Longer shelf-life, fewer preservatives: GEA launches new D-tec valve for beverages

02 May 2019 --- GEA is expanding its aseptic D-tec range with a new double-seat valve which can increase the hygiene levels, and therefore the shelf-life, of beverages and dairy products. The valve – D-tec D/DV double-chamber valve – is designed with a sterile leakage chamber which is hermetically sealed from the atmosphere by two side valves. It can be used on a wide range of beverage applications, from soft drinks to fruit juices, milk-based and lactic acid-fermented products. If manufacturers adapt their process chain accordingly, the D-tec range can help them achieve the desired shelf life with fewer preservatives, according to GEA.

With the D-tec double chamber valve, GEA now offers aseptic valves for both hygiene classes “Aseptic” and “UltraClean,” which are tailored to the special conditions of the respective applications. In September 2018, the company launched the D-tec P/DV control valve for ultraclean applications. 

“Aseptomag, our metal bellows technology, is the benchmark in hygienic processing, which we use for highly sensitive products such as baby food and UHT milk as they demand an uncompromising aseptic execution of processes and components,” explains Pascal Bär, Product Manager for GEA Aseptic Valve Technology. 

GEA recommends the D-tec D/DV double-chamber valve for UltraClean applications where processed foods must be completely protected from the environment by a condensate barrier. Credit: GEA.“However, a wide range of beverages produced by our customers are not promoted under aseptic conditions. In fact, they fall into the second highest hygiene level according to the VDMA guideline, which is hygiene class IV ‘UltraClean.’ That is why our new D-tec D/DV meets the process requirements of this hygiene class,” he notes. 

With the D-tec D/DV double-chamber valve, GEA has completed its UltraClean valve range, allowing customers to now fully integrate D-tec equipment into their production processes. 

“Equipping the interfaces in process plants with as few valve types as possible is often a decisive criterion to our customers. Spare parts handling and warehousing become increasingly complex when different valve types must work together,” says Bär.

Ensuring operational safety
To ensure UltraClean applications, GEA uses a hermetically sealed D-tec stem diaphragm because it reportedly provides improved contamination protection against the atmosphere and ensures microbial stability of products throughout their manufacturing process. 

The membranes are made of thermoplastics that are more flexible than stainless steel. For example, this makes them well-suited to compensate for pressure surges, says Bär. They are, to a certain extent, more forgiving to process errors. In the event of a diaphragm rupture, the leakage detection system ensures a high degree of operational safety. 

Bär adds: “Our product development is directed towards ensuring equipment availability and profitability for beverage and food producers. The new double-chamber valve fulfills this; it can be used very flexibly and combines a high level of hygiene with manageable operating costs. Also, the maintenance-friendly design minimizes system downtimes.”

The valve is available in valve sizes ranging from DN 40 up to DN 80 and OD 1.5 inch up to OD 3 inch. The valve sizes DN 100 and OD 4 inch will be introduced in the near future. The valve seat can be executed as both soft and hard sealing – the latter with the TEFASEP gold seal, which GEA recently introduced. In addition, D-tec double-chamber valves can be equipped with one, two or three T.VIS control tops of various designs. The GEA D-tec D/DV considers all common industrial standards.

Earlier this year, GEA worked with PET Engineering and replacement meal brand Huel on a ready-to-drink (RTD) product. The packaging design needed to meet two main requirements: coherency with the existing product portfolio and functionality. The bottle was produced by GEA’s aseptic line which is based on an integrated aseptic blowing, filling and capping process and it is equipped with a 100 percent aseptic blower. The line has also obtained the FDA LONO certificate for producing and distributing in the US ambient temperature and shelf-stable low acid beverages.