GEA FHT ReThink it Cool MARTIJN BOEGELS OCTOBER
GEA FHT Re-Think it Cool MARTIJN BOEGELS, OCTOBER 2020
GEA at a Glance "Engineering for a better world" is the driving and energizing principle connecting GEA’s employees. As one of the largest systems suppliers GEA makes an important contribution to a sustainable future with its solutions and services, particularly in the food, beverage and pharmaceutical sectors. Across the globe, GEA’s plants, processes and components contribute significantly to the reduction of CO 2 emissions, plastic use as well as food waste in production. 4, 931 18, 490 EUR million order intake GEA FHT & Knippenberg College Employees (Full-time equivalents) Fiscal Year 2019 GEA is listed on the German MDAX and the STOXX® Europe 600 Index and also included in the DAX 50 ESG and MSCI Global Sustainability indexes. 2
Strong local presence around the globe GEA locations (sales offices, service branch or other GEA sites) Employees in 2019 (FTEs) Revenue in 2019 Regional revenue split in 2019 (only continued operations) North America 1, 675 890 million Latin America 512 365 million 18 GEA FHT & Knippenberg College 7 Western Europe, North and Central Europe Middle East & Africa 3, 072 3, 278 684 million 814 million 14 17 DACH & Eastern Europe 6, 861 1, 000 million 20 Asia Pacific 3, 092 1, 126 million 23 3
Our mission We strive to be the world‘s most respected technology group offering cutting-edge solutions for sustainable processes that improve people‘s everyday lives. GEA FHT & Knippenberg College 4
Our long-term strategy GEA FHT & Knippenberg College Pursue clear technology and market leadership Further develop food processing focus & solutions for demanding production processes Become truly global by getting closer to our customers Use portfolio management as tool to leverage strengths & allocate resources Build an organization and capabilities to support strategic vision Drive sustainable value creation 5
1. 2 bn Global population growth (2015 – 2030 f) Important global megatrends are propelling our technologies & underlying markets 79% Middle class growth (2015 – 2030 f) Greater demand for Healthier, functional & personalized safe food Alternative Demographic change protein sources 63% growth of people aged 65+ (2015 – 2030 f) GEA FHT & Knippenberg College 6
Megatrends support our business GEA FHT & Knippenberg College URBANIZATION AND GROWING MIDDLE CLASS GREATER FOOD SAFETY AND QUALITY ENERGY SCARCITY AND STRICTER ENVIRONMENTAL REGULATIONS Growing demand for processed food and medication Readiness of industry to invest more for greater process reliability Greater interest in efficient and resource-saving production processes GEA offers components and process technology for processed food, ready meals, fortified lifestyle beverages and food, medications GEA offers certified hygienic/aseptic processes and components to meet the strict standards of the industry GEA offers intelligent engineering processes for resource-friendly technologies, energy-saving machines and processes, as well as heat recovery 7
Our applications – in touch with GEA every day Dairy Farming and Processing Approx. one quarter of processed milk comes from GEA production systems Food Every third chicken nugget is produced using GEA technology GEA FHT & Knippenberg College Approx. every third process line for instant coffee was installed by GEA Beverages Pharma Approx. every second liter of beer is brewed with the aid of systems and process solutions from GEA Every fourth liter of human blood for making plasmaderived products is processed using GEA equipment Chemical More than one third of all polymer producers are using GEA drying technology Refrigeration and Heating Marine Each industry we serve utilizes industrial refrigeration technology from GEA Every second container ship in the world sails with GEA marine equipment on board 8
