Dairy Process Technology

ProcessTechnology for Dairy andDairy-LikeProducts N I R O P O W D E R T E C H N O L O G YNiro Process EngineeringDivisionDAIRYLEAVE THIS FLAP OPEN WHILE READING T H E B O N D S O F M I L K A R E S T R O N G E R T H A N T H E B O N D S O F B L O O DGaelic Proverb1. 2.3.4.5.6.7.8.Products page 4-11• Agglomerated Milk Powders• Baby Food• Whey• WPC, Permeate, and Lactose• Coffee WhitenerLiquid Treatment page 12-13and ConcentrationSpray Drying page 14-16• Compact Spray Dryer• Multi-Stage Dryer• Tall Form Spray Dryer• FILTERMAT® Spray Dryer• Integrated Filter DryerAfter Treatment page 17-18• Fluid Bed After-Dryer/CoolerPowder Handling page 19Sanitary Design page 20Safety Precautions page 21Customer Services page 22Financing page 231. Reception2. Storage3. Evaporation4. Feed system5. Spray dryer6. After treatment7. Powder storage8. Powder packingFrom Milk Deliveryto Finished ProductKnow-how through R&DNiro know-how is founded on comprehensive research and developmentand strengthened through co-operationwith dairy organisations and universities.Product TestingCustomers from all over the world come toNiro to test new products in our pilot testfacilities. Before being launched onto themarket, most of our own new developmentsare tested full-scale at leading dairies.Thousands of Niro dairyplants operate daily all overthe world. Our engineeringranges from single pieces ofequipment to complete plants, handling milk all theway from reception throughliquid processing, evaporation, and drying to final bagging off. Milk• Butter• Buttermilk• Cream• Crystallized whey• Milk permeate• Milk protein• Skim milk• Whole milkWhey• Acid whey• Demineralized whey• Lactose• Sweet whey• Whey, delactosed• Permeate• Whey protein concentrate (WPC)Formulated products• Baby food• Cappuccino• Cocoa milk with/without sugar• Coffee whitener• Fat filled milk• Fat filled whey• Ice cream• Milk replacer• WhippingsOther• Casein• Caseinates• Cheese• Condensed milk• Fermented milk products• Hydrolyzed dairy products• YoghurtThe full range of dairy and dairy-like products – all processed in Niro plantsllejefoto(layscan)page 2page 3A P P R O X . 6 0 0 M I L L I O NT O N N E S O F M I L KW E R E R E P O R T E D P R O D U C E D I N T H EW O R L D I N 2 0 0 1Dairy DataFrom liquid to powder,Niro takes products all the wayMilkIn milk, Nature has created a uniqueway of feeding little ones safely andcompletely. Children need plenty ofmilk to build bones and teeth, andmilk also supplies essential fat andproteins. Finally, milk plays a majorrole in food for adults with essentialvitamins and minerals. Dried Dairy ProductsSpray drying makes milk widelyavailable, independent of local supplies of fresh milk, and it expandsthe use of dairy products in food-stuffs. An increased demand for speciality products with particularfeatures poses new challenges for theplant designer. Whey products inparticular are difficult to dry due totheir high contents of lactose andminerals, but new techniques, devel-oped by Niro, now enable even theseproducts to be dried with success. Design for PerformanceNiro is an engineering company specialising in evaporation, spraydrying and complementary processes.Every plant is designed carefully tomeet individual product specifica-tions. Mechanical execution is alwaysin agreement with official standards, and superior hygiene and safety areintegral features of every modernNiro plant. Durable RelationshipsAt Niro, we take pride in keepinggood relations with our customers.This is illustrated by the fact that mostnew business comes from satisfiedcustomers who want to enlarge theirproduction capacity, up-grade plants,or invest in new processes. Niro staysat the forefront of the dairy processbusiness supported by local representatives all over the world.Design for PerformanceAgglomerated milkpowder dissolvingquickly in cold waterAtomizer wheel formilk drying.Spherical wheelspeed 100-200 m/spage 4FunctionalityEvery day, millions of litres of milk areprocessed into dry products. By far thelargest part ends up as ordinary skimmilk and whole milk powders. These products are market commoditieswith little requirement for product functionality. Consumer demand forspecific product properties, particularlyin the food industry, has resulted in thedevelopment of many different drydairy products, ranging from instantwhole milk powder to speciality foodingredients. Thus the dairy industryinvests heavily in the development and production of such products, oftenin close collaboration with specialistsfrom Niro.PropertiesMilk is unique in its content of valuablenutrients. Both the chemical compo-sition