Bucher

From nature
to taste
New and Optimised BUCHER UNIPEKTIN Hydraulic Fruit Press HPX 6007
Juice World 2012, St. Petersburg
From nature
to taste
Agenda: 1. Introduction of Bucher Unipektin company 2. Scope of supply 3. Product presentation Bucher Unipektin hydraulic press HPX 6007 4. Optimized Mash Preparation 5. HPX: pressing results 6. Comparison HPX Press Belt Presses - Yield / Throughput - Costs - Economical Comparison 7. Summary
From nature
to taste
since August 2010

Juice World 2012, St. Petersburg page 3
Scope of Supply Juice Industry Product reception, mill Press
Filtration
Adsorber / Ion exchange
Aroma recovery / Concentration

page 4
Scope of Supply Evaporators Evaporators for citrus, fruit puree, milk, coffee, malt, yeast, pectin
page 5
Scope of Supply Dryers DryCab vacuum drying cabinets DryBand Vacuum belt dryers Zeodration Zeolite water adsorbers
page 6
Scope of Supply Sludge Dewatering Technology
HPS Presses
page 7
BUCHER UNIPEKTIN Hydraulic Fruit Press HPX 6007 Product presentation
page 8
HPX 6007 Improvements

High reliable hydraulic system Optimized drainage system
Processcontrol with tele service
Hygienic, closed juice exit and tank
Comfort option for protection guard
page 9
Looped drainage elements, continuous rotation

Rotation during loosening, No rotation while pressing Rotation while loosening & pressing
HPX 5005 iP
HPX 6007
x
Advantages: Improved loosening Better pomace discharge Lower maintenance cost (encreased life time of brakes, wear-free juice outlet) Hygienic closed juice tank
page 10
Drainage system: Improved loosening

HPX 5005 iP HPX 6007
Strong forming of blocs
Optimal loosening
Field trials HPX 5005iP vs HPX 6007, Switzerland 2010
page 11
Drainage system
Pressure plate front side:
Pressure plate back side:
Apple, no mash enzymes used:
Clean pressure plate on the back side
Higher filling volume (500 800kg) -> higher capacity (ca. 5%)1)
1)
Field trials, Switzerland, 2010
page 12
Looped drainage elements, continuous rotation

Advantages: Higher capacity due to better pomace loosening Higher capacity due to higher press volume Higher efficiency and lower maintenance cost (life time of rotation brakes , no telescopic pipe seals)
page 13
Hydraulic system
Pressure filter
Improved oil quality
Sealkant -Seals
Improved long time tightness
Oil cooler with air

Cooling without using water
Separate blocs for press piston and basket functions

Easier diagnosis, Better accessability Reduction of pressure loss
Pressure sensor instead of switches

Higher reliability Easier diagnosis
page 14
Oil cooling variants

Max. Ambient temperature: T max < 32 C T max > 32 C T max > 32 C
Air cooler
Air- & Water cooler (Optional) Reduced water consumption
Water cooler
No water consumption
T max< 30C: 0.25 0.4 m3/h T max 3040C: 0.3 0.5 m3/h
page 15
NetService Worldwide access
Worldwide access to all Bucher Unipektin machines and plants
page 16
Process control
Improved support for System diagnosis
Process diagnosis
Operation
page 17
Process control
Advantages: Improved reliability with PLC system from Siemens (S7); Long availability for spare parts Interface to an overall control PC for external operation and data transfer Tele service with Bucher Unipektin Net Service concept Optimised, robust process loops improve the control and flexibility for adaptations to different product characteristics Automatic press cleaning program with interface to external chemical dosing system Sensor analysis for extended system diagnosis
page 18
Protective guards:
Access possibility via back side door. Door analoguos to the operation side. (Supervision: OPTIONAL)
No Access via back side door. Door mechanically locked (STANDARD)
page 19
Bucher Unipektin Extraction Line

- Technical Details - Economical Calculations
page 20
Introduction Challenges for AJC producers:

