur in the US, with sales 

reaching nearly half a million cases a year. 

Back in 1878 Wilhelm Mast had founded 

the wine wholesale business Mast- 

Jägermeister. But it was his son Curt who 

developed the recipe for the herbal liqueur 

in 1934: he launched it a year later as 

a digestive health tonic with restorative 

qualities. Some of the claims for the drink 

were rather dubious and it took until the 

1970s for it to become recognized as a 

mainstream liqueur and cocktail mixer. 

Although the mix of 56 different herbs 

used to make Jägermeister is a company 

secret, some of the blooms, roots and 

fruits are known. These include cinnamon 

bark from Sri Lanka, bitter orange skins 

from Australia, ginger from southern Asia 

and santal leaves from the East Indies. 

trip by a vision of a giant stag – with a 

glowing cross between its antlers – that 

stared at him through the darkness. Hubert 

recognized this as the ‘hand of God’, a sign 

that forced him to change his ways. He 

sought solace from the church, became a 

missionary, later a bishop and was finally 

canonized as the Patron Saint of Hunters. 

Unique flavor 

During Jägermeister’s five-week 

manufacturing process the ingredients 

are milled, ground and weighed 

before undergoing a process known as 

maceration. This involves systematically 

extracting several substances from the 

mix of herbs to produce an essence that 

forms the base of the drink’s unique semisweet 

flavor. The maceration process is 

repeated several times in large 7,000-liter 

tanks before the mixture is drained and 

filtered. The liquid is then stored in oak 

casks for a year before sugar extract, 

caramel, softened water and alcohol are 

added in the final process that results 

in the 35 per cent proof herbal liqueur. 

Mast-Jägermeister has its headquarters 

at Wolfenbüttel in Lower Saxony where 

the liqueur is made at three different 

locations. In 1996 one of the most modern 

production units in Europe was added 

at Kamenz. The GEA Group, through its 

engineering specialist company GEA TDS, 

has played a key role in the development 

of the Jägermeister brand. When the 

manufacturer needed to increase the 

output at their Wolfenbüttel plant, GEA TDS 

The distinctive green Jägermeister bottle 

sports a logo depicting a stag’s head with 

a glowing cross between its antlers. The 

name of the drink translates literally to 

‘hunt master’ and refers to the German 

folk hero Saint Hubert, a wild hunter who 

had no regard for animals. Legend claims 

Hubert was confronted while on a hunting 

won the contract to modernize the plant by 

installing new pipe and electrical systems, 

to engineer the maceration tanks and to 

devise a new process technology control 

system that gave Mast-Jägermeister the 

facilities to almost double production. What 

is astonishing is that GEA TDS managed 

to install the new system and switch from 

the old to the new process without any 

interruption to the manufacturing process. 

Expanding markets 

Today Mast-Jägermeister exports 75 per 

cent of its total production to 80 countries. 

Most is destined for North America and 

Europe but an increasing market is starting 

to develop in South Asia. The famous 

liqueur now nestles in ninth position in the 

Top 100 Premium Spirits ratings, with a 

loyal following among young trendsetters 

who frequent the dedicated Jägermeister 

lounges. The brand’s appeal to rock music 

lovers is recognized by the company’s 

astute sponsorship of heavy metal and 

ska bands including Metallica and Motley 

Crue. And they also support motorsports. 

Jägermeister mixes well with Coca- 

Cola but The Spirit World beverage 

magazine has suggested a cocktail they 

call the Mahogany as an alternative. This 

comprises ½ ounce of dry vermouth; ¾ 

ounce of Jägermeister and ¾ ounce of 

Benedictine stirred with ice and strained 

into a cocktail glass that has been misted 

with cinnamon tincture made by soaking 

cinnamon sticks in vodka for a couple of 

weeks. Only for the brave perhaps. 