and the physical properties of themilk powder play an important role inits use with quick and complete reconstitution adding convenience tothe products. AgglomerationSmall single particles dissolve instantlyin water. Powder consisting of smallparticles is, however, difficult to disperse. Big particles are easy todisperse in water, but dissolve onlypartially. Agglomeration optimisesquick dispersion of the agglomerates aswell as quick and complete dissolutionof the small particles forming the agglo-merate. Furthermore, agglomerationNiro sets the trend in modern process plant design. We meet specific requirementsto powder properties, whilealways keeping plant performance and drying economy in focus.AgglomeratedMilk PowdersThe art of achieving perfect product functionalityNozzle atomizerwith four nozzlesand fines returnMicrophoto (x300)of agglomeratedwhole milk powderfrom an MSDTMimproves the product’s flowability andreduces dust problems during powderhandling. Agglomeration is a result of wetand/or semi-dry particle collision.Control is achieved by returning dry fine powder to the wet spray during different stages of spray drying.Mastering the agglomeration techniques is the art of modern spraydrying – the art of Niro. Plant operation and economics areother important parameters. Niro product specialists and plant designerskeep those factors in mind when designing spray drying plants to meetour customers’ individual needs.Agglomerated Whole Milk PowderIn whole milk powders, some of the fatis present as free fat. Free fat rejectswater making it impossible to dissolvethese powders properly in cold water.Homogenization of the whole milkconcentrate prior to drying reduces thecontent of free fat in the final powder.However, to be called ‘instant’ wholemilk powder, it must be agglomeratedas well as have a surface-active agent(lecithin) applied to improve water affinity. The product then becomesinstant – even in cold water.Agglomerated High Protein PowderPowders with high protein contenthave a very high affinity to water.During rewetting, such powders dissolve so quickly that the particle surface instantly turns into a gel, which prevents further water penetration. The product is left as gellumps with dry material inside.Agglomeration and a surface-activeagent, such as lecithin, can be used tocontrol dissolution speed. And controlling the spray drying processagain improves powder functionality.N I R O P O W D E R T E C H N O L O G Ypage 5A P P R O X . 6 M I L L I O NT O N N E S O F M I L K P O W D E R ( S K I M A N D W H O L E )W E R E R E P O R T E D P R O D U C E D I N T H EW O R L D I N 2 0 0 1Dairy DataAgglomeratedmilk powderT-profiles used for the sanitary VIBRO-FLUIDIZER®CIP nozzles in the VIBRO-FLUIDIZER® above and below air distribution platepage 6Every baby food producerhas individual recipes andproduct requirements. Niroadds process and designexpertise delivering plantsto meet even the strictestdemands on product standards.Formulations Infant formulas are developed to be asclose to human milk as possible. Thedigestive system develops as the babygrows older, and baby food formulatorsmust take this into account. Further-more, most producers have developedproducts tolerated by hyper-allergicbabies. As cow's milk differs in composition from human milk, it isused only as an ingredient in the finalblend along with whey proteins, demineralized whey, maltodextrine,lactose, essential fatty acids, vitamins,and minerals.Ingredient MixingBaby food products must be blended tothe precise composition. The variousingredients come as dry powders, solidfat or liquid oil, and milk concentrate. as a reliable alternativeCompletemilk powderfactoryPressure nozzle.Nozzle atomizationresults in good powder flowabilityBaby FoodN I R O P O W D E R T E C H N O L O G Ypage 7Baby food production involves several handling procedures such asdissolution, melting, and mixing. The blends need cooling, pasteur-ization, pre-concentration, and homogenization prior to drying.Integrating each separate process into a continuous process calls for the best expertise on the market – the expertise of Niro.Baby Food DryingBefore drying, the wet mix is preconcentrated in an evaporatorfinisher to reduce production costs.The concentrate is then dried in oneof Niro’s special spray dryers, designed to minimize product heatexposure. Since most baby food products are required to be instant,the preferred dryer is typically designed to allow for product agglomeration during drying. All these features add to the quality of the formulated baby food product.Meeting Hygienic StandardsEvery Niro plant meets the strictesthygienic standards. All surfaces in contact with the product are made of stainless steel orother materials accepted and approved by the authorities (FDA).Bends are smooth, surfaces are polished, and hollow spaces and cavities are avoided in the plantdesign. Finally, the plant is supplied with built-in CIP facilitiesallowing producers to meet even thestrictest hygiene requirements. H U M A N M I L K H A S O N EO F T H E H I G H E S T C O N T E N T S O F L A C T O S E( M I L K S U G A R ) , 6 . 