Presentación CBNA - SECAGEM E RESFRIAMENTO DE … · Geelen Counterflow Cooler ... • Sanitary Design Cooler ... SECAGEM E RESFRIAMENTO DE ALIMENTOS EXTRUSADOS E PELETIZADOS - …

SECAGEM E RESFRIAMENTO DE ALIMENTOS

EXTRUSADOS E PELETIZADOS

II CONGRESSO CBNA SOBRETECNOLOGIA DA PRODUÇÃO DE ALIMENTOS PARA ANIMAIS

CENTRO DE EVENTOS EXCELLENCE - MARINGÁ - PR

4 de setembro de 2013 – quarta-feira

Diego Clivio – GEELEN COUNTERFLOW

Agenda:

1) Short Company Introduction

2) Short Speaker Introduction

3) Feeds Pellets - Cooling process

4) Petfood & Aquafeed – Drying & Cooling

a) Moisture Uniformity

b) Energy Efficiency

c) Sanitation Degree

Agenda:








• Exclusively engineering, building and servicing of counterflow dryers and coolers, since 1980

• Sales 2012 : +/- € 24 millon

– 50% dryer, 50% coolers

– 95% export, > 50% out of Europe

• Sales and Service offices in USA, China and Argentina

• Full time employees: +/- 85

• +/- 400 new dryers/coolers per year

• > 7500 references worldwide

Geelen Counterflow

Aquafeed &

Petfood

Feeds

• Higher flexibility.

• Production on order.

• New plate material production and handling machines.

• > € 1.000.000,= investments.

Agenda:








•1989 – 1996, Foods & Industrial Engineer career.

•1994 – 1999, mechanical and electrical installations in several industries. Industrial automations.

•1999 – 2006, worked for Molino Chacabuco – Argentina, technical area, producing feed pellets and petfood –Experience using horizontal and vertical dryers.

•2006 – present, Geelen Counterflow Latin America Sales Manager

Diego Clivio – Industrial Engineer

Agenda:








• Avoid product deterioration due to high temperature

• Avoid condensation on product storage silos

• Avoid condensations on final product bags

• Condensation means free water => Higher Water

Activity (Aw)

Why do we need to cool feeds?

• Invented in 1978 for

animal feed industry

• Now almost standard in

fish feed and petfood

industry

• Low air volume levels

• Little maintenance

• Clean operation

Geelen Counterflow Cooler

• Filling with product

Principle of counterflow cooling

• Start product flow

• Discharging

• Reaching level

Principle of counterflow cooling

• Discharging after pre-set time

• End of production run:• start total emptying

• Deck 100% open in order to clean out

• Fire protection

– Thermostate/PT100

– Fire valve

Safeties in counterflow cooler

• Overfilling cooler protection– Overflow sensor cooler

• Door switch– Disconnect all power

• Overflilling hopper protection– Overflow sensor hopper

• Air Volume

– Product Temperature

– Evaporation

– % Coating / Specific Heat of product

• Air Speed in Cooler

– Product Size & Density

• Retention Time

– Product Diameter

Cooler Sizing, depends on:

Watch the

animation

•Swivel valve discharge cooler

Agenda:








• Avoid product deterioration due to high Water

Activity, need to keep Water Activity below 0,62

Why do we need to dry extruded

feeds (Petfood-Aquafeed)?

Moisture uniformityInfluenced by:

Product dimensions

Pellet ingredients

Retention time

Drying air temperature

Moisture % in and out

Dryer type

Uniformity air temperature

Uniformity air volume

Uniformity product layer

Uniformity % product in

Air temperature control

Air volume control

Retention time control

% Inside pellet

Sample to sample

Samples in time

Pellet to pellet

Moisture control system

Extruder

coater

Dryer

Cooler

moisture %

Dryer control Target %

dryer

Target %

End productmoisture %

Capacity+moisture

Meal

Water

Steam

Fat

Water

zone 2

zone 1

etc

• NIR (Near Infrared)

(off- and online)

• Loss in weight system

(offline)

• Micro wave

(off- and online)

Moisture measuring systems

Applications

Sensorhead:

Temperature up to

140°C

Example

(Max-min)/2 = 0,47

6. Moisture uniformity over time

Setpoint `

Setpoint

Time

Moisture

Max.moisture

•Worst case results in moisture uniformity over time……..

•……determine setpoint, to avoid excessive moisture……..

•…….if moisture uniformity over time can be improved….

•….…we can move the setpoint closer to target.

Agenda:








Definition Dryer Efficiency

Efficiency of a dryer is being defined as “the

amount of energy in kJ that has to be added

in order to evaporate 1 kg of water”.

Goal Dryer Efficiency

Calculation for 1 kg water:

T product into dryer : 85 oC

Specific heat water : 4,2 kJ/kg/oC

Energy to heat up to 100 oC : 4,2*1*15=63 kJ

Energy to evaporation : 2260 kJ

Total (2260 + 63kJ) : 2323 kJ

Goal: 2300 – 2700 kJ/kg water

Efficiency measuring systems

Two ways to measure energy efficiency:

1. Measure gas or steam consumption

2. Measure product and air parameters

1. Measure gas consumption

Install gasmeter (1 per heater)

Measure not only gas consumption but also

capacity, moisture into the dryer and moisture out

of the dryer to define kJ/kg evaporated water

2. Measure product and air data

Measure all product and air data:

• Data product entering the dryer

• Data product leaving the dryer

• Data air entering the dryer

• Data air leaving the dryer

Remark: please ask Geelen to assist while doing these measurements

Measurements

See dryer as black box.