25

26 

last year us publisher scholastic 

announced that boy wizard harry 

potter’s final adventure (the 

deathly hallows) would be printed 

on at least part-recycled or 

sustainable paper. all 12 million 

copies. that’s as high profile as 

green publishing can get. and it’s 

a sign of our changing demands 

on the paper industry. 

o you thought the paperless office would become a 

reality? and that electronic publishing of newspapers 

and magazines would destroy their printed 

counterparts? both seemed possible when email and 

the web began to dominate our lives. instead, the paper 

industry is still thriving. 

why? well, it seems most offices are still buried under 

mounds of paper, not least emails printed and kept 

for posterity. the big sea change has been in attitudes 

to paper. where we once sniffed at the idea of using 

recycled paper, associating it only with woolly-jumper 

charities or environmental organizations, it is now the 

thing to do. either that or at least paper that can be 

proven to originate in sustainable forests. 

the paper industry is now at the forefront of europe’s 

drive to recycle. and with good reason. on average, one 

tonne of 100 per cent recycled paper diverts 1.3 tonnes of 

waste paper from landfill, needs 50 per cent less energy 

to manufacture and saves 1.32 tonnes of carbon dioxide. 

today’s recycled paper is considered equal in both 

quality and performance to its virgin counterpart. one 

hundred per cent recycled paper is uncoated, though 

there are part-recycled coated papers that still qualify for 

sustainability accreditation. 

but sustainability isn’t just about recycling. over 

the last few decades the paper industry has managed 

to reduce its energy and water needs, as well as 

harmful emissions. 

process improvements 

paper and pulp production is energy intensive. but there 

are signs of effective moves towards energy saving. 

perhaps the most high profile is combined heat and 

power (chp). around 96 per cent of energy produced at 

european paper mills is derived from chp technology. 

today about 50 per cent of the european pulp and 

paper industry’s energy consumption comes from 

biomass fuels, which are carbon neutral. pulp and 

paper mills also recover energy from their waste stream 

by using biomass as a primary energy source in the 

manufacturing process. 

however, much of the energy needed for the paper 

industry is produced by the combustion of fossil fuels. 

while great strides have been made in the reduction of 

the resulting sulfur dioxide emissions – through the use 

of sulfur-free or low-sulfur fuels, natural gas and more 

process control techniques – nitrogen oxide emissions, 

which can affect ozone quality, are harder to control.

some paper producers are taking environmental matters 

into their own hands. earlier this year there were reports 

of an increased rate of deforestation in the amazon. but 

brazil-based orsa, one of the largest global integrated 

paper and cardboard box producers, manages the world’s 

biggest private tropical forest in the amazon where they 

harvest only 30 cubic meters of timber per hectare every 

30 years, just below the natural regeneration rate. 

which leads us back to sustainable forests – a term 

bandied about but not easy to define. broadly, it’s about 

achieving a balance between our increasing demand for 

forest-derived products and preservation of the forest 

health and diversity on which those products – and 

community livelihoods – depend. 

formal recognition 

fortunately, there are several high-profile organizations 

– and countless other bodies – who provide guidelines, 

carry out audits and award accreditations to everyone 

in the paper trail who wants to be green and be seen to 

be green. that goes for foresters, pulp producers, paper 

mills, merchants and printers. 

one of the best known is the forest stewardship council 

(fsc), an international non-governmental organization. 

founded in 1993 in response to public concern about 

deforestation, it provides a trustworthy labeling scheme 

for paper and other wood-based products that come from 

well-managed and sustainable forests. their so-called 

chain of custody carefully documents each stage in the 

management of wood-based products from harvesting of 

new material to selling of finished product. 

gEa and thE PaPEr Industry 

Several of GEA’s companies make valuable contributions to 

paper industry processes. 

Plate heat exchangers from GEA Ecoflex are used in all 

stages of pulp and paper manufacturing processes, 

contributing to optimum product flow – economical, valueadding 

and ecological, since they have optimal heat transfer 

values, clean media separation and closed circulations to 

make best use of water and energy. 

GEA Barr-Rosin’s Superheated Steam Dryer – used to dry 

material from wood chips to paper pulp – incorporates 

unique, environmentally-friendly technology. Using 

superheated steam to dry a range of products in a closedloop 

system, it releases no particulate emissions and has 

an energy recovery of between 80 and 90 per cent. With no 

oxygen present, the steam atmosphere avoids the risk of fire 

or explosions. 

Paper recycling produces waste water which needs to be 

cleared of residues. GEA Westfalia Separator’s decanters 

offer a cost-effective solution that also protects the 

environment by reducing the need for fresh water and 

minimizing pollutants. These include whiteners, inks and 

dust-inhibiting agents. 