4 % .C O W ’ S M I L K H A S A L A C T O S E C O N T E N TO F 4 . 6 %Dairy DataWhey crystallizationtankspage 8WheyWhey is no longer just aproblematic by-productof cheese production. Ithas high value as rawmaterial for a variety offood ingredients – andits importance is stillincreasing.Origin Every litre of milk used in cheese pro-duction gives an equal amount of whey.Whey composition and quality dependon a wide range of factors includingbreeding and feeding of the cows, timeof year, and the type of bacteria andrennet used in the cheese production.The treatment of the whey from thecheese vats also has a significant influ-ence on the final whey powder quality.Whey TreatmentMany smaller cheese producers do notprocess the whey on site and, therefore,have problems with product deteriora-tion. The high bacteria load and presence of active enzymes in the rawwhey make it extremely important toseparate fat and cheese particles, and topasteurize and cool the whey immediately after removal from thecheese vats. Storage and transport hasto be under cooled conditions. Niro's affiliated companies in the GEAGroup offer processes and systems forwhey treatment. Niro specialises inmembrane filtration, evaporation, andspray drying of whey, and has developed parameters and plantdesigns to enable optimal economicalproduction while reducing operationalproblems such as evaporator foulingand powder deposits in the dryer. Valuable nutrients available at low price.Microphoto (x100)of non-caking whey powderN I R O P O W D E R T E C H N O L O G Ypage 9Whey CompositionTraditionally, whey has been used asan animal feed, but is now becomingincreasingly important as raw materialin the food industry. Whey powderhas an extraordinarily high water andfat binding ability and is, therefore,widely used as filler in food productssuch as bread, cakes, and delicatessenproducts. Huge quantities of whey areused by the food industry replacingthe more expensive skim milk powder.But whey is much more than just askim milk replacer. With all the essential amino acids, valuable minerals and a broad range of othervaluable compounds present, whey istoday gaining a market as raw materialfor all kinds of food ingredients. Functional FoodThe present trend towards a higherdegree of specialisation, including themarketing of functional foods, such asenergy drinks, dietary products, andproducts with a high content of vitamins or minerals, has a great influence on the whey powder market. In some markets the demand for wheyis exceeding the supply, and its propercollection, handling, and processingbecome increasingly important. So does the choice of partner for whey processing, which is why most manufacturers go with the best and choose Niro.1 4 0 M I L L I O N T O N N E S O FW H E Y I S P R O D U C E D A N N U A L LY. O N LY 2 0 % I SD R I E D , C O R R E S P O N D I N GT O 1 . 8 M I L L I O N T O N N E SO F P O W D E RDairy DataHOHHHHOOHHH OHCH2OHOH HOOHH HHOHCH2OHOH HHO HHOOHHH OHCH2OHOH HOOpage 10One Product – A World of OptionsThe dry solids in whey are mainly lactose, proteins, and minerals. The different compounds are e.g. used as ingredients in baby food, health products, functional foods, and pharma-ceuticals. Niro and its affiliated compa-nies in the GEA Group offer a widerange of technologies for fractionation ofwhey into its constituents.Whey proteins can be isolatedfrom whey using membrane filtrationand subsequent drying in a spray dryer.Whey permeate contains lactoseand minerals that are difficult to treat in conventional spray dryers. Niro’sadvanced drying systems, however,overcome these problems. Lactose processing involves isolation from permeate by evaporation,crystallization, decanting, further purification, and drying in a speciallydesigned Niro fluid bed dryer.Niro has a variety of processes adaptedfor whey products, and is working continually on new developments tomeet the requirements of tomorrow’smarket. W H E Y C O M P O N E N T SB A S E D O N T O TA L S O L I D S :L A C T O S E 7 2 %P R O T E I N 1 4 %A S H 1 0 %FAT 1 . 5 %L A C T I C A C I D 2 . 