Groundbreaking innovations – recent examples FOOD GEA Oxy. Check® Quality control system DAIRY FARMING PHARMA GEA Dairy. Robot R 9500 GEA CONSIGMA® Automated milking system Tablet production • • • Fully automated milking system for professional dairy producers Available as single or multi-box system Leading 3 D camera technology Tailored concept for low water and energy consumption Innovative cell count sensor to support herd health “Grade A” certification from U. S. FDA GEA FHT & Knippenberg College • • • In-line quality control system that inspects each package Checks residual oxygen content and seal integrity of each modified atmos-phere pack leaving thermoformer Non-invasive measurement technique which does not damage the film or break the seal No time-consuming sample testing No packaging material or food wasted • • • Flexible continuous tableting line Faster, more consistent and reliable tablet production with reduced use of resources Requires 70% less space than batch plants and can be built more quickly FDA approval for a therapy manufactured using GEA CONSIGMA® technology Award-winning 9
GEA’s corporate targets as contribution to the UN Sustainable Development Goals • Lost day frequency rate • Reducing water consumption ≤ 5. 6 (2020)/≤ 5. 0 (2025) • Lost day severity rate ≤ 120 (2020)/ ≤ 110 (2025) • Proactive initiate rate ≥ 100 (2020)/ ≥ 200 (2025) • Further developing & extending GEA Care Health Management GEA FHT & Knippenberg College by 2. 1% (2020), by 14. 1% (2025) and by 50% (2050) per EUR 1 million in sales (base year 2018) • Monitoring signatories’ • Expanding our life-cycle compliance with the GEA Code of Conduct for Suppliers and Subcontractor as well as implementing effectiveness checks along the supply chain • Continuously improving and extending human rights documentation and actions in order to comply with the German National Action Plan (NAP) analysis and product end-of-life concepts to better represent the CO 2 footprint in the product-use phase (2020) • Reducing total waste by 2. 1% per € 1 million in sales (base year 2018) in 2020 • Continually developing and improving our management systems by ensuring all GEA production sites have DIN ISO 9001, DIN ISO 14001 and DIN ISO 45001 certification until 2025 • Continually reducing CO 2 emissions (scope 1 + scope 2) by 2. 0% (2020) compared to the previous year and in relation to sales, by 18. 3% (until 2025) and by 50. 7% (until 2050) compared to base year 2015 • Demonstrating ethical leadership by publishing a statement on human rights in line with UN Guiding Principles on Business & Human Rights and signing on to the UN Global Compact’s 10 principles (2020) • Implementing OECD guidelines on the responsible use of minerals from conflict & highrisk areas (2020) 10
Sustainable solutions – recent examples MANAGING ENERGY RESOURCES Industrial heat recovery Holistic process optimization ANIMAL WELFARE PROTECTING OCEANS GEA Dairy. Milk M 6850 GEA Bilge. Master Early warning system for mastitis detection Treatment of bilgewater Innovative sensor measures somatic cell count in each udder quarter individually during the milking process Benefits: • Minimized treatment • Safeguarding the healing process • Increasing herd health and productivity GEA FHT & Knippenberg College Integration of heat pumps for upcycling and decarbonizing waste heat in food, beverage and dairy production, where 60% of total energy use is typically for heating and cooling Benefits: • Approx. 30% reduction in energy costs • Significantly smaller carbon footprint • Potential elimination of, or reduced reliance on, traditional, high-energy-consuming boilers Modular separators process shipping bilgewater contaminated by fuel and lube oil spills Benefits: • Meet or undercut water regulations for sensitive oceans: Reduction of residual oil content of water discharged back into the sea from 15 to 5 ppm • Reuse of recycled oil as fuel oil 11
GEA group structure GEA FHT & Knippenberg College From heterogeneous business areas to technologically-oriented divisions 12
Food & Healthcare Technologies Division Pasta, Extrusion & Milling // Bakery // Slicing & Packaging // Food Solutions // Frozen Food // Pharma & Healthcare Safe foods and medicines for a growing population The vast product range of Food & Healthcare Technologies includes solutions for food processing, covering preparation, marinating and further processing of meat, poultry, seafood and vegan products, pasta production, baking, slicing, packaging, confectionery as well as frozen food processing. We also offer equipment for cereals handling and milling and for producing cereal-based snacks, breakfast cereals as well as dry and wet pet food. Our solutions for the pharmaceutical, biopharmaceutical & nutraceutical sectors include components, equipment and entire plants for processing solid, liquid, semi-solid, viscous, hazardous and hygroscopic products, either for batch or continuous production. ~ 960 € million revenue ~ 67 ~ 7 € million EBITDA % EBITDA before restructuring measures ~ 3, 450 Employees (FTE) Pro forma figures 2019 for group structure applicable from January 1, 2020 GEA FHT & Knippenberg College 13