28 

yannick petitJean’s peripatetic 

working life has seen him travel 

far and wide. now managing 

director of gea’s westfaliasurge 

french business, he’s come a 

long way in the agricultural 

industry since he first worked 

on his father’s farm close 

to diJon (in france) as a young 

man. he tells generate about 

the importance of making the 

most of your opportunities.

hen the train goes past, you either 

jump on it or watch it leave you 

behind,” said yannick petitjean, 

managing director of gea westfaliasurge 

france sas. it’s certainly the attitude he 

has shown through a fascinating career, 

during which he has worked abroad and 

travelled extensively in the last 14 years. 

petitjean’s enduring interest in agriculture 

began at home, working on his father’s 

wheat and livestock farm close to dijon. 

another consistent theme in his life has 

been his love of languages – with french 

as his native tongue, he graduated with 

a degree in english and german and can 

also get by in turkish and russian. it’s this 

mixture of linguistic skills and agricultural, 

specifically dairy, expertise that has 

enabled him to go far, savoring the rich 

cultural experiences that come with 

spells abroad. 

“i’ve always been interested in applying 

business skills to the agricultural world 

and my first big chance came when i 

was studying for a masters degree in 

international development, emergency and 

humanitarian assistance.” aged just 22, 

petitjean was asked if he wanted to spend 

a year in the gabon in africa, heading up 

a new dairy company making yogurts. 

he jumped at the chance. “i’ve always 

believed in the importance of taking the 

opportunities that come along – if you don’t 

try you will never know. my year in the 

gabon was a fascinating micro-project – 

with a small team we had to launch a new 

product, grow sales and make the business 

stable. the yogurt was good and the 

business was successful.” 

on his return to france, he completed his 

training with a course in export sales and 

it was during this that he had a threemonth 

secondment in the milk cooling tank 

manufacturer gea westfaliasurge Japy’s 

export department. 

“it was a three-month position and they 

told me there was no chance of me being 

taken on permanently.” but petitjean 

clearly did something right as he was 

subsequently offered the position of area 

sales manager for germany, austria, 

benelux and switzerland – a testament to 

both his potential and his range of 

linguistic skills. 

petitjean’s career took a different direction 

when, still on the masters course, he 

spent two years working for french 

humanitarian group acf (action contre 

la faim/action against hunger), coordinating 

the logistical side of its food and 

aid programmes, first in turkey and then in 

parts of the former ussr like georgia and 

chechnya. “the challenge was to deliver 

the aid, which consisted of wheat, food, 

milk and oil. by getting the food to the right 

people, we wanted to help kick-start the 

countries’ agricultural activities.” 

gea westfaliasurge Japy manufactures 

milk cooling tanks which are used at farms 

to store the milk prior to collection by the 

dairies – so it’s a crucial element in any 

dairy farm’s operations. from 1997-2007 

yannick worked in a variety of mainly 

export-based roles, managing customers 

and distributors over an ever-expanding 

geographical area that most recently 

with chechnya in the middle of a civil war, 

this was some challenge. adds petitjean: 

“we were situated away from the areas 

where the fighting was taking place but 

conditions were stressful because of the 

presence of so many people with guns and 

refugees fleeing from the fighting.” 

included asia and latin america, travelling 

for two weeks out of most months. 

since becoming managing director of gea 

westfaliasurge’s french business, he is 

travelling far less abroad but still very often 

across france and his role is more about 

setting the overall strategy for the future. 

“when i took over, my first target was to get 

all the gea westfaliasurge employees in 

france on board and aligned to our future 

goals. we have also had the challenge 

of integrating gea westfaliasurge’s new 

product range, namely the t!tan milking 

robot, into the business and we have 

russia there is currently big investment in 

the sector which means herds can number 

over 1,000 cows. but whatever the size 

of the farm, the challenges remain the 

same – to help the farmers improve 

processes and productivity in an 

increasingly price-driven market, and to 

improve gea westfaliasurge’s share of the 

french market.” 

already sold more than 25 milking robots 

to french farmers.” 

although petitjean’s not traveling as much 

these days, other old habits die hard. 

he regularly plays language games with 

his children – nine-year old grégoire 

and six-year old lucie – to improve 

their english. 

and gea westfaliasurge’s acquisition of 

canadian manure handling equipment 

company J houle and fils inc, which 

extends the division’s overall scope of 

products, will add another string to the bow 

of the french business. 

petitjean’s experience with gea 

westfaliasurge Japy means he knows 

and has worked with many people across 

gea westfaliasurge, some of whom he 

is working with again in his new position. 

as a result, his knowledge both of the 

company and of the european dairy market 

is excellent. 

