symposium modena, italy may 21, 2016 … · fermenter components • customized design for nearly...

CETOTEC

VINEGAR TECHNOLOGYSymposium Modena, Italy

May 21, 2016

Agenda

• About us

• Projects

• Processes

• Products

• A Family company

Founded by Sylvia Sellmer-Wilsberg and

Hans-Werner Wilsberg in 1996

• Research & Expertise

Cetotec has established itself as a Global leader in

vinegar technology - combined expertise in

microbiology, biotechnology, and mechanical

engineering

• Integrated technology and service

Fermenter, aerators, foam system, process control,

on-line alcohol measurement, microfiltration systems,

Consulting, engineering and training

CETOTEC.COM 3

About us

20 years of Vinegar Expertise

• Our Base

We are located in Bad Honnef, Germany

close to Cologne

• International reach

Cetotec’ s equipment has made it to each of the

world’s continent – we have installations in

China, Japan, US, South America, Australia,

Russia, Africa, and all over Europe.

CETOTEC.COM 4

About us

20 years of Vinegar Expertise

Agenda

• About us

• Projects

- Burg Group

- De Nigris

- Mendes Goncalves

• Processes

• Products

Some of our recent projects

Vinaigrerie Fuchs (Burg Group)

La Tremblade, France What does it take to build an industry-leading partnership ?

Flexibility and curiosity

• Together with Europe's leading alcohol vinegar producer Burg group,

we have pushed the boundaries of high-concentration vinegar

production

• Since almost 20 years De Burg and Cetotec are working in close

cooperation to develop solutions for the optimization of vinegar

production processes

• In cooperation with Burg group, we’re already working on producing

vinegar with 25 percent acidity

Acetificio M. De NigrisCaivano & San Donnino, ItalyCan tradition and innovation go hand in hand ?

Yes, and they must, as our partnership with DeNigris

shows

• San Donnino plant equipped in 2011 with new

fermentation and filtration equipment

• Key element is a Fermenter F600 with 60m³ working

volume

• New DeNigris plant in Caivano equipped with Cetotec

fermenters F600 and F250 in 2015

• The factory is almost completely automated –

visualization and remote control via computer

or smartphone

Mendes Gon�alvesGolega, PortugalCustomized technology and efficient fermenters for the

smallest production batches

• Mendes Gonçalves produces sauces, spice mixes and gourmet

vinegars from a variety of exotic ingredients

• Cetotec has provided Mendes Gonçalves with lab equipment &

Fermenters (Fermenter SF6, SF600 )

• They are using the ACETOSCAN for measurement of alcohol and

acidity in less than one minute

Agenda

• About us

• Projects

• Processes

– Flow sheet semi-batch process

– Flow sheet fed-batch process

• Products

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Semi-batch processfor wine, cider and specialty vinegars

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Defined

mixture of

raw material

(6-14%

alcohol) and

nutrients

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��The Semi-Batch-Process is a

fermentation process at which

1/3 of the fermentation liquid is

discharged when reaching a

residual alcohol content of

~0,3% and replaced by

charging fresh mash.

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Flow-sheet Semi-Batch process

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Fed-batch process (for alcohol vinegar with more than 20% acidity)

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The Fed-Batch-Process is a

fermentation process at which

2/3 of the fermentation liquid is

discharged when reaching a

residual alcohol content of

~0,3% and replaced by slowly

recharging the respective

ingredients.

During the ongoing batch,

alcohol and nutrients are

apportioned in a certain

quantity so that the total

concentration increases slowly.

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Nutrient mixing /

dosing (nutrients

in concentrated

vinegar 15-20%)

Water

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Agenda

• About us

• Projects

• Processes

• Products

– Installations

• Fermenter

• Aerator

• Foam system

Type

Volume

[l]

Diameter

[m]

Total height

[m]

Vinegar

[l10% / year]

SF6 6 0,16 0,57 1000

SF15 15 0,22 0,78 2000

SF25 25 0,27 0,99 4 000

SF50 50 0,34 1,07 8 000

SF100 100 0,43 1,31 16 000

SF150 150 0,50 1,47 24 000

SF200 200 0,55 1,67 31 000

SF300 300 0,64 1,89 47 000

SF600 600 0,85 2,02 94 000

SF1000 1000 1,05 2,16 157 000

Lab Fermenter - ranging from 6 to 1.000 l working volume -

Type

Volume

[l]

Diameter

[m]

Total height

[m]

Vinegar

[l 10% /

year]

