BioChop hygienisation unit for animal by-products
At the Rybjerg Biogas plant in Denmark, Landia has installed a BioChop hygienisation unit, which meets the EC-regulation concerning animal by-products not intended for human consumption
At the Rybjerg Biogas plant in Denmark, Landia has installed a BioChop hygienisation unit, which meets the EC-regulation No 1774/2002 health rule concerning animal by-products not intended for human consumption. A 2.5 m3 Landia BioChop hygienisation unit at Rybjerg adheres to the regulation which states that Category-3 animal by-products must be pasteurised or hygienised at 70C for at least one hour -and that the size of the solid parts must not exceed 12 mm. Landia has also developed a PLC (Programmable Logic Controller) for the control system to regulate all phases of the hygienisation process.
An integrated data logger, which has become an integral part of the Rybjerg biogas plant, registers the hygienisation time and the temperature.
The BioChop can also function as a heat exchanger, making the heated substrate easily pumpable, whilst the chopping of particles to less than 12mm ensures optimum use of the biogas plant reactor tank, resulting in increased gas production.
Paint dissolvers and mixers in hazardous areas
Kreis Dissolvers and vacuum mixers manufactured by Wilhelm Niemann have recently been certified for Group 11, Category 1 (Zone 0) operation.
Kreis Dissolvers and vacuum mixers manufactured by Wilhelm Niemann have recently been certified for Group 11, Category 1 (Zone 0) operation. Many manufacturers offer machines for Group 11, Category 2 (zone 2) environments, however satisfying the requirements for Group 11, Category 1 (Zone 0) certification is much more demanding. Manufacturers of solvent based paints, inks and coatings have to ‘zone’ the solvent laden atmosphere inside the mixing container of their high speed dispersers.
This is not easy and without increased extraction or a nitrogen blanket, can easily be interpreted as being zone 0.
In order to meet the highest level of safety, Wilhelm Niemann have developed a properly engineered and certified solution for the Kreis Dissolver so that all customers can comply with the latest legislation.
Turbo introduces new mixer into bakery sector
Food processing equipment manufacturer Turbo Systems has introduced to the UK bakery sector a range of specially engineered aeration machines that have a unique method of mixing and executing liquids
A leading manufacturer of food processing equipment, Turbo Systems , has introduced into the UK bakery sector a range of specially engineered aeration machines that have a unique method of mixing and executing liquids. Manufactured in The Netherlands by the specialists in mixing equipment, Shuffle Mix BV, the machines are equipped to handle products ranging from 50 up to 1000 litres. This now gives Turbo the capacity to premix, pump, aerate and deposit a variety of products, including cakes, sponges, creams, macaroons, Swiss rolls and other aerated products.
The patented system of Shuffle mix is based on the traditional method of churning milk, in which a handle, attached to a disk with several holes, moves up and down mixing the liquid in a wooden barrel.
Shuffle mix uses this principle and operates using a stainless steel bar (handle) with multiple disks mounted on a tube, pumping both the product and the air.
When the bar moves back, turbulence behind the holes is created, which mixes the air with the product to create an evenly blended mixture.
The latest model is able to deal with particle sizes as small as 5mm cubed and is designed to allow a massive 95% of the product to be processed effectively.
The mixing process virtually eliminates any resistance to the product, which ensures the temperature remains low and allows a large number of products to be processed without the need for additional cooling.
Although a cooling system can also be fitted if required.
Its sophisticated mixing chamber creates an environment that has virtually no dead spots with 0.05mm clearance between aeration pin discs and the chamber wall.
This increases the quality of the product passing through the shearing action achieving a higher quality finished product.
Some advantages of the Shuffle mix include a small footprint for minimal factory space, in-line mixing tubes to remove dead spots and make cleaning easier, PLC controls to allow simple integration with existing systems, and its compact and light structure makes moving effortless.
The machine is comprised of two stainless steel mixing tubes, each containing a shaft onto which shuffle discs are fitted, and a fixed stainless steel pipe called the ‘mixtube’.
The mixtube is jacketed to enable cooling or heating liquid to circulate and maintains an optimum temperature of the product.