“the traditions and sizes of dairy farm 

operations differs from country to country. 

for example, a herd of 45 cows is a medium 

size by french standards, whereas in 


30 

this stunning shot was taken at gea 

procomac spa’s bottling technology facility 

in Italy. It may remind you of flowers, but 

what’s actually happening to the pet 

(polyethylene terephthalate) tops is an 

intrinsic part of the mechanical bottling 

process. these bottles are being sterilized, 

with penetrating nozzles spraying liquid 

peroxide solution over them at high pressure, 

before they are rinsed in sterile water. 

then these spotless bottles are 

filled with fruit juices by one of gea 

procomac spa’s spanish customers.


31

gEa strEngthEns IndustrIal 

rEfrIgEratIon BusInEss 

The GEA Group has strengthened its industrial 

refrigeration business with the acquisition of UK-based 

company International Cooling Group (ICG). ICG 

manufactures evaporators and condensers for the 

industrial refrigeration market under brand names 

Searle, Raffel and Dawmec. In 2007, ICG generated 

sales of approximately EUR 70 million. This acquisition 

improves the competitiveness of GEA´s Refrigeration 

Division in Europe. 

Worldwide, GEA’s Refrigeration Division employs 

3,300 people in more than 45 companies who design, 

engineer, manufacture, install and maintain innovative 

refrigeration components and systems for a variety of 

industrial applications. 

www.gearefrigeration.com 

nEW mInEral oIl sEParators 

from gEa WEstfalIa sEParator 

GEA Westfalia Separator has developed a new 

generation of mineral oil separators called eagleclass. 

GEA Westfalia Separator Mineraloil Systems has 

launched the high performance products at the 

Shipbuilding, Machinery and Marine Technology 

international trade fair in Hamburg in September 2008. 

Eagleclass joins the range of products that protect the 

world’s oceans through the effective treatment of fuel, 

lube and hydraulic oils, sludge and bilge water. The 

new eagleclass products have been customized to meet 

the needs of the marine, oil field, energy and industry 

sectors: and the separators are more compact, lighter, 

more energy efficient and will improve performance. 

www.westfalia-separator.com 

32 

BIoEthanol fIrst In ukraInE 

GEA Wiegand is supplying engineering equipment 

for Ukraine’s first bioethanol production plant. The 

production plant in Zolotonosha has been commissioned 

by KoronAgro and full-scale production is planned to 

start in mid-2009. 

GEA Wiegand, a leader in bioethanol production, 

is delivering complete process technology for the 

KoronAgro plant. Largely produced by fermenting 

sugar and starch-containing materials like corn and 

sugar cane, bioethanol can be used as an alternative 

fuel for vehicles. 

www.gea-wiegand.com 

gEa nIro Puts Pharma ExPErtIsE on shoW 

GEA Niro, a worldwide specialist in spray drying, is 

offering a guided tour of its Pharma Test Station as part 

of the European conference on Spray Drying Solutions 

for the Pharmaceutical Industry in Copenhagen in 

December 2008. 

The event will enable existing and potential customers 

to find out about the engineering industry’s latest spray 

drying technologies and processes and see first hand 

demonstrations of spray drying solutions. Conference 

delegates will also have the opportunity to visit Niro’s 

state-of-the-art Pharma Test Station – the world’s most 

advanced GMP test station for spray drying – which can 

be used to refine products and processes and produce 

material for safety, stability and toxicology studies and 

clinical trials. 

www.niro-pharma-systems.com 

Boost for us daIry BusInEss 

World-leading dairy equipment supplier GEA 

WestfaliaSurge has acquired Norbco, Inc., the company’s 

exclusive supplier of conventional heavy - and mediumduty 

milking parlor stalls. In addition to parlor stalls, 

Norbco manufactures and distributes farm equipment 

including ventilators, cow mattresses, barn curtains, 

barn cleaners and free stalls. 

“Norbco is a long-time, well-respected manufacturer 

of high-quality equipment, and it is with great 

pride that we combine the strengths of the Norbco 

product line with those of WestfaliaSurge,” says Vern 

Foster, President and CEO, GEA WestfaliaSurge, Inc. 

“The Norbco acquisition gives us another important 

component to provide more complete, innovative 

solutions to meet the goals of today’s dairy producer.” 

Norbco equipment is available in more than 300 

dealerships across North America. WestfaliaSurge 

provides a complete line of milking equipment and 

supplies and, through the Houle brand, livestock 

manure-handling equipment for dairies of all sizes 

and management styles. 

www.westfaliasurge.com

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