Foodec Centrifuge - FEAE · This process named Foodec Ce\൮trifuge is object of an Italian patent...
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Foodec Centrifuge Extracción y clarificación simultanea de mostos Giacomo Costagli Market Unit Food, Beverage and Olive Oil XVII CONGRESO NACIONAL DE ENÓLOGOS I ENCUENTRO DE ENÓLOGOS DE IBEROAMÉRICA Mérida, 26-28 de Mayo de 2016
Transcript of Foodec Centrifuge - FEAE · This process named Foodec Ce\൮trifuge is object of an Italian patent...
Foodec Centrifuge
Extracción y clarificación simultanea de mostos
Giacomo Costagli
Market Unit Food, Beverage and Olive Oil
XVII CONGRESO NACIONAL DE ENÓLOGOS
I ENCUENTRO DE ENÓLOGOS DE IBEROAMÉRICA
Mérida, 26-28 de Mayo de 2016
www.alfalaval.com
Contenido
• Tecnología actual para la extracción y clarificación de mostos y sus aspectos críticos
• Innovaciones a lo largo de los años. Situación actual del desarrollo.
• El nuevo proceso Foodec Centrifuge patentado por Alfa Laval para extracción y clarificación simultanea de mosto
© Alfa Laval Slide 2
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Vinificación de uva blanca Extracción por prensado y clarificación sucesiva
Decantación estática Flotación
Centrifugación Filtración
+ Recuperación de fondos (10-35% de
mosto)
20-30% mosto de prensa
70-80% mosto flor
Cosecha Despalillado Prensado Clarificación del mosto Fermentación
• Mano de obra • Tiempo • Costos
• Bombeos y tuberías
• Mano de obra • Tiempo • Lavado • Espacio
• Mano de obra • Tiempo • Espacio • Costes • Sostenibilidad
Resumiendo: Tiempos largos con calidad variable y alto costes de los servicios
Moderador
Notas de la presentación
Most common technology for «high quality» white juice expression is based on pneumatic press: Batch process: «semi continuous» if several presses used in parallel Draining & pressing in the same equipment Need for further juice clarification before fermentation Relevant hold-up volume & time Juice clarification bottoms to be treated
www.alfalaval.com © Alfa Laval Slide 4
Innovación a lo largo de los años. Extracción de mostos y posterior clarificación
• La tecnología en los años ha ido avanzando optimizando el diseño de las prensas y los procesos de clarificaciones como la introducción de la flotación y la optimización de la filtración de mostos y fondos.
• La innovación mas impactante ha pretendido ser la producción del mosto mediante la centrifugación en continuo. Los primero trabajos relativos al uso del decanter en el sector enológico para la producción de vino blanco empiezan en 1981. Desde entonces se ha avanzado en la investigación.
– Foster M. D. and Dