Post on 10-Apr-2018
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GEA Heat Exchangers /HVAC Systems
HVAC solutions for the food
and beverage industry
Air quality and conditioning in purest form
GEA HVAC Systems | Grolsch Brewery, Netherlands
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Air Eco2nomy oers benets for you as user and for the envi-
ronment. Through demand-driven air t reatment with obser-
vance of the applicable standards, with a minimum of energy
consumption, GEA HVAC Systems (HVAC = Heating, Ven-
tilation, Air Conditioning) accepts responsibility for your
room climate and for our earth.
As processor or wholesaler of foods and beverages, you are just
as keen for top product quality as are warehouse operators and
retailers. But its not only high product quality, good taste, and
freshness that your customers expect: they also want low prices.
The operation of building services is a major inuence on over-
all costs including HVAC. Keeping these costs low and assur-
ing good room climate at the same time: this is a task that we
have accepted and that we fulll day after day.
It is a welcome challenge for us to nd the optimal solution for
your business. By the expert selection and combination of ourproducts, or with the aid of modication of existing equipment,
we create perfect room climate for you. Our solutions lter air,
and can disinfect, heat, and cool it with energy-saving air trans -
port. But we dont stop there: our systems can regulate relative
humidity and eectively remove extracted air. All of this takes
place with superior-quality components that are controlled by
advanced electronic systems. The result: assurance of high air
quality with low consumption of resources and low operating
expenses. This is what we call Air Eco2nomy.
Air Eco2nomy is more than just engineering. It is an attitude that
creates values with a future: awless conditioning of air, conser-
vation of energy resources and climate, and security for compa-
nies and investors.
Air Eco2nomy
The signs of the times
are plain enough
Ventilation with climate control is
precision work in the temperature
control and conditioning of room air.
This, after all, is the only way of
harmonizing optimal eects and maxi-
mum energy savings. For example,
at Grolsch breweries in the Netherlands,
where special central air-handling
units ensure good and clean air.
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Eective ltration of air
Optimal disinfection of air
Eective air routing and removal
of spent or contaminated air
Energy-saving transport of a ir
Provision of the required
relative humidity
Cooling of production halls
HVAC solutions for the food and beverage industry
First-class air treatment
for top product quality
Systems from us assure product quality, enhance work pro-
ductivity, and reduce cleaning expenses. Reduction in clean-ing costs results from eective cooling of production halls,
lowering of microbe concentration, dehumidication of the air
and not least by reliable operation of HVAC equipment.
The food and beverage industry extensively requires extremely
hygienic air conditions and eective cooling, to assure optimal
processing of easily perishable products. Air quality has a direct
eect here on the quality and the durability of foods and bever-
ages. This is highly evident in the example of a meat-processing
plant that GEA HVAC Systems equipped with air-treatment units.
This plant includes a cooling system that allows packing of cold
cuts at around zero degrees Celsius and that disinfects supply
air which assures the enhancement of product durability and
of plant productivity. Thanks to reduced microbe concentration,
wet cleaning of the production line is necessary less frequently.
Availability of the machines accordingly rose by several hours
per week.
As another example, the dehumidication expertise of GEA
HVAC Systems pays o in the salt bath of a cheese production
plant. Technology derived from the climate control of indoorswimming pools has enabled the regulation of humidity in
cheese plants by equipment that can over the long term with-
stand the aggressive salty air prevailing there.
Disinfection of supply air and eective cooling have signicant positive eects in the
processing of easily perishable goods on their quality and on their durability.
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Chocolate
Chocolate snacks demand maintenance of
temperature within precise ranges, to assure
that the products are not too soft and not too
tough. Within the required range, processing
of chocolate bars is successful, with retention
of their appetizing appeal.
Dairy products
Dehumidication provides the ideal production
climate for dairy foods and at the same time
prevents formation of mold in protection of
both the product and plant facilities.
Beer
Special air-handling units highly
eectively supply clean air even tothe largest of production spaces.