Managing director of Turbo Systems, Andy Lang, commented on the new equipment: ‘Shuffle Mix BV and Turbo Systems have over 80 years combined experience developing food processing machinery.
And from our initial conversations with Shuffle Mix BV, it became apparent that its innovative equipment would complement the Turbo range and we were very happy to act as its UK distributor.
The Shuffle mix range is a unique offering and we are very excited to see the reaction in the bakery sector.’
Shockwave technology helps soft drinks mixing
The patented Pursuit Dynamics PDX technology is delivering dramatic process improvements and energy savings to companies that use thickening agents and stabilisers in the production of soft drinks
New technology delivers dramatic improvement in dispersion of gums for producers of soft drinks. The Pursuit Dynamics patented PDX technology is delivering dramatic process improvements and energy savings to companies that use thickening agents and stabilisers in the production of soft drinks. Thickening agents such as xanthan gum and pectin are commonly used in the production of soft drinks, as are stabilisers such as CMC (sodium carboxyl methyl cellulose), guar gum and gum arabic.
Dissolving these powdered ingredients is often problematic.
For example, they can be slow to hydrate, often requiring the base liquid to be heated which therefore consumes valuable process time and energy.
Powders that are insufficiently hydrated can build up on vessel walls, leading to a requirement to clean the vessel and dispose of the spent ingredients plus there is wastage through the need to overdose the ingredients to take account of the incomplete hydration - or, conversely, a reduced yield has to be accepted.
While hard-to-wet powders can agglomerate and become difficult to disperse, the hydroscopic properties of other powders can lead to entrainment difficulties and bridging problems.
Furthermore, the powders can have a tendency to float on the surface of the base liquid or they can agglomerate, either way, the rate of dissolution is reduced.
As the powders become hydrated the solution increases in viscosity and reduces the performance of conventional mixing equipment.
Finally, because of the nature of the mixing equipment used and the abrasive properties of the powders the rotating parts of conventional mixing systems inevitably wear leading to a need for regular maintenance.
As an alternative, Pursuit Dynamics offers its PDX shockwave technology that pumps, mixes, entrains and heats, all in one easy-to-clean process that has no moving parts.
Several ingredients can be simultaneously wetted and hydrated thereby eliminating the need for pre-mixing.
Agglomerations are dispersed as they pass through the supersonic region of the PDX unit.
Full dissolution consistent quality and maximised yield are achieved and the need for costly integrated stabilisers is eliminated.
The PDX system is energy-efficient and manufactured in food grade 316L stainless steel.
In trials conducted using a PDX system with a 25mm bore, the following concentrations of powders were processed: 1.1% CMC (12,000 litres/hour), 1.7% guar gum (13,000 litres/hour), 12.4% maltodextrin (12,000 litres/hour), 9% pectin (10,000 litres/hour), 21.4% purity gum (9,000 litres/hour) and 1.5-2.0% xanthan (12,000 litres/hour).
The process is scalable either by using multiple PDX units of the same size or larger single units.
For any given size of PDX unit, the throughput is controllable to match the production demand for continuous processes.
The technology can be integrated as either a batch or continuous flow system.
For more information about how PDX can save costs and process time in the production of soft drinks, please contact Pursuit Dynamics
Chemineer reactor agitator bound for India
From its base in Derby, England, mixing technology specialists Chemineer have designed and built a new polystyrene reactor agitator for a major petrochemical plant in Mumbai, India
From its base in Derby, England, mixing technology specialists Chemineer have designed and built a new polystyrene reactor agitator for a major petrochemical plant in Mumbai, India. The reactor gear drive has been manufactured by Chemineer with a specially enhanced lubrication system for low-speed, high torque operation to allow the unit to run at a very low rate via a variable speed drive. Working with its joint venture company in India, GMM Pfaulder, this latest order follows the successful installation of a similar reactor supplied by Chemineer to the same Mumbai-based petrochemical company in 1997.
Typically operating at 37rpm, the Chemineer reactor has a 70KW drive and double flight helix on a 1:1 pitch.
The unit is able to withstand temperatures of 2600C.
In addition to this major new order, Chemineer is also currently supplying reactors to other regions of India, mixing equipment for a new desalination plant in Saudi Arabia, and a range of agitators to Spain and Belgium.
