View
229
Download
4
Category
Preview:
Citation preview
Modularization and StandardizationAPC Dairy Powders & Nutricional Formula
GERHARDT JACOBSEN, COPENHAGEN, SEPTEMBER 2016
2Insert text with "Insert Header and Footer" November 22, 2017
Name: Gerhardt Jacobsen
Job position: Safety and Concepts
History with GEA: Joined GEA Niro in 1974 (Niro Atomizer)
Project Engineer Niro Atomizer, Denmark, 1974 - 1979
Technical Manager Niro, Mexico, 1979 - 1982
Project Manager Niro Hudson, USA, 1982 - 1988
Project Manager in FODA, Niro Denmark, 1988 - 2000
Safety and Environmental Resource Manager FODA, GEA Niro, 2000 - 2015
Safety and Concepts GEA Denmark - APC Dairy 2015 - ∞
GEA at a Glance
GEA is one of the largest suppliers of process technology for the food industry and a wide range of other industries.
The international technology group focuses on process technology and components for sophisticated production processes in various end-user markets.
The company is listed on the German MDAX stock index and included in the STOXX® Europe 600 Index. In addition, the company is listed in selected MSCI Global Sustainability Indices.
GEA – “engineering for a better world”
3
Order intake (EUR)
4,674 million
Employees (FTEs)
16,937
Operating EBITDA (EUR)
566 million
Operating EBITDA margin
12.6%
Revenue (EUR)
4,491 million
Earnings per share (EUR)
1.48
GEA – a powerful partner throughout the world
4GEA at a Glance
Employees in 2016 (FTEs)
Revenue in 2016
North America1,709804.6 million
% 18
North and Central Europe2,924663.8 million
% 15
DACH &Eastern Europe
6,301902.1 million
% 20
Asia Pacific2,8671,050.1 million
% 23
Western Europe, Middle East & Africa
2,727805.0 million
% 18
Latin America409266.4 million
% 6
% Regional revenue split in 2016 (only continued operations)
Customer-centric sales and service activities are u nified under the umbrella of a single country organization.
Our applications – in touch with GEA every day
5
Approx. one quarter of processed milk
comes from GEA production systems
Around every third process line for
instant coffee was installed by GEA
Every third chicken nugget is produced by GEA technology
Approx. every second liter of beer is brewed with the aid of systems and process solutions
from GEA
Every second container ship in the world sails with GEA marine equipment on board
Each industry we serve utilizes GEA’s industrial refrigeration technologies
Every fourth liter of human blood is handled by GEA equipment
More than one third of all polymer producers are using GEA Drying technology
Dairy Farming and Processing
Food
Beverages
Pharma
Chemical
Utilities
Marine
GEA at a Glance
6Insert text with "Insert Header and Footer" November 22, 2017
Milk FatProducts
Sour Cream Butter
Dairy Spreads
Sweet Cream Butter
Anhydrous Milk Fat (AMF)
Ghee
APC Dairy application overview
APC Dairy
Product Clusters
NutritionalFormula
Infant Milk Formula
Follow on / follow up Formula
Dietary Nutrition
Growing up Milk
Applications
Market Milk Products
Pasteurized / Fresh Milk
Ultra Heat Treated (UHT) Milk
Extended Shelf Life (ESL) Milk
Flavoured Milk
Milk Mix Drinks
Condensed Milk
Sweetened Condensed Milk
Whipped Cream
DairyIngredients
Whey & Milk Permeate Powder
Whey Powder
Lactose Powder
WPC / WPI Powder(Whey Protein Concentrate / Isolate)
Casein / CaseinatePowder
MPC / MPI Powder(Milk Protein Concentrate / Isolate)
Yoghurt Powder
Cheese Powder
Milk Powders
Skim Milk Powder
Whole Milk Powder
Fat Filled Milk Powder
Buttermilk Powder
Coffee & Tea Whitener
Cheese
Fresh Cheese
Cream Cheese
Soft Cheese
Semi Hard Cheese
Hard Cheese
Processed Cheese
Pasta Filata Cheese
White Cheese
Desserts & Fermented Products
Stirred Yoghurt
Set Yoghurt
Drinking Yoghurt
Sour Milk Drinks
Sour Cream
Buttermilk
Concentrated Yoghurt
Desserts