Food & Healthcare Technologies Division Bakery Pasta, Extrusion & Milling Slicing & Packaging Our solutions for pasta and extruded food include cereals handling and milling plants processing and packaging lines for fresh and dry pasta, including gluten-free products, as well as for cereal-based snacks and breakfast cereals and dry pet food. Our slicing & packaging portfolio includes slicing and loading systems, vertical packaging equipment and thermoforming systems. Our machines are designed to meet the highest uptime requirements and bring automation and ease-of-use benefits, while meeting all hygienic standards to ensure product safety. We continue to innovate by offering more sustainable packaging as well as solutions for improved MAP testing to ensure food quality and reduce waste. GEA bakery capabilities range from single equipment components to integrated production lines for cakes, pies, biscuits, cookies, crackers, layer cakes and snacks. Energy-efficient tunnel ovens, depositors, dough forming systems and filling injectors make up this hard-working portfolio. GEA FHT & Knippenberg College 14
Food & Healthcare Technologies Division Food Solutions Pharma & Healthcare Our portfolio encompasses preparation and further processing equipment, including single machines and complete automated lines. We offer solutions for defrosting, cutting & grinding, mixing, forming, marinating, cooking, steaming, in-line smoking and frying. Our technology can be used for processing poultry, meat, seafood, vegetarian, as well as plantbased or alternative protein foods. A global specialist in solid and liquid dose technology, our robust, flexible and cost-effective pharmaceutical manufacturing equipment and fully integrated process lines maximize operational reliability and productivity. Our portfolio includes tablet compression and coating, granulation and drying, batch and continuous processing, contained materials handling, freeze-drying and fermentation. Frozen Food GEA freezers provide consumers with highquality products with an extended shelf life. Our portfolio consists of spiral- tunnel- and carton freezers. Combined with our award-winning freezer control sensor technology, manufacturers can ensure accurate and consistent product quality while reducing their energy costs. GEA FHT & Knippenberg College 15
Technasium Food & Healthcare Technologies GEA ontwerpt en produceert onder andere machines voor de voedselverwerkende markt en is altijd op zoek naar nieuwe benaderingen en ontwikkelingen. De business unit Food & Healthcare Technology - Frozen Food richt zich op het proces van het invriezen van voedsel op industriële schaal. De markt en benadering van het invriezen van voedsel op industriële schaal is vrij traditioneel en we willen deze traditie doorbreken. Er zijn echter nogal wat belangrijke aspecten bij het bevriezen die niet mogen ontbreken. Hygiëne is hier een van en omdat we ook hiermee kijken naar onze voeding moet je dit ook niet willen loslaten. Hier willen we ons dan ook op gaan focussen in deze opdracht; hygiene en dan met nadruk op het reinigen van onze machine. GEA FHT & Knippenberg College 16
Inhoud 1. 2. 3. 4. 5. 6. 7. GEA FHT & Knippenberg College Bekijk diepvriesproducten in je omgeving die afkomstig zijn van een industrieel proces (bijv. Supermarkten, restaurants, . . . ) Leg in uw eigen bewoording uit hoe producten worden ingevroren en welke aspecten daarbij van belang zijn. Beschrijf de principes van hygiëne en het belang hiervan voor de industrie. Onderzoek de huidige CIP systemen en leg het proces in eigen bewoordingen uit. Onderzoek reinigingsprincipes in de industriële voedsel verwerkings markt en vergelijk het met de oplossing van GEA. Bereken met hoeveel tijdwinst in het reinigingsproces een klant winstgevend kan opleveren mbt een aanschafprijs van € 250. 