Wine and champagne
True enjoyment of luxurious beverages is possible
only if ideal ambience is assured to match the intended
culinary delight. And this is not least a matter for
climate control: in creation of coziness and comfort in
a quiet, unobtrusive manner.
Meat and sausage products
Sophisticated disinfection and cooling of air assures
hygienic conditions and enhances product quality and
plant productivity.
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If you more closely examine a system from GEA HVAC Systems,
and perhaps even cast a glance into its insides, you will see
more than just sheet metal and electronics. You will also nd
a great deal of know-how in there. This expertise optimally
combines functionality, cost eectiveness, and hygiene.
GEA HVAC Systems is the leading specialist for supply and ex-
haust ventilation, temperature control, and humidication or
dehumidication of the air that you require. And we develop all
the primary components and unit designs in our own company,
for which our engineering-design specialists resort to decades
of valuable experience. Continuous improvements mark the ad-
vances made in our main equipment groups prompted as they
are by new production techniques, further-optimized materials,
insights gained from practice, and new customer wishes. These
ongoing advances are highly evident in our central air-handling
systems, unit heaters, chillers, and extract fans.
Our Inst itute for HVAC Technology puts our prototypes through
rigorous testing. Simulations and prototype testing eectively
reveal whether new ideas can in fact be successfully imple-
mented before products to go series production. In the Insti-
tute for HVAC Technology, we can also simulate specic appli-
cation cases. It is even possible to physically simulate spatial
congurations in order to test and optimize planning. This oers
planners and operators valuable support when their special
problems demand unconventional solutions.
Our expertise whether integrated in our equipment, or pro-
vided as service means a major benet for you: you buy func-
tionality, combined with eciency. And you can be sure that our
products function in harmony with each other. This is also guar -
anteed by the closed-loop control system developed in our labs.
It manages all HVAC units and, thanks to its bus system, enables
inclusion of sensors as well as system integration into a build-
ing management system.
Expectations and responsibility
We make sure that quality
requirements are satisfied
Services provided by GEA HVAC Systems
for the food and beverage industry:
Development of essential system components
in GEAs own labs
Support by the GEA Institute for Simulation,
as well as tests under highly realistic conditions
Production according to high standards, for a
maximum of quality
Products certied according to accepted standards
HVAC equipment design, with optimization
according to hygienic standpoints Possibility of deviations from series-production
models, to satisfy special requirements
Optional add-on versions and especially targeted
choice of materials, depending on areas of use
Control technology, developed by GEA, with
communications via bus
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Processing of ham, sausage, and other meats
Slice for slice, hygienically packed
When we can combine good taste and durability, then you and
GEA HVAC Systems have done good work. You: because you
have designed your production to assure fast and high-quality
processing of easily perishable products. We: because our air
treatment ensures the best processing temperatures and even
prevents microbe problems as a result.
When sausage and ham come onto the table, or when steaks and
roasts sizzle away, the last thing consumers want is to worry
about their health. And there is no need, since you and we have
already done the worrying. Eective air treatment and cooling
of the air prevent microbes from propagating, and fresh meat
stays fresh.
Solutions based on GEA HVAC systems have already proven
eective in numerous meat-processing applications, including
at Artland Convenience in Badbergen, Germany. During process-
ing, HVAC systems from GEA ensure that the sensitive products
are dressed under well-cooled conditions. The design and cong-
uration of equipment according to Hygiene Directive VDI 6022additionally ensure that structural-design measures eectively
prevent the collection of debris and formation of microbe pock-
ets. Optimized equipment design furthermore simplies regu-
lar cleaning and disinfection.
The fact that hygiene not only enhances the durability of meat
products, but also improves the e ciency of their processing, is
conrmed by an example from cold-cut packing at German sau-
sage specialists Hans Kupfer & Sohn GmbH & Co. KG Wurstspe-
zialitten. The ham that is packed here in thin slices has a large
surface area and is therefore especially susceptible to microbes.