Rice Desserts
Ice Cream
Ice Milk / Cream
Frozen Yoghurt
Sherbet
Sorbet / Water Ice
Dessert Ice
Cream
Milk FatProducts
Sour Cream Butter
Dairy Spreads
Sweet Cream Butter
Anhydrous Milk Fat (AMF)
Ghee
APC Dairy application overview
APC Dairy
Product Clusters
NutritionalFormula
Infant Milk Formula
Follow on / follow up Formula
Dietary Nutrition
Growing up Milk
Applications
Market Milk Products
Pasteurized / Fresh Milk
Ultra Heat Treated (UHT) Milk
Extended Shelf Life (ESL) Milk
Flavoured Milk
Milk Mix Drinks
Condensed Milk
Sweetened Condensed Milk
Whipped Cream
DairyIngredients
Whey & Milk Permeate Powder
Whey Powder
Lactose Powder
WPC / WPI Powder(Whey Protein Concentrate / Isolate)
Casein / CaseinatePowder
MPC / MPI Powder(Milk Protein Concentrate / Isolate)
Yoghurt Powder
Cheese Powder
Milk Powders
Skim Milk Powder
Whole Milk Powder
Fat Filled Milk Powder
Buttermilk Powder
Coffee & Tea Whitener
Cheese
Fresh Cheese
Cream Cheese
Soft Cheese
Semi Hard Cheese
Hard Cheese
Processed Cheese
Pasta Filata Cheese
White Cheese
Desserts & Fermented Products
Stirred Yoghurt
Set Yoghurt
Drinking Yoghurt
Sour Milk Drinks
Sour Cream
Buttermilk
Concentrated Yoghurt
Desserts
Rice Desserts
Ice Cream
Ice Milk / Cream
Frozen Yoghurt
Sherbet
Sorbet / Water Ice
Dessert Ice
Cream
9Insert text with "Insert Header and Footer" November 22, 2017
10Insert text with "Insert Header and Footer" November 22, 2017
11
Insert text with "Insert Header and Footer"
GEA PTC DRYING Standardization
12Insert text with "Insert Header and Footer" November 22, 2017
Standard Components
13Insert text with "Insert Header and Footer" November 22, 2017
14Insert text with "Insert Header and Footer" November 22, 2017
GEA APC DAIRY POWDERSApplication Standardization
Standard Concepts Flow Diagrams
15Insert text with "Insert Header and Footer" November 22, 2017
What is a
How did the
Why have a
What can we expect from a
Where is a
How are the
Who owns the
Where can I find the
CONCEPT
CONCEPT
CONCEPT
CONCEPT
CONCEPT
CONCEPT
CONCEPT
CONCEPT
arrive
used
maintained
information
What is a “CONCEPT”
16Insert text with "Insert Header and Footer" November 22, 2017
• Concept = (kladde) (rough) draft
• Concept Cars, Prototype Vehicles
• A Concept is A general statement of the idea behind a design.
• A concept is The general idea behind a slogan, pitch, or campaign.
• Any preliminary undertaking including ideas, strategies, proposals, impressions , models, views, designs, artwork or diagrams which are origi nated by the Niro Group.
• During the Schematic Design phase, the initial designs shown to the campus to determine a direction for the Schematic Design.
• Conception = (undfangelse)
17Insert text with "Insert Header and Footer" November 22, 2017
A “APC Dairy Powders Concept Flow Diagram” consists of a flow-diagram containing all basic information needed to design a functional systems/modules that can be combined in a variety of functional combinations to a functional plant.
The concept flow diagram shall be seen as a 80/20 concept:• 80% standard/re-use • 20% freedom for customization during project development.
Level of information
18Insert text with "Insert Header and Footer" November 22, 2017
1
2
3
4
5
6
7
Pre design Basic DesignDetailed design
Production design
CONCEPT Flow Diagrams
PROJECTCONCEPT Flow Diagrams
SALES
History of Concept flow diagrams
19Insert text with "Insert Header and Footer" November 22, 2017
Idea of conceptual design was born in Dairy 1988
Dairy (Medusa) 1994
Dairy (Basis for Configurator) 2000
Dairy (AutoCAD) 2001
Food and Dairy (New Symbols) 2003
Food and Dairy (Implementation of configurator 2005
Food and Dairy Implementing RD no. 2009
APC Dairy Powder New Organization 2015
APC Dairy ………… may implement the system for complete fa ctories ?