Tough competition for apples Quality assurance - GMP-standards - TAB Clients Audits - Hygiene - Safety - Documentation / Traceability
page 21
Introduction
Fruit (Raw Material) 70 80 % of total AJC production costs
Yield: Decisive for Economical Efficiency

5 % w/w more yield reduces the total AJC production cost by 3.5 - 4 % !
page 22
Optimized Mash Preparation Apples

Enzymes (50 80 mL/t Mash)
CM-50 Mill
Mash Heater
25 30 C 30 - 60 min
Mash Holding
1 or 2-Step Leaching (15-25 % w/w Water/Mash)
HPX
page 23

CM-50 Mill
Mash Heater
25 30 C 30 - 60 min
Mash Holding
HPX
page 24

CM-50 Mill
Mash Heater
25 30 C 30 - 60 min
Mash Holding
HPX
page 25

CM-50 Mill
Mash Heater
25 30 C 30 - 60 min
Mash Holding
HPX
page 26

CM-50 Mill
Mash Heater
25 30 C 30 - 60 min
Mash Holding
HPX
page 27
HPX 5005i PH: Pressing Results

HPXi PH: Capacity-Yield Correlation
100 Product: Apples 95
1-step Leaching ( 15 % w/w Water/Mash)
90 Yield [% w/w]
30C Mash Temperatur Mash Enzyme

85
Treatment OMP With
80 No Mash Enzyme Treatment
75
25C Mash Temperature
70 0
Without OMP
5 10 15 20 25 Throughput (incl. dumping) [t/h]
page 28
HPXi 5005 PH: Pressing Results

Capacity-Yield Correlation: China, 22. - 23.09.04
100
10.7 t/h;
95
94 % w/w
90 Yield [% w/w]
85
80
75
HPX 5005i PowerHydraulic

0 5 10 15 20 Throughput [t/h] 25 30 35 40
70
page 29
HPX 6007: Pressing Results Apples

CM-50 Mill
Mash Heater
25 30 C 30 - 60 min
Extraction Results:
Mash Holding
1-Step Leaching (15 % w/w Water/Mash)
Throughput: 10 t/h
HPX 6007
Yield: 93 % w/w
page 30
HPX 6007: Pressing Results Apples

CM-50 Mill
Extraction Results:
Mash Heater
25 30 C 30 - 60 min
Mash Holding
2-Step Leaching (25 % w/w Water/Mash)
Throughput: 8 t/h
HPX 6007
Yield: 95 % w/w
page 31
Comparison: Bucher HPX
Belt Presses
Three Extraction Systems Dominate AJC Market:

Bucher Unipektin Hydraulic Presses > 1200 pcs. Belt Presses > 500 pcs. Decanters
page 32
HPX Presses: Features

Highest primary yield of all extraction systems: 84 90 % w/w Simple process, one or multiple additional extractions (leaching) within the same press; total yield: 92 95 % w/w Highly automated, self optimising, comprehensive process data recording Flexible process, multi purpose system Reference juice quality Hygienic design Highest investment
page 33
Belt Presses: Features

Primary yield: 72 80 % w/w Acceptable yields only as 2 staged system with water extraction belt press cascades total yield: 86 91 % w/w High throughput: up to 25 t/h Standard juice quality, but high sediments Difficult to clean, poor hygienic design Low automation, no automatic process adaptation Not suited for stone fruits, berries Low investment
page 34
Comparison: Bucher Unipektin HPX

100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% 3 97
Belt Presses
80
87
Juice Yield Juice in Pomace 12 Bx Insoluble Solids
1. Extraction
17 3
10 3
Mash
Belt Press
HPXi
page 35

100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% 17 3 10 3
Belt Presses
Dilution of juice: 12 Bx 4.8 Bx
Water Addition
Water Addition Juice in Pomace Insoluble Solids 25 15 17 3 10 3
Belt Press
HPXi
Belt Press
HPXi
page 36

100% 90% 80% 70% 60% 50% 40% 30% 42 20% 25 10% 0% 3 3
Belt Presses
Total Yield:
80.0% + 10.0%
Total Yield:
87.0% + 6.0%
= 90.0 %
= 93.0 %
Juice in Pomace approx. 5 Bx Insoluble Solids
Additional Yield: 25 %w/w 10.0 %yield
Additional Yield: 15 %w/w 6.0 %yield
2. Extraction
17 3 10 3
Belt Press
HPXi
Belt Press
HPXi
page 37
Yield: 2-step leaching with HPX