As a result, our solution uses ionization to kill microbes before
they can enter the processing plant. And one positive side eect:
since there are fewer microbes throughout the entire packing
line, expensive wet cleaning is not required so often. This saves
several hours of work per week and adds up to around 20 % more
machine operation time. GEA air is good for your sales.
HVAC technology for rigorous hygienic
requirements:
Optimized equipment design and eective
lter technology prevent accumulation
of debris and microbes, thereby enhancing
hygiene
Development of condensate is constructively
retarded, and collected condensate is safely
removed
Smooth surfaces, model characteristics in
conformity with the relevant standards, and
well-designed inspection openings and doors
simplify routine cleaning
Optional microbe disinfection prevents the
entry of pathogens Quiet operation of the units enables roof
installation in areas where commercial and
residential use are mixed
GEA central air-handling systems, designed according
to VDI 6022, oer smooth surfaces and sophisticated
structural design, which enable hygienic air treatment
and assure fresh processing of sausage and meats.
Please consult our product brochure for greater details
on the GEA CAIR line.
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Reduced microbe concentrations in supply air can ensure more durable
meat products, as well as less-frequent cleaning of production lines. This means
benets for both consumers and for plant processors.
The HVAC solution for easily perishable sausage and meats
GEA CAIR > For hygienic air treatment and air cooling
[Reduction of microbe concentra-
tion] [Operation around the clock]
[Constant 0 C room temperature]
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The salt bath, in which cheese remains for several hours, releases moisture.
Rugged central air-handling systems dehumidify the air, so that mold has no
chance in the hall, and no water condensate drips from the ceiling.
Effectively prevents mold and formation of condensate
GEA CAIRfricostar > Counters high humidity
[Constant 65 % rel. humidity]
[Corrosion-protected] [Constant
15 C room temperature]
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Dairy products
Nowhere cheesy
Its pleasant enough at a Thalasso spa, but its absolutely
necessary in the production of cheese: the dehumidication
of salty air. Technology and competence gained by GEA in
HVAC systems for indoor swimming pools prevents forma-
tion of mold in the salt baths of cheese production. At the same
time, they likewise protect building structures from moisture
damage.
Air Eco2nomy stands for more eciency and more benets. Users
enjoy double advantage from dehumidiers that assure constant
relative humidity, for example, in the salt-bath rooms of cheese
plants such as that of the company Mritz-Milch in Waren, Ger-
many. These systems prevent condensation on wal ls and ceilings,
and the dripping of condensate into the salt baths but avoid at
the same time corrosion damage to the building structure.
The selection of various eective materials for the HVAC units
themselves and for the heat exchangers as wel l as specia l coat-
ings enables production of dehumidiers that are resistant to
aggressive air. Here, industrial users prot from the experiencethat GEA HVAC Systems has gained in sea-water and thermal
swimming pools, and in conventional indoor baths. Actually,
HVAC systems for salt-bath rooms in cheese production dier
from those in swimming pools in only one component: a larger
evaporator. This is necessary to prevent icing owing to a low
room temperature of around 15 C.
It goes without saying that maintenance of GEA dehumidiers
is a simple matter. Generously dimensioned service doors sim-
plify work such as cleaning and lter exchange, reduce risks of
soiling, and keep downtimes to a minimum.
Experience from swimming pool technology
implemented for cheese production:
Dehumidifying technology tried and
proven in swimming-pool applications and
in the food and beverage industry Selection of various corrosion classes for
dierent requirements
Eective energy recuperation, to enable
low operational costs
Systems that are based on proven GEA
central air-handling units
Modular engineering design that allows
installation of large service doors for ease
of cleaning
Based on proven GEA central air-handling systems, and outtted with
resource-saving technology, our units are optimally suited for dehumidi-
cation in the processing of food and beverages. Please consult
our product brochure for greater details on the GEA CAIRfricostar line.
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Chocolate
Not too hot and not too cold
When producers temptingly cover luscious cookie lling with
chocolate, precise temperature control is absolutely necessary.
Only this will ensure perfect application of the sweet, dark
mass with creation of the gentle wavy structure of the appe-
tizing and silky glossy chocolate surface.