Energy consumption dryer =

(energy product out – energy product in)

+ (energy air out - energy air in)

+ energy radiation

Measurements

Measure data product entering the dryer

• Capacity; in general recorded by extruder: dry meal + added steam + added water (in conditioner + extruder)

• Or capacitiy: measure 1 minute output of extruder


• Moisture after extruder (incl. flash off)

• Or Moisture into dryer (excl. flash off)

• Be sure that during sampling, storage and grinding no moisture disappears!


• Measure by continuously moving the temperature sensor

Measure data product leaving the dryer

• Be sure that during sampling, storage and grinding no moisture disappears

Measure data product leaving the dryer

• Measure by continuously moving the temperature sensor

Measure data air entering the dryer

• Measure dry bulb temperature and RH (Relative Humidity)

• Or measure dry bulb AND wet bulb temperature

Measure data air leaving the dryer

• Measure air speed with pitot tube or anemometer

• Or measure airvolume by measuring the power consumption of the motor of the fan

Measure data air leaving the dryer

• Measure dry bulb temperature and RH

• Or measure dry bulb AND wet bulb temperature

Measurements

Online efficiency indicator

• Geelen introduced the online energy efficiency indicator to give the operator an indication how much energy is being used.

• Based on real time energy calculation, performed by the PLC.

• Geelen won the “VICTAM GOLD Award” for this improvement.

How improve energy efficiency?

• For bigger pellets: increase retention time

• Decrease heater temperature in first drying zone

• Decrease heater temperature in last drying zone

• Re-use cooling air

Energy efficiency

Vertical dryer more efficient because of :

• Internal recirculation

• Less open area’s where hot air passes

• The driest product comes in contact with the

driest air

• Use of energy in cooling air improves

efficiency

Conclusion

• Typical energy consumption for belt dryers is

between 3000 and 4500 kJ/kg evaporated

H2O due to higher exhaust air volumes and

higher exhaust temperatures.

• If cooler air is used as make-up air for the

dryer, energy consumption of a counterflow

dryer is below 2700 kJ/kg H2O

Agenda:








Food Safety – Why?

Easy to clean, inspect and repair without entering the equipment

Minimize penetrations, moving parts, ledges, seams & dead spaces

Geelen Food Safety equipment design features & improvements

•Dryers

• Easy inspection & cleaning access

• Doors on each deck

• All product contact surfaces visible

• Spot cleaning with hose or air wand

• Gravity flow is self cleaning

Dryers

•Easy maintenance access

• Low amount of moving parts.

• Minimal need for confined space entry

• Clean-In-Place compatible.

• Quick startup/shutdown.

Coolers

• Under most Food Safety process analyses coolers are considered a high risk environment for microbial activity and require a higher level and frequency of cleaning/inspection.

• In addition to the features shown for dryers Geelen has recently developed the following Food Safety options for

coolers.

•Large access panel doors

Geelen Food Ssafety equipment design features & improvements

Coolers

•Large hopper access door

•Rounded hoods, exhaust & collection trough. Stainless steel flat bar structural

ribbing.

Coolers

•CIP nozzle configurations

•CIP delivery system

•Clean-In-Place, CIP

• Thermal – dry

• Thermal – wet

• Chemical

• Water – hot/cold

• Air

•Video

Geelen Food Safety Equipment Design Summary

• Geelen is ready to provide equipment features to meet the next generation of animal food process standards and regulations:

• Easy inspection and cleaning

• Exposed product contact surfaces.

• Minimization of process down time.

• Integration of Clean-In-Place systems.

•The benefit for our customers is :

• Lower risk of food safety related incidents

• Improved traceability & recall if/when an incident occurs.

• Lower net cost of incident response expenses and liabilities

• Enhancement of market perception as a “Trusted” brand.

•Food Grade Design

• Also the (aqua)feed and petfood industry has a growing awareness for hygiene and food safety.

• Geelen Counterflow dryers and coolers already have a major advantage in this field due to their principle, with few moving parts, gravity flow and easy access.

• By applying the knowledge gained with our new food design dryers to other industries, even further improvements are possible.

•Hygiene

• The cooling step is one of the most critical spots in yourproduction line for(re)contamination.

• Temperature and moisturelevels often are ideal forgrowing undesired organisms.

•Salmonella

•Food-Chain

•Audit






• Alto Grau de Sanitização

• A melhor Eficiencia Energética

• Excelente Uniformidade da Umidade

• Baixa manutenção

• Automatismo


Geelen Counterflow Dryingsolutions:

• Continuos dryers (video)

• Batch dryers (video)

• Sanitary Design Cooler (video)

• Dryers&Coolers decks (video)

Diego Clivio – GEELEN COUNTERFLOWE-mail: [email protected]: +549-236-441-8899Skype: diego.clivio

Presentación CBNA - SECAGEM E RESFRIAMENTO DE … · Geelen Counterflow Cooler ... • Sanitary Design Cooler ... SECAGEM E RESFRIAMENTO DE ALIMENTOS EXTRUSADOS E PELETIZADOS - …

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