5 %Dairy DataWhey ProductsWhey protein concentrate (WPC),permeate, and lactose With fractionation,whey is up-graded,adding extra value tothe dried product.N I R O P O W D E R T E C H N O L O G Ypage 11Growing MarketLarge quantities of coffee creamers areproduced for use with dried coffee.These are marketed direct or mixedwith dried coffee and sugar into a greatvariety of ready-to-drink mixes. Allover the world creamers are used forconvenience, particularly in workingenvironments. And with the develop-ment of processes for foaming creamers,the market for cappuccino mixes for useat home has grown considerably.Designed for ConvenienceAlthough coffee creamers are non-dairyin origin, they share many character-istics with dairy products, being high infat and carbohydrate content and quite difficult to dry in a conventional processing plant. The Niro MSD™ is aspray dryer and an agglomerator in oneunit. This dryer is particularly suitedfor drying high fat and carbohydrate-containing products and making themconvenient to use. For creamer products to be convenient in use, they mustmeet a wide range of require-ments. In addition to having acreamy taste and character, theproducts must be agglomeratedand instant – demands met toprecision by Niro spray drying technology. Creamers and cappuccino mixesCoffee WhitenerMulti-distributionsystem on top ofcalandriapage 12Integral Parts of the ProcessLiquid processing includes reception,cooling, storage, separation, pasteurization, and evaporation. Theseprocesses are all integral parts of theNiro dairy solutions.The different membrane techniques, suchas reverse osmosis, micro- and ultrafiltra-tion, remove water and isolate certainsubstances. Membrane processes areessential in the fractionation of e.g. whey,and ultrafiltration in particular is a precondition for the production of arange of speciality products such asWPC. GEA Filtration masters thosetechnologies and provides the full rangeof membrane filtration systems.Falling film evaporatorwith thermal vapourrecompression (TVR)Falling film evaporatorwith mechanical vapourrecompression (MVR)As a member of the GEA Groupof companies Niro has directaccess to state-of-the-art liquidprocessing engineered byTuchenhagen, WestfaliaSeparator, and GEA Filtration.Liquid Treatment and ConcentrationThe more water removed upstream ofthe dryer, the better the plant economyN I R O P O W D E R T E C H N O L O G Ypage 13Ultrafiltrationplant for wheyFive piston highpressure pump forhomogenizationEvaporationRemoving water in a spray dryer ismore costly and requires more energythan in an evaporator. In addition tomembrane filtration, Niro offers a variety of evaporator designs for preconcentration of all the differentdairy products. Niro dairy evaporators are typicallymulti-stage types with either mechani-cal or thermal vapour recompression. The evaporators are with built-in pre-heaters, pasteurizers, and flash coolers depending on the application. In addition, Niro has designed specialdirect steam injection pasteurizers with regenerative systems for minimumsteam consumption. The units also provide the possibility of making tailor-made heat classified powders.The Niro flash cooler gives an instanttemperature drop before the crystallization of whey concentrate toprovide small crystals and efficient crystallization.HomogenizationWhole milk and other products withhigh fat content need homogenizationprior to drying. Niro Soavi has developed a range of high-pressurepumps and homogenizers, which areused for all fat containing products.Homogenization under high pressureturns fat globules into microscopic size,optimal for digestion, and allows theproduction of dried powder with a lowfree fat content. Niro Soavi homoge-nizers are recognised worldwide fortheir performance and stability.A N E VA P O R AT O R S U P P LY I N G C O N C E N T R AT E F O R A 1 5 T O N N E S P E R H O U R S P R AYD R Y E R C O N TA I N S U P T O1 0 0 , 0 0 0 M E T R E S O F T U B E S .A P P R O X . 1 5 0 , 0 0 0 C O W S A R EN E E D E D T O K E E P T H E P L A N TR U N N I N G C O N T I N U O U S LYDairy DataTangential swirl heaterfor direct steam injectionpage 14Spray DryingSince Niro’s founder inthe 1930’s applied forpatents on rotary atomizers and launchedthe new technology tothe dairy industry, Nirohas been at the fore-front of spray drying. Niro has maintained the position as aworld leader in evaporation and spraydrying technology and is working continually on new ideas, improve-ments of equipment, and optimisationof plant design. Still stricter demands toe.g. product specifications, hygiene,plant safety, and environmental protection pose new challenges to bemet by our plant designers. Tailor-Made Spray DryersNiro offers a great variety of spraydryer designs, every one with its ownparticular features. The first prioritywhen selecting the dryer design is givento the product – its chemical composi-tion and the required physical structure,the preferences of the operator, and thelimitations given by the location of theplant. Every Niro spray drying plant isdesigned to meet every criterion andensure customer satisfaction.The heart of the milk powder factoryB Y AT O M I Z I N G 1 L I T R E O F C O N C E N T R AT E , Y O U O B TA I N 1 . 