100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% 10 3 10 3 12.5 10 3 10 3 12.5 10 3 9 3
Total Yield:
87.0% + 5.5% + 2.5%
= 95.0 %
1st Leaching
87
2nd Leaching Dilution of juice: 5.3 Bx 2.3 Bx
Dilution of juice: 12 Bx 5.3 Bx
Additional Yield 1: 12.5 %w/w 5.5 %yield Additional Yield 2: 13.5 %w/w 2.5 %yield
Water Addition Juice in Pomace Insoluble Solids
es s
tl ea ch
m ac e
ch
1s t
Po
1s
Po
Po
2n
m ac e
m ac e
pr
le a
page 38
Alternative Process: Belt Press + HP

Mash preparation (with CM50 mill) 1st extraction with belt press Warm water (50C) addition to pomace Enzyme treatment (1 hour) 2nd extraction with HP
page 39
Alternative Process: Belt Press + HP
Belt presses for 1st extraction; Bucher Unipektin HP presses for 2nd extraction HP presses
Pcs. per press t/h Belt press Water addition Mash B Bucher HP Total Yield 2 25.0% 2 15.0 3.8 7.5 Total t/h 30.0 7.5 15.0 15.0 Yield % w/w 75.0 Comment Mash A
75.0 17.0 92.0
Mash B relative to Mash A
page 40
Line Yields and F/C-Ratio

Line yield = Press yield line losses Line losses: filtration, general juice handling Line losses with belt presses: 3 % due to high suspended solids Line losses with Bucher Unipektin HPX: 2 % due to low suspended solids F/C-Ratio: fruit/concentrate ratio, kg fruit required per kg concentrate
F / C Ratio = Brix _ Concentrat e 100 % * Brix _ Fruit Line_ Yield %
kg kg
page 41
Line Yields and F/C-Ratio

kg 70 Brix 100 % * = 6.55 12 Brix 89.0 % kg
Belt Press + Bucher Unipektin HP: F / C Ratio =
Bucher Unipektin HPX with 1 Leaching:
F / C Ratio =
kg 70 Brix 100 % * = 6.41 12 Brix 91.0 % kg
Bucher Unipektin HPX with 2 Leachings:

F / C Ratio =
kg 70 Brix 100 % * = 6.27 12 Brix 93.0 % kg

page 42
Economics: Concentrate Earnings
Capacity 30 t/h Total Processed Apples: (line capacity 30 t/h; 100 days/year) F/C-Ratio: Total Concentrate: (calculation: Apples t/y / F/C-Ratio) Total Concentrate Earnings: (Concentrate Price: 1500 EUR/t) t/year t/t t/year EUR/year 1500
2x Belt Press Cascade 65'000 6.73 9'658 14'487'370
2 x BP + 2x HP 65'000 6.55 9'924 14'885'496
4 x HPX 4 x HPX 1 Leaching 2 Leachings 65'000 6.41 10'140 15'210'608 65'000 6.27 10'367 15'550'239
page 43
Economics: Water Evaporation
Capacity 30 t/h Total Processed Apples: (line capacity 55 t/h; 120 days/year) Leaching water Additional water evaporation Additional water diafiltration (= retentate volume *2) Total additional water evaporation kg/kg) Additional steam costs (15 EUR/t) t/year % t/year t/year t/year t/year EUR/year 15
2x Belt Press Cascade 65'000 25 6'500 3'714 10'214 2'554 38'304
2 x BP + 2x HP 65'000 25 6'500 3'714 10'214 2'554 38'304
4 x HPX 4 x HPX 1 Leaching 2 Leachings 65'000 15 0 0 0 0 0 65'000 25 6'500 0 6'500 1'625 24'375
page 44
Economics: Summary
2x Belt Press Cascade EUR/year EUR/year EUR/year EUR/year EUR/year EUR/year EUR/year EUR/year EUR/year EUR years 14'487'370 -38'304 14'449'066 0 1'500'000 -52'500 -150'000 0 0 0 2 x BP + 2x HP 14'885'496 -38'304 14'847'193 398'126 1'500'000 -52'500 -150'000 0 398'126 0 0.00 4 x HPX 4 x HPX 1 Leaching 2 Leachings 15'210'608 0 15'210'608 761'542 3'000'000 -105'000 -300'000 -202'500 559'042 1'500'000 2.68 15'550'239 -24'375 15'525'864 1'076'798 3'000'000 -105'000 -300'000 -202'500 874'298 1'500'000 1.72
Capacity 30 t/h Total Concentrate Earnings: Additional steam costs: Total earnings: Additional earnings: Investment: Interest (7 % on 50 % of investment): Depreciation (within 10 years): Additional financing costs: Net additional earnings: Additional Investment: Return on Investment (ROI):
page 45
Economics: Conclusion
BUCHER UNIPEKTIN HPX Press:

Superior Economical Efficiency Short ROI Time for Additional Investment
page 46
Summary
An efficient juice extraction requires optimized mash preparation The BUCHER UNIPEKTIN CM50 grinder provides optimum mash structure BUCHER UNIPEKTIN HPX press: - highest yield - high throughput - low sediments - good hygienic design BUCHER UNIPEKTIN HPX press has superior economical efficiency
page 47

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From nature

Juice World 2012, St. Petersburg

since August 2010

Scope of Supply Juice Industry Product reception, mill Press

Adsorber / Ion exchange

Aroma recovery / Concentration

Juice World 2012, St. Petersburg

Juice World 2012, St. Petersburg

Juice World 2012, St. Petersburg

Scope of Supply Sludge Dewatering Technology

Juice World 2012, St. Petersburg

BUCHER UNIPEKTIN Hydraulic Fruit Press HPX 6007 Product presentation

Juice World 2012, St. Petersburg

HPX 6007 Improvements

Processcontrol with tele service

Hygienic, closed juice exit and tank

Comfort option for protection guard

Juice World 2012, St. Petersburg

Looped drainage elements, continuous rotation

Juice World 2012, St. Petersburg

Drainage system: Improved loosening

Strong forming of blocs

Field trials HPX 5005iP vs HPX 6007, Switzerland 2010

Juice World 2012, St. Petersburg

Pressure plate front side:

Pressure plate back side:

Apple, no mash enzymes used:

Clean pressure plate on the back side

Field trials, Switzerland, 2010

Juice World 2012, St. Petersburg

Looped drainage elements, continuous rotation

Juice World 2012, St. Petersburg

Oil cooler with air

Separate blocs for press piston and basket functions

Pressure sensor instead of switches

Juice World 2012, St. Petersburg

Oil cooling variants

Air- & Water cooler (Optional) Reduced water consumption

NetService Worldwide access

Worldwide access to all Bucher Unipektin machines and plants

Juice World 2012, St. Petersburg

Juice World 2012, St. Petersburg

Juice World 2012, St. Petersburg

No Access via back side door. Door mechanically locked (STANDARD)

Juice World 2012, St. Petersburg

Bucher Unipektin Extraction Line

Juice World 2012, St. Petersburg

Introduction Challenges for AJC producers:

Juice World 2012, St. Petersburg

Fruit (Raw Material) 70 80 % of total AJC production costs

Yield: Decisive for Economical Efficiency

Juice World 2012, St. Petersburg

Optimized Mash Preparation Apples

1 or 2-Step Leaching (15-25 % w/w Water/Mash)

Juice World 2012, St. Petersburg

Optimized Mash Preparation Apples

1 or 2-Step Leaching (15-25 % w/w Water/Mash)

Juice World 2012, St. Petersburg

Optimized Mash Preparation Apples

1 or 2-Step Leaching (15-25 % w/w Water/Mash)

Juice World 2012, St. Petersburg

Optimized Mash Preparation Apples

1 or 2-Step Leaching (15-25 % w/w Water/Mash)