F30 3000 1,50 3,2 470.000

F60 6000 1,85 4,2 940.000

F90 9000 2,15 4,6 1.420.000

F120 12000 2,40 5,0 1.900.000

F200 20000 2,80 5,8 3.100.000

F250 25000 2,85 7,4 4.200.000

F300 30000 3,20 7,7 5.000.000

F400 40000 3,55 8,4 6.600.000

F500 50000 3,80 9,2 8.200.000

F600 60000 4,00 9,7 9.900.000

F750 75000 4,35 10,1 12.300.000

F850 85000 4,65 10,1 15.400.000

F1100 110000 4,80 11,2 21.000.000

Industrial Fermenter - ranging from 3 to 110 m³ working volume -

• High quality stainless steel tank with cooling coil

inside

• Aerator with highest possible oxygen enrichment

and optimal mixing results of fermentation liquid

• Efficient and energy-saving foam system

• Proven vinegar process control using SIEMENS

PLC and touch panel

• Alcocontrol / Acetoline for the on-line measurement

• Reliable, stainless steel charge and discharge

pumps

Fermenter components


inside


• Efficient and energy-saving foam system


PLC and touch panel

• Alcocontrol / Acetoline for the on-line

measurement


pumps



inside


• Energy-saving foam system


PLC and touch panel


measurement


pumps



inside




PLC and touch panel

• Alcocontrol / Acetoline for the on-line alcohol

measurement


pumps



inside




PLC and touch panel


measurement


pumps


• Customized design for nearly every fermenter size

• Hydrodynamic optimized rotor and stator

design to give a maximum mass transfer and best

mixing results between fermentation broth, air and

substrates.

• Intense mixing of alcohol and water

• Low energy consumption due to use of energy

saving motors (IE3)

Aerator

exhaust air

foam collecting

pipe

foam

pump

• Foam in the fermentation of vinegar is built

up by dead cells, their metabolic products

and insoluble extracts from the raw materials

• All these substances are undesired

in the final product and have to be removed

from the fermentation liquid

• The Cetotec foam system performs

exactly this task

Foam system

Agenda

• Introduction

• Processes

• Products

– Installations

– Process measuring & control

• On-line alcohol measurement

• Process control for fermenter

• Visualisation

• Now ethanol and acetic acid can

be measured simultaneously and

fully automated during the

production process

• Measurements can be integrated

to a Siemens PLC for precise

production control

• Up to now it has been possible to

measure only the alcohol

concentration on-line

• Acetic acid could only be measured

by taking samples and testing them

in the laboratory

• Calibration was required more often

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On-line alcohol measurement

• Measurement of the alcohol concentration

in the fermenter

• As consumables only the polymer

membrane is needed

• Long term stability

• Easy installation – only a sensor port is

needed

• Simple to calibrate and operate

• Short response time, high accuracy

Alcocontrol system

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• The measurement functionality is based on NIR

spectroscopy

• Ethanol and acetic acid show specific

“spectral fingerprints“, which is generated by the

adsorption of the penetrating light and thereby

weakened in a characteristic way

• These fingerprints can be used to identify

substances and to quantify the concentration

in a mixture of substances without any

cross-sensitivity

Acetoline - on-line measurement of

acetic acid & alcohol

• Simultaneous measurement of alcohol and acetic acid

concentration in less than 1 minute

• Easy installation beside the fermenter

• Can be integrated to a Siemens PLC

for precise production control

• Automated sampling

• High precision

Measurement range: 0 – 20% Alcohol; 0 – 25% Acetic acid

Acetoline - on-line measurement of

acetic acid & alcohol

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Process control for wine vinegar

using the semi-batch process

The Ceto-SEMI fermentation software

with Siemens PLC controller and

user-friendly colour touch panel controls

the activation of motors, pumps, sensors

and the actual process control.

Operating the software via the touch

panel is comprehensive and logically

structured thus can be mastered efficiently

in a very short time.

Visualisation

• Process Software, being specially designed

for vinegar fermentation

• Fermenter is displayed with filling level,

temperature, air volume, alcohol content, etc.

• With the help of a modern and customized

visualization software, it is possible to directly

monitor and control the PLC via a PC or any

other electronic visualization device

• Several fermenters or filtration systems can

be integrated and therefore centrally

monitored and controlled.

Agenda

• Introduction

• Processes

• Products

– Installations


– Filtration

• Filtration systems

• Filtration modules

Filtration systems

• The filtration step following the storage is

essential in order to produce a micro-

biologically stable product.

• Micro-porous hollow fibre membranes are

used with 0,2 µm

• Our cross-flow filtration systems range from

small plants with capacities of 250 l/h up to

fully automated large-scale plants with a

capacity of 3.200 l/h

Type # Modules Surface

CB 01 1 6,3m²

CB 02 2 12,6m²

CB 04 4 25,2m²

CB 06 6 37,8m²

CB 08 8 50,4m²

Filtration systems - Advantages

• One compact system

• Fully automatic PLC process control

• No consumables are needed

(except for cleaning agents)

• Filtration modules especially designed

for vinegar filtration

• Automatic back-flushing system to ensure

a proper flow and pressure

Agenda

• Introduction

• Processes

• Products

– Installations


– Filtration

– Lab equipment

Acetoscan

• Simultaneous measurement of

ethanol and acetic acid concentration

in less than 1 minute

• Easy installation

• Analysis without any sample

preparation

• No consumables or dangerous

additives necessary

• High accuracy & reproducible results

Measurement range: 0 – 20% Alcohol; 0 – 25% Acetic acid

THANK YOU

FOR

YOUR ATTENTION !

symposium modena, italy may 21, 2016 … · fermenter components • customized design for nearly...

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