In the beginning the drive came from PCO
Process Control
20Insert text with "Insert Header and Footer" November 22, 2017
Hot Air
Cold Air
Hot Air
Hot Air
Cold Air
Hot Air
Hot Air
Cold Air
Hot AirHot Air
Hot Air
Hot Air
Amb. Air
Cold Air
Hot Air
Hot Air
Hot Air
Cold Air
Hot Air
Cold Air
Existing
APC Dairy Powders
Dryer Concepts
21Insert text with "Insert Header and Footer" November 22, 2017
22Insert text with "Insert Header and Footer" November 22, 2017
23Insert text with "Insert Header and Footer" November 22, 2017
Feed System
24Insert text with "Insert Header and Footer" November 22, 2017
Feed System
Main Drying System
25Insert text with "Insert Header and Footer" November 22, 2017
Feed System
Main Drying System
Exhaust System
26Insert text with "Insert Header and Footer" November 22, 2017
Feed System
Main Drying System
Exhaust System
Post Drying System
27Insert text with "Insert Header and Footer" November 22, 2017
Feed System
Main Drying System
Exhaust System
Post Drying System
Fines Return System
28Insert text with "Insert Header and Footer" November 22, 2017
Feed System
Main Drying System
Exhaust System
Post Drying System
Fines Return System
Powder conveying System
CIP System
Agent Adding System
CIP Tank System
Safety System
29Insert text with "Insert Header and Footer" November 22, 2017
Feed System
Main Drying System
Exhaust System
Post Drying System
Fines Return System
Powder conveying System
CIP System
Agent Adding System
CIP Tank System
Safety System
Buffer and Storage
Transport and Treatment
Atomization
30Insert text with "Insert Header and Footer" November 22, 2017
Feed System
Main Drying System
Exhaust System
Post Drying System
Fines Return System
Powder conveying System
CIP System
Agent Adding System
CIP Tank System
Safety System
31Insert text with "Insert Header and Footer" November 22, 2017
Feed System
Main Drying System
Exhaust System
Post Drying System
Fines Return System
Powder conveying System
CIP System
Agent Adding System
CIP Tank System
Safety System
=B1
=R1
=E1
=F1
=G1
=H1
=L1
=N1
=Q1
=P1
IEC/EN 81346
32Insert text with "Insert Header and Footer" November 22, 2017
Feed System
Main Drying System
Exhaust System
Post Drying System
Fines Return System
Powder conveying System
CIP System
Agent Adding System
CIP Tank System
Safety System
=B1
=R1
=E1
=F1
=G1
=H1
=L1
=N1
=Q1
=P1
IEC/EN 81346
33Insert text with "Insert Header and Footer" November 22, 2017
Feed System
Main Drying System
Exhaust System
Post Drying System
Fines Return System
Powder conveying System
CIP System
Agent Adding System
CIP Tank System
Safety System
=B1
=R1
=E1
=F1
=G1
=H1
=L1
=N1
=Q1
=P1
Configurator
34Insert text with "Insert Header and Footer" November 22, 2017
Feed System
Main Drying System
Exhaust System
Post Drying System
Fines Return System
Powder conveying System
CIP System
Agent Adding System
CIP Tank System
Safety System
=B1
=R1
=E1
=F1
=G1
=H1
=L1
=N1
=Q1
=P1
35Insert text with "Insert Header and Footer" November 22, 2017
What can we expect from modularity
� Variety external - commonality internal� Economies of scale� Reduced order lead-time� Reuse� Decoupling tasks and design freedom� The ease of product upgrade, maintenance,
repair and disposal, faster product evolution
36Insert text with "Insert Header and Footer" November 22, 2017
Variety external - commonality internal1. Plants can be customized to the needs of our
customers by using the existing combinations/Modules.
2. The amount of combinations are many but all combinations are engineered and ready for use.
3. All Modules are specified according to the experiences collected by GEA Niro over many years.
37Insert text with "Insert Header and Footer" November 22, 2017
Economies of scale1. Less mistakes. 2. Less guarantee work.3. If a concept is used it is possible to do safety
analysis and other evaluation documentation based on conceptual design and time is saved on the individual projects. (EU Directives)
4. By repeating the process the specifications for the equipment can be standardized and better agreement can worked out with the sup suppliers.
5. Lower cost.
38Insert text with "Insert Header and Footer" November 22, 2017
Reduced order lead-time1. Reduced engineering hours by using pre-
engineered processes.2. Shorter spec. meeting, 3. Faster specifications to “Process Control”4. Pre made equipment lists.
39Insert text with "Insert Header and Footer" November 22, 2017
Decoupling task and design freedom 1. Smaller systems are easier to overview2. If the interfaces of the modules are known the
individual systems/modules can be redesigned independently.
3. After sales can work with separate systems.
40Insert text with "Insert Header and Footer" November 22, 2017
The ease of product upgrade, maintenance, repair and disposal, faster product evolution
1. Dynamic maintenance2. Dynamic upgrade, 3. Dynamic customer requirements implementation4. Dynamic response to feedback from the field and
from customers and from in house
41Insert text with "Insert Header and Footer" November 22, 2017
42Insert text with "Insert Header and Footer" November 22, 2017
43Insert text with "Insert Header and Footer" November 22, 2017
44Insert text with "Insert Header and Footer" November 22, 2017
45Insert text with "Insert Header and Footer" November 22, 2017
46
Insert text with "Insert Header and Footer" November 22, 2017
Spray Dryer
Powder Handling
AtomizationSystem
Main Drying System
Post Drying System
Powder Treatment and
Conveying
Transport and Treatment
System
Exhaust System
Fines Return System
Process Gas Energy
Systems
Process Gas Intake System
CIP Tank System
Safety System
CIP System
Buffer and Storage System
Energy Liquid System
Agent Adding System
47
Insert text with "Insert Header and Footer"
Intake
Powder Handling
Pre-Treatment
Separation
Extraction
Evaporation
Wet mixing
Spray Dryer
48Insert text with "Insert Header and Footer" November 22, 2017
Discussion
Recommended