Neil Davies, Operations Manager at Chemineer, commented: ‘Despite the astronomic rise in world steel prices, these latest orders clearly demonstrate that we can truly compete in the global market.
‘We have a depth of mixing technology in which we are recognised for our ability to provide highly efficient, cost-effective, long-term mixing solutions’.
Babcock Wanson acquires activities of SAFMAT
Babcock Wanson France, a subsidiary of CNIM group, has purchased from WOLF France, a subsidiary of group TUI, the SAFMAT industrial burner activity
Babcock Wanson France, a subsidiary of CNIM group, has purchased from WOLF France, a subsidiary of group TUI, the SAFMAT industrial burner activity. From its well respected and extensive experience in industrial boilers, Babcock Wanson has developed a high level expertise on technologies controlling the optimum operation of the boiler: the burners, the water treatment equipment, the conditioning products and all the associated services. This technological control allows Babcock Wanson to offer its customers complete and integrated solutions, making it possible to optimise their boiler house with all the associated guarantees.
Industrial burners from SAFMAT are famous for their high level of performance.
This is as a result of the know-how of SAFMAT technicians, having proven competence in the optimisation of combustion and the maintenance of these burners.
This acquisition gives Babcock Wanson additional strength and integrity in the market of industrial boilers and burners and further adds to its substantial pool of expertise bringing its customers all the advantages of the resulting extended competence and service.
Agitator technology stirs up drinks industry
The unique ability of the ‘Visco-Jet’ mixer is to safely blend heat-sensitive or fragile media of any viscosity while eliminating foaming by not producing bubbles and even giving big energy savings
The unique ability of the ‘Visco-Jet’ mixer’s agitator technology to thoroughly and safely blend heat-sensitive or fragile media of any viscosity while eliminating foaming by not producing bubbles and even giving big energy savings has brought particular acclaim for this system in the drink and beverages industry. Available in the UK from Orthos, Visco-Jet mixers have special cup-shaped agitators creating dynamic flow conditions at low operating speed that rapidly process virtually any aqueous medium without shear, heat or other damaging forces in containers of any size or shape. An added benefit is that container fill-level has no effect on complete mixing and homogenising performance, enabling plant to operate significantly more flexibly and cost-effectively.
But especially valued is the fact that a single universally deployable agitator design combines the advantages of product preservation with major cost-savings from reducing drive energy requirement and ending the user need for a wide selection of different stirrer types.
The ’secret’ lies in the particular geometry of its cone-shaped stirrer mechanism.
Through ingenious spatial and angular proportions, the agitator produces a prolonged flow and turbulence with low circumferential speeds, very gently and quickly guaranteeing an optimal homogenous mixing process.
Unlike conventional mixing devices, it does not produce turbulent flow at the edges, which eliminates shearing action.
Combined with the low rotational speed and short mixing time, this means media is not significantly heated and that optimal heat and cold transfer is guaranteed.
Foaming is avoided as air is not entrained during mixing.
Energy savings of up to 300% over conventional blade stirrers are provided by the Visco-Jet low-speed agitator design only needing low drive levels of 1.5 to 5kW regardless of media viscosity.
At the same time, low circumferential speeds of just 2 to 3m/sec, and even down to down to 0.35m/sec, also enable even perishable media to be processed safely.
Costs are further reduced, especially in the Drink and Bev industry, by only one agitator stage usually being needed for large container volumes.
For example, a single unit with three agitators and a 1.8m diameter is sufficient to fully homogenise the contents of a 3m diameter 15m3 capacity container.
Another major benefit of the Visco-Jet agitator system is that the stirring action spreads throughout the media and eliminates ‘dead’ points in all usual container geometries, including square.
All areas of the product are fully mixed without the need for additional inserts.
Various folding versions of the Visco-Jet that fit through the smallest holes and open out by centrifugal force allow use of this system in almost any container, even interchangeable transport units.
Agitators of virtually any diameter can be supplied for stationary applications.
Bayonet quick-release couplings facilitate fast stirrer cleaning and replacement.
Downstream quality for your upstream processes!