000, 00 (marge factor GEA zetten we op 1, 5), baseer je berekening op de capaciteit van kipnuggets, met een eindgewicht van ± 22 gram. Beschrijf een alternative oplossing die het reinigingsproces kan optimaliseren en geef een kostenraming van de potentiële ontwikkelingskosten, tijdsbesparing en commerciele prijs. Apr May OPDRACHT Orientation Idea Practice Presentation Mar 3. 4. 5. Feb 2. De oplossing moet gemakkelijk en snel te produceren en te installeren zijn Solide oplossing die in modules kan worden gebouwd en met een lange levensduur (10 -15 jaar) Overzicht van benodigde expertise Gebruik van professionele terminologie Volledig adviesrapport Jan 1. Dec GEA heeft ook een aantal vereisten voor een CIP: Nov PLANNING WENSEN X X X X 17
Questions ? GEA FHT & Knippenberg College 18
CIP System 19
S-Tec Cleaning system options 1/4 2 Zone (Belt cleaning only) • Spray bars on the infeed section below and above the belt • Ring of nozzles over the belt stack to apply foam and provide rinse top-down Wall mounted stainless steel cabinet comprising the booster pump, valves and controls and room for 2 x 20 ltr drum of detergents. S-Tec Spiral Freezer, Chiller, Proofer 20
S-Tec Cleaning system options 2/4 4 Zone (Product zone cleaning) • • • As 2 zone plus: Internal spray bar (rotates with the drum) Volumetric nozzles in the vertical columns Wall mounted stainless steel cabinet comprising the booster pump, valves and controls and room for 2 x 20 ltr drum of detergents/disinfectant. S-Tec Spiral Freezer, Chiller, Proofer 21
S-Tec Cleaning system options 3/4 6 Zone • • • As 4 zone plus: Rotating spray nozzles in the walkway area Static nozzles in the evaporator plenum Wall mounted stainless steel cabinet comprising the booster pump, valves and controls and room for 2 x 20 ltr drum of detergents/disinfectant. S-Tec Spiral Freezer, Chiller, Proofer 22
S-Tec Cleaning system options 4/4 6 Zone Recirculating • • • As 6 zone plus: Rotating spray nozzles in the walkway area Static nozzles in the evaporator plenum With a recirculating system, water and cleaning agents are captured and recycled through the spiral after filtration, heating and new chemical dosing. System is acting like a giant dishwasher. Recirculating system: hot water tank, dosing station, delivery pump, recycling trough, return pumps and filters on a skid mounted separate to the spiral. S-Tec Spiral Freezer, Chiller, Proofer 23
CIP Consumption 2 Zone 1. 5 Kw Zone 1 Zone 2 Under and over belt infeed Ring around the top of the drum · · · The supply of hot softened water @ 85 lm and maximum 60 C to our 1 1/4” Bsp male inlet to panel @ min 3 bar max 5 bar The supply of cold water @ 85 lm to our 1 1/4” Bsp male inlet to the panel @ min 3 bar max 5 bar The connection of compressed air 12” 20 cfm. 4 Zone 4. 0 Kw Zone 1 Zone 2 Zone 3 Zone 4 Under and over belt infeed Ring around the top of the drum Side foam nozzles Internal drum spray bar and heated joint · · · The supply of hot softened water @ 200 lm and maximum 60 C to our 1 12” Bsp female inlet to panel @ min 3 bar max 5 bar The supply of cold water @ 200 lm to our 1 12” Bsp female inlet to the panel @ min 3 bar max 5 bar The connection of compressed air 12” 20 cfm 6 Zone 7. 5 Kw Zone 1 (also 5 zone) Zone 2 Zone 3 Zone 4 Zone 5 Zone 6 Under and over belt infeed Ring around the top of the drum Side foam nozzles Internal drum spray bar and heated joint Evaporator nozzles Walkways · · · The supply of hot softened water @ 250 lm and maximum 60 C to our 1 12” Bsp female inlet to panel @ min 3 bar max 5 bar The supply of cold water @ 250 lm to our 1 12” Bsp female inlet to the panel @ min 3 bar max 5 bar The connection of compressed air 12” 20 cfm GEA FHT & Knippenberg College 24
CIP Informatie Via de onderstaande links kunnen jullie meer informatie vinden mbt CIP (Cleaning In Place): • https: //www. gea. com/en/products/cleaners-sterilizers/cip-sip/index. jsp • https: //www. gea. com/en/products/freezers/spiral-freezers/s-tec-spiral-freezing-chilling. jsp • https: //www. hmdis. co. uk/our-services/spiral-cleaning-systems/ Andere informatieve links: • https: //www. youtube. com/watch? v=Lmx 8 j 14 Q 33 Y • https: //www. youtube. com/watch? v=7 m 9 MKr 0 Kj. Tg • JBT – competitor: GEA FHT & Knippenberg College 25
gea. com
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