Just the very sight of it makes your mouth water: delicate choco-
late encases a crunchy cookie core, creamy bars, or other sweet
temptations. The appealing appearance depends in good part on
the right ambient air. If the room temperature is too cold, the
chocolate mass becomes tough. If too warm, only a tiny thin
chocolate cover would be possible.
To assure that a chocolate cover absolutely succeeds, HVAC sys-
tems must keep the temperature constant: for example, in the
production of Mars products in the Netherlands. These systems
feature heater and cooler banks. As are the other components of
the units, these heat exchangers are easily accessible and can be
cleaned from two sides. The use of stainless steel for essential
components also simplies regular cleaning, and enhances hy-gienic conditions.
In the bakery, where the crunchy cookie llings of sweet snacks
are created, the HVAC units are not required to be able to heat.
Here instead, the air cools by gently sweeping past the freshly
baked products. To remove spent air from the hall, special ex-
haust-air fans are used, with motors installed outside the air ow.
This prevents tiny cookie or nut particles oating in the air from
soiling the motors. The exhaust-air units are especially tted with
two fans, so that one can be disassembled and cleaned while the
other continues to remove the vitiated air from the building.
Special solutions for continous operation:
Exhaust-air fans for roof installation,
with two fans for uninterrupted operationduring maintenance
Installation of the motor outside the
air ow, for reliable operation
Enclosures that are easy to open for
maintenance
Integration of the control system for the
extraction units into the overall HVAC
plant
Availability of various sizes for demand-
driven selection
Extracted-air fans by GEA HVAC Systems are eectively suited for
dusty environments, hot vapors and gases, air containing grease, and even
explosion-endangered atmospheres with each requirement covered
by the especially designed individual models. And of course, GEA models
are also available for unproblematic extracted-air requirements. Please
consult our product brochure for greater details on the GEA RoofJETT line.
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When HVAC systems must be periodically cleaned, several times a year as in
the Mars plant in the Netherlands ease of access to the units is absolutely essential.
Stainless steel simplies work, thanks to its smooth, hygienic surfaces.
HVAC solutions, so that sweets are a pleasure
GEA CAIR and GEA RoofJETT> The perfect team for supply and exhaust air
[Easy cleaning] [Special hygienic
versions] [Constant temperature]
[Redundancy in the fans]
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Beer breweries stint on power, not taste
GEA CAIRplus > With a license to save
[Advanced control systems]
[Energy recuperation]
[15 kW savings per unit]
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Beverages
Tingling climate control for
traditional thirst-quenchers
Series-model saving functions and energy recuperation make
it possible for breweries, for example, to reduce their energy
costs. The brewery Grolsch is among the companies that
thanks to GEA HVAC Systems have achieved outstanding
effi ciency.
Beginning from 1615, the beer brewed in Grol in the Netherlands,
Grolsch beer, has developed from a regional to an internationally
acclaimed beer. The best-known product is in the bottle with the
distinctive swing-top cap. In 2004, the company Koninklijke
Grolsch completed a new brewery, which was equipped with
30 GEA central air-handling units. Ten dierent models were
ordered, most of which were large models for the bottle-lling
line. These units are of course in compliance with standards, but
are by no means conventional: GEA has reduced the air resist-
ance of these units and has saved 120 kW (15 kW per unit) of
consumed power. As a result, the HVAC systems satised the
stipulations of the company to make the new brewery an exam-ple of power saving. At Grolsch, almost all of the GEA central
air-handling units have been equipped with energy recuperation
systems to enhance e ciency.
In addition to energy savings, however, Grolsch also expected
that noise-emission characteristics and service life would satisfy
strict demands. All units, consequently, have very quiet fans.
They also have double enclosures, which contribute to noise re-
duction. The galvanized-steel outside and inside walls of the
units, in addition to other corrosion-resistant materials, also
guarantee long life cycles.
The modular conguration of GEA central
air-handling units assures flexibility:
Framed structure with panels that can
be easily removed
Integrated thermal insulation and noise
attenuation
Selection of various energy-recuperation
systems
For indoor or outdoor installation
Various modular grid dimensions
Optional control of the drives viafrequency converters
Thanks to modular congurations, there is virtually
no requirement that GEA CAIRplus central air-handling
systems cannot satisfy. Even with extremely varying
user requirements, these units are highly attractive with
their e cient partia l-load operation and innitely va riable
fan control resulting in turn in great cost eectiveness.
Please consult our product brochure for greater details on
the GEA CAIRplus line.
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Filters
Here theres no way get through
As much as necessary, and as little as possible this also
applies to our lters. They optimally retain debris, but result
in extremely little pressure drop and consequently use very
little power. A key factor in production environments with
strict stipulations placed on air purity.
Filters by GEA HVAC Systems mean that you can satisfy strin-
gent stipulations for air purity. Coarse debris and tiny dust par-
ticles we have something against both of them. But, to prevent
ne lters from clogging up prematurely early, we can propose
in case of rigorous demands that you implement a lter cas-
cade. The rst stage retains coarse particles and insects, and the
second and possibly third stages take care of the nest dust
particles.
You can also depend on GEA ltration e ciency. Sophisticated
manufacturing processes and the development competence of
our company guarantee that, for example, lter media have a
uniform ltration eect and that lter frames t perfectly and
are su ciently tight. But feel free to conrm our claims by look-ing at the results provided by independent testing agencies:
Eurovent, for example, has tested our ne-par ticle lters and has
certied that they conform to the technical data: and not only
for one selected model, but also for our complete series. For you,
this means a plus in safety and a clean solution for your produc-
tion-oor air.
Filters for a wide range of requirements:
Filter solutions for supply and
extracted air
Filter units for central and decentral
solutions
Coarse and ne lters, gas lters, odor
lters, etc. Development and production all at
GEA facilities
Advanced machines for precise series
production and individual frame sizes
Certied ne-particle lters in classes
F5 to F9
Uniform lter eectiveness and low
pressure drop
Bag lters oer large surface areas and,
consequently, great ltration eectiveness,
without excessively impeding the air ow.
They are therefore the ideal solution for
ltration of ne pollen and dust. Please
consult our product brochure for greater
details on GEA air lters.
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Reference projects
What we have cause to be proud of
Altmark-Kserei Uelzena,
in Bismark, Germany
GEA central air-handling
systems
Badische Staatsbrauerei
Rothaus, in Freiburg,
Germany
GEA unit air heaters
Photo credits
Cover motif and photo on page 12: Grolsch Brauerei
Page 2: Veer image agency
Page 3: Stephan Meyer-Bergfeld, in Oldenburg, Germany
Page 9: Getty Images
Page 10 and 11: Mars
Grolsch Brauerei, in
Enschede, the Netherlands
GEA central air-handling
systems
Mars, in Veghel,
the Netherlands
GEA central air-handling
systems, and GEA
air-extraction fans
Fleischfabrik Artland,
in Badbergen, Germany
GEA central air-handling
systems
Danone, in Rotselaar,
Belgium
GEA central air-handling
systems
Harry-Brot, in Soltau,
Germany
GEA fan-coil units
Alpro, in Wevelgem,
Belgium
GEA central air-handling
systems, GEA unit air
heaters, and GEA fan-coil
units
You are on this level of our documentation structure. You can order printed
copies at no charge from the top 3 levels, from info@gea-airtreatment.com.
You can download all brochures as PDF les from the following Internet site:
www.gea-airtreatment.com
Application brochures
Image brochure
Product brochures
Data & Facts and operation manuals(available only as PDF)
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The complete addresses are available on the
Internet under: www.gea-air-eco2nomy.com
www.gea-air-eco2nomy.com
12/2009PR-2009-0003-GB
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ttomodificationCopyrightGEA
www.papp.cc
Customer proximity, sales structures
Reachable always and everywhere!
GEA Air Treatment
Middle EastUAE-Dubai
Tel. +971 / 4 / 887 3881
GEA K limatechnik
GmbH & Co KG
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