Modularization and Standardization - PD-Symposiumpd-symposium.org/files/pad/8. Gerhardt Jacobsen.pdfModularization and Standardization APC Dairy Powders & Nutricional Formula GERHARDT

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


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



11

Insert text with "Insert Header and Footer"

GEA PTC DRYING Standardization


Standard Components



GEA APC DAIRY POWDERSApplication Standardization

Standard Concepts Flow Diagrams


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”


• 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)


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


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


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


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




Feed System


Feed System

Main Drying System


Feed System

Main Drying System

Exhaust System


Feed System

Main Drying System

Exhaust System

Post Drying System


Feed System

Main Drying System

Exhaust System

Post Drying System

Fines Return System


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


Feed System

Main Drying System

Exhaust System

Post Drying System

Fines Return System


CIP System

Agent Adding System

CIP Tank System

Safety System

Buffer and Storage

Transport and Treatment

Atomization


Feed System

Main Drying System

Exhaust System

Post Drying System

Fines Return System


CIP System

Agent Adding System

CIP Tank System

Safety System


Feed System

Main Drying System

Exhaust System

Post Drying System

Fines Return System


CIP System

Agent Adding System

CIP Tank System

Safety System

=B1

=R1

=E1

=F1

=G1

=H1

=L1

=N1

=Q1

=P1

IEC/EN 81346


Feed System

Main Drying System

Exhaust System

Post Drying System

Fines Return System


CIP System

Agent Adding System

CIP Tank System

Safety System

=B1

=R1

=E1

=F1

=G1

=H1

=L1

=N1

=Q1

=P1

IEC/EN 81346


Feed System

Main Drying System

Exhaust System

Post Drying System

Fines Return System


CIP System

Agent Adding System

CIP Tank System

Safety System

=B1

=R1

=E1

=F1

=G1

=H1

=L1

=N1

=Q1

=P1

Configurator


Feed System

Main Drying System

Exhaust System

Post Drying System

Fines Return System


CIP System

Agent Adding System

CIP Tank System

Safety System

=B1

=R1

=E1

=F1

=G1

=H1

=L1

=N1

=Q1

=P1


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


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.


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.


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.


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.


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






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


Discussion

Documents

Modularization and Standardization - PD-Symposiumpd-symposium.org/files/pad/8. Gerhardt Jacobsen.pdfModularization and Standardization APC Dairy Powders & Nutricional Formula GERHARDT