Would you like to incorporate downstream aseptic design and quality, as well as reduced maintenance and unrivalled mixing performance, in an upstream mixer, without breaking the budget?
Would you like to incorporate downstream aseptic design and quality, as well as reduced maintenance and unrivalled mixing performance, in an upstream mixer, without breaking the budget? NovAseptic has the answer! The totally revolutionary Upstream Mixer (USM) has been developed in close co-operation with our customers whose targets were to couple durability of the top mounted mixer with the cleanability, flexibility and aseptic design of the bottom mounted magnetically driven GMP Mixers. Maintainability was high on the agenda, and as such, both the male and female silicone carbide bearings are now easily replaceable on site, shortening downtime to an absolute minimum.
The Upstream Mixer Tank Plate can be either welded or flange mounted to provide additional flexibility.
Mechanical seals, steam locks and baffles are now a thing of the past.
Such is the efficiency of this new mixer that two models are capable of covering a range of processes up to 20 000 litres, minimising the need for spare parts both in our warehouse and at our customers premises.
The result of our joint efforts is a magnetically coupled mixer suited to the heavy duty nature of upstream processing, totally cleanable in place, and at an extremely competitive price.
Choose the USM mixer from NovAseptic and get the aseptic performance of a downstream mixer at the start of your production chain - and all of this for a price you won’t believe!
Optimisation of your aseptic mixing processes
When specifying an aseptic mixing process, enhanced performance, repeatability and the ability to clean and steam in place are all critical considerations
When specifying an aseptic mixing process, enhanced performance, repeatability and the ability to clean and steam in place are all critical considerations. These features are built-in when you choose NovAseptic as your aseptic processing partner. At NovAseptic, we believe that our customers should have the ability to improve and optimise their mixing techniques prior to installation in order to ensure ‘Right First Time’ performance.
Recently three complete new mixing concepts have been added to compliment our established range of GMP mixers, these being the Upstream mixer, High Shear mixer and High Shear Inline mixer.
Collectively we have created a powerful toolbox to exceed our customers processing requirements, whether that be emulsifying, downsizing, creating suspensions or gentle mixing/blending.
Throughout the continuous development process our products have been optimised to meet the specific needs of the entire processing chain, from upstream to final filling.
To assist in verifying and optimising your specific mixing processes, we have recently installed the capability to perform representative tests within our fully equipped ‘Pre-Validation Centre’.
Situated within our Gothenburg Headquarters, this fully equipped test centre is available for your use.
We have installed state of the art test vessels, the largest being a new 5000 litre unit, as well as support services such as clean steam and water for Injection, ensuring that your simulations are performed to mirror production like conditions.
With a mixing solution from NovAseptic you can minimise on-site validation time and reduce production costs from day one!
Visco Jet mixer proves to be a smooth move
Better mixing of fruit smoothies and yoghurt based drinks in a shorter time and with less foam in the finished product is a snapshot of the advantages resulting from retrofitting two Visco Jet mixers
Better mixing of its fruit smoothies and yoghurt based drinks in shorter time and with less foam formation in the finished batch is a snapshot of the advantages that the company ‘Pete and Johnny’ has described after retrofitting two ‘Visco Jet’ mixers from Orthos into existing tanks at their plant in Newark, Nottinghamshire. Blending time is quoted as having been reduced by 60% and efficiency has ‘greatly’ improved by simplifying the on/off cycling required while a completed batch is being bottled. Both of the new mixers have variable speed drives.
Because only one impeller stage is now required instead of the two or three needed on the old type of mixer, and since this single impeller is at the bottom of the tank, it has proved perfect for mixing small batches in tanks normally too large to do so.
This is said to have meant the ultimate in production flexibility for P and J, now part of Pepsico.
Another advantage of the patented low-speed Visco Jet machines is their very low energy usage combined with exceptionally gentle but thorough mixing of virtually any kind of aqueous medium up to 100,000 mPas viscosity.
A unique cone-shaped impeller gives prolonged flow and turbulence at low circumferential speed to ensure rapid mixing while eliminating shearing action that can break up or damage heat-sensitive or fragile products.
Foaming is avoided as air is not entrained during mixing.