The technology group GEA has specified its process solution for flavour manufacturing and developed a new machine design as well as control and cleaning elements for the production facilities from the handling of raw materials right through to final packaging. With this, the company helps flavour manufacturers to ensure the taste, consistency and repeatability of their products.

When producing flavours, there is much opportunity for something to go wrong. An ingredient added too quickly into a mixing vessel, inconsistent temperature, insufficient mixing or incomplete homogenization can all have an effect further downstream that affects the outcome. A programmed control and automation should rule out deviations.

The new GEA integrated line controls all the individual unit operations precisely and, by doing so, controls the output. But repeatability is not just a question of adjusting a computerised control system. Achieving a consistent product also requires very precise engineering to allow the component parts of the line to work together in harmony. For example, feeding systems must be calibrated specifically to match the capabilities of the mixer, and the size of the mixer must be scaled precisely with the size of the dryer to ensure compatibility.

In order to comply with the hygiene regulations, every production plant must be cleaned efficiently. Yet, flavours and aromas can linger in equipment even after they have been cleaned to the most scrupulous hygiene standards. Any residue of the previous flavour may easily taint the next product, destroying the allimportant consistency. To prevent this, GEA has done much more than provide an efficient rotating-ball cleaning system.

With its overall concept, the company has eliminated sharp edges or dead zones in machines, pipework and valve systems, where even the smallest quantities of products could become trapped. Special materials have been carefully chosen to provide smooth internal surfaces to which no product can adhere. The size of cleaning fluid tanks has been calculated to ensure that they hold precisely the right volume of medium to clean the whole system efficiently in less than four hours. Even gasket materials have been chosen to ensure that they do not harbour traces of product. These elements combine to ensure the efficiency of the CIP (Cleaning in Place) system making it efficient and enabling fast product changeover, reduced downtime, minimal waste and low use of water and detergents.

There is also another key factor in maintaining repeatability. When producing multiple products on the same line, it is critical that products are processed in the correct sequence to help to prevent any tainting from one to the next. Purer flavours such as melon or strawberry, which are instantly recognized by consumers and are often consumed on their own, take precedence. Stronger flavours such as orange, garlic, chilli, curry, which are usually mixed with dishes, come later.

The control system on the GEA line is capable of not only managing the recipe for each product, but sequencing the production for maximum efficiency ensuring that after each operation the line is cleaned sufficiently. Deep cleaning can be performed at the end of the sequence before the programme begins again. This also helps to minimize the use of chemicals and water and reduces plant downtime.