5 X 1 0 1 0PA R T I C L E S W I T H A D I A M E T E R O F 5 0 µA N D A T O TA L S U R FA C EA R E A O F 1 2 0 m 2Dairy DataPressure nozzle atomizer in operationRotating atomizerwheel in operationN I R O P O W D E R T E C H N O L O G Ypage 15PreheatingPrior to atomization, the product is preconcentrated and possibly preheated. The feed must remain liquid and the viscosity kept suffi-ciently low to allow for proper atomization. However, a higher concentration of dry matter in thefeed to the dryer results in reducedenergy consumption of the overallprocess and the powder achieves ahigher density. AtomizationNiro spray dryers are equipped with a rotary atomizer or high-pressurenozzles. For maximum operationalflexibility some dryers can be designed for nozzle as well as rotaryatomization. This allows the plantoperator to choose the best atomiza-tion system for specific products. Niroair dispersers are designed to fit Niroatomizers and to ensure maximumcontact between particles and dryingair whilst preventing wet particles reaching the chamber wall.The ChamberThe spray drying chamber is sized for the required capacity, and thedesign is chosen to match the type of atomization used and the product to be dried. Some chambers are equipped with static, integrated fluidbeds for better energy utilisation andgentler product treatment at lowertemperatures.Product SeparationThe drying chambers have a conicalbase where the first separation ofpowder and drying air takes place.The remaining dust from the dryingair is removed in a cyclone and/orbag filter. Conventional spray dryerswork with cyclones, which are still inuse for some applications. However,most modern spray dryers are equipped with a bag filter, which canbe cleaned in place – the SANICIP™.From this bag filter, the powder fraction can be recycled to the process,giving insignificant powder loss.FinesThe powder fraction from the SANICIP™ bag filter or the cyclone is recycled to the process, where it can be used for agglomeration. If agglomeration is not required, the fines can be conveyed to the VIBRO-FLUIDIZER®Conical part of spray dryingchamber with the integratedfluid bed in a CDI DryerMSD™ Dryer with removableinsulating panels Conical part of CDP Dryerwith powder outlet ductfrom the integrated fluid bedPowder layer on the belt of the FILTERMAT®Spray Dryer (FMD)page 16All-in-One UnitThe latest development for the industryis the Niro Integrated Filter Dryer,IFD™, where spray drying, second-stage drying, powder cooling, andpowder separation are all integrated in a single unit. This compact designrepresents a new and unique principleof spray drying: Once again Niro hastaken the lead. T H E I F D ™ D R Y E R R E Q U I R E S 5 % L E S S E L E C T R I C E N E R G Y A N D 1 5 % L E S S B U I L D I N G S PA C EDairy DataFilters integrated in theIFD™ spray dryer reduceplant space requirementsStationary fluid bed withcombined back mix andring formed plug flow section with product outletinto the vibrating sieve.Spray dryer type:Integrated Filter Dryer - IFD™N I R O P O W D E R T E C H N O L O G Ypage 17AfterTreatment Fluid Bed DryersSecondary drying at reduced temperature in a fluid bed gives agentler treatment than can be obtainedthrough full drying in one step in thespray dryer. Secondary drying takesplace in an integrated static fluid bedbuilt into the bottom of the spraydrying chamber. But secondary dryingcan also take place in an external fluidbed dryer, the VIBRO-FLUIDIZER®,giving great flexibility in dryer configuration.After treatment includessecondary drying andcooling and forms anessential part of powderproduction.Secondary drying and cooling of powderNiro VIBRO-FLUIDIZER®page 18Niro BUBBLE PLATE™The art of the fluid bed technique isthe ability to control an even air distribution in the powder layer. No lumps, no channelling, constantpowder layer, and complete emptyingof the fluid bed are essential in operation. The unique Niro BUBBLE PLATE™ is sanitary, thanksto its smooth surface and the fabrication technique of the holes.Furthermore, it ensures complete emptying of the fluid bed.Powder CoolingThe VIBRO-FLUIDIZER® gives a lenient product transport and cooling.Cooling usually takes place in thesecond part of the fluid bed, but theentire bed can be designed for cooling,depending on the product to be treated. If cooling is the only issue, apneumatic cooling system can be usedinstead of the VIBRO-FLUIDIZER®.This costs less to acquire, but is moreexpensive to operate. Pneumatic conveying and cooling is used only for products where the physical structure is of minor importance.T-profiles used for the sanitary VIBRO-FLUIDIZER®T H E N U M B E R O FH O L E S I N T H E P E R F O R AT E D P L AT EO F A 3 1 . 5 m 2V I B R O - F L U I D I Z E R ®E X C E E D S 5 0 , 0 0 0Dairy DataInternal view of a NiroVIBRO-FLUIDIZER®BUBBLE PLATE™- air distribution platesVIBRO-FLUIDIZER®Partly dried dairy powders from a spray dryer can be difficult to fluidize. Most external fluid bed dryers are therefore designed asvibrating units to ease fluidization.The VIBRO-FLUIDIZER® is used for second-stage drying, third-stagedrying, and powder cooling. Coating of particle surfaces with e.g. lecithin can also be done in theVIBRO-FLUIDIZER®. The entire fluidbed complies with even the strictestsanitary criteria.Automatic Avalon carouselbagging-off equipmentRobot bag palletizerBag heat sealing andbelt transportThe Product Determines the SolutionIf the powder produced is e.g. anordinary skim milk powder, it can beconveyed by conventional methods,including pneumatic transport. If theproduct is an agglomerated powder,mechanical treatment must be minimised in order to maintain product structure. Niro specialises in supplying lenient powder handling and, where needed, vacuum transport systems.Powder Storage and PackingStorage and packing systems are also available from Niro. AvalonEngineering, another member of theGEA Group, supplies bagging-offlines from small, semi-automatedsystems to large, fully automatedlines filling and palletizing up totwelve 25 kg-bags per minute, or 18 tons per hour. N I R O P O W D E R T E C H N O L O G Ypage 19Retaining Powder PropertiesPowderHandlingConveying, storage, andpacking require great carein order to maintain thephysical properties acquired during drying. Top of 100 m3 milk powder silos. Silos are equipped with automatic self-cleaning filtersBottom of powder silos. Pipelinesconnected for vacuum conveyingproduct to bag filling machinespage 20Liquid HandlingLiquid processing is always done inways to minimize bacteria growth.Preheating uses waste heat from theplant, always with strict attention to hygiene.EvaporationTo eliminate heat contact surfaces,Niro has developed new preheatersand a special pasteurizer with directsteam injection and a regenerative section. This swirl heater provides fastand efficient heating for product heattreatment - for specific classifications - prior to evaporation. All this allows for a 20-hour production cycle between cleaning avoiding the risk ofbacteria growth such as thermophilesand their spores.For efficient CIP of the evaporatorNiro has introduced a "hydro cyclone", which collects and discharges impurities that wouldotherwise block the distribution platesabove the calandria during CIP.Spray DryingThe spray dryer is equipped withappropriate drying air filtration andSanitary Designfor maximum plant hygieneRecognising hygiene as a safetyissue, sanitary designs are basedon the Niro Sanitary Code. This code is updated continually. It draws from official standards agreed duringthe past 50 years as well ascodes issued by organisationsall over the world such as 3AStandard (USA), IDF, and theEU Hygiene and FoodstuffsDirective (93/43/EEC).T-profiles used for welding where 3AStandard radii require-ments must be metRetractable CIP-nozzleReverse jet nozzle forSANICIPTM CIP-able bagfilter and IFDTM dryerDismantable insulation panels Retractable CIP-nozzle mounted on a VIBRO-FLUIDIZER®N I R O P O W D E R T E C H N O L O G Ypage 21Dried dairy products have a potentialrisk of fire and explosion. Based onown statistics collected over the last40 years, we are convinced that explosions can only be ignited by anopen flame or a large smoulderinglump of powder. Fires most commonly start by self-ignition ofpowder deposits, and only 4-5% offires turn into explosions. To maintain maximum safety, Niro focuses on:Warning All process parameters that present arisk are monitored and protected bytemperature and pressure alarms.New detection systems can be used tomonitor CO contents in the outlet air. PreventionTo minimize the risk of fire, we aim toavoid powder deposits and eliminatehot surfaces in the dryer. Fire extinguishing systems are integralparts of the design and are suppliedto prevent explosions by extinguishing fires quickly and safely.Niro recommends that plants are kept free of dust outside the dryer to avoid the risk of dust explosions inthe working areas.ProtectionAll dryers are provided with explosion venting connected withducts to the outside. Other protectionsystems may be incorporated as well. Our main goal is to encourage andassist our customers to implementmaximum protection of personnel andminimal equipment damage in case ofan accident. Niro stays updated onthe newest standards and directivesworld-wide.The design of a spraydrying plant must addressmore than optimum product quality. It must alsoobserve maximum safetyfor plant and people.as built-in featuresSafetyPrecautionsCIP facilities. All surfaces in contactwith the product comply with theabove standards and materials areFDA approved. All equipment isdesigned for proper drainage during CIP.All drying plants are designed withsmooth surfaces avoiding hollowspaces. Furthermore, they are equipped with CIP nozzles wheneverappropriate. The SANICIP™ bag filter enables wet cleaning, whichensures proper cleaning of bags andhousing. For the ultimate in hygiene – customers have confidence in Niro.Sanitary sound attenuator SOUNDCIP™ 1 m m O F D U S T O N T H E F L O O R O F A 5 x 5 x 5 mR O O M W I L L , I F S U S P E N D E D , C O R R E S P O N D T O 1 0 0 g / m 3.M I L K P O W D E R E X P L O D E S AT6 0 g / m 3, I F I G N I T E DDairy DataSanitary rotary valveRetractable CIP-cleaning nozzlepage 22Rotary atomizerPlant RetrofitsPlants operating continuously for many years require more than justmaintenance. To keep plants on streamand up-to-date, Niro has a special taskforce of experienced engineers who, onrequest, will evaluate existing systemsand quote for their rebuilding as analternative to investing in a completelynew plant.After SalesOur spare parts programme has onefocus: Maximum uptime for our customers. We carry a large stock ofessential parts and offer service programmes for key components aswell as full service contracts with visitsby experienced staff from local Nirooffices all over the world.Process AdaptionThe food and dairy industry is dynamicwith market demands and raw materials changing over time. Althougha new investment may not be needed,plant operators may benefit from a visitfrom one of our product specialists forprocess modification and optimisation.Laboratory and Test StationOur in-house laboratory and pilot plant facilities enable customers to havetheir products tested assisted by Niro product specialists. We also co-operatedirect with customers to develop new products and refine existing processes under established confidentiality agreements.Customer Services Reliable operationMore than just plants – Niro supplies performance.With the term “reliable operation” Niro provides arange of services to keepplants up and running.Multi Stage Dryer at the Niro TestStation, DenmarkN I R O P O W D E R T E C H N O L O G YFinancingpage 23Accessing FundsNiro is able to access funds and/or guarantees to make it possible for customers to implement their projects,especially in markets where access toinvestment capital is limited.Our financing experts have a widespread network of contacts withbanks and multi- and bilateral financialinstitutions in most parts of the world. All-Round ExpertiseWith in-house project-financing experi-ence as well as industry and technologyknow-how, Niro is the unique partner atany stage of the planning, design, anddelivery of an industrial processingplant. An expertise that makes it obvious that if you want the best indairy processing, look to a market leader – look to Niro.The decision to invest ina spray dryer or a complete plant is a complex one. Niro offersproject financing assistance to customersplanning to invest inindustrial processingplants.DAIRYNiro A/S • Gladsaxevej 305 • PO Box 45 • DK-2860 Soeborg • DenmarkTel: +45 39 54 54 54 • Fax: +45 39 54 58 00 • food.dairy@niro.dk • www.niro.comNiro A/SNiro is a world leader in industrial processing,with evaporation, spray drying, freeze drying,and fluid bed processing as core technologies.Today, Niro stands for an international groupof companies which forms the ProcessEngineering Division of the GEA Group.N I R O P O W D E R T E C H N O L O G YProcess EngineeringDivisionA company of mg technologies groupBNA 834/GB 04.03 opusProcess Technology for Dairy and Dairy-Like Products Spray Dryer SDITall Form Dryer™TFDCompact Spray Dryer CDPOPEN PAGE FOR SPRAY DRYING PLANT OVERVIEWFILTERMAT®Dryer FMDIntegratedFilter DryerIFD™Compact Spray Dryer CDIMulti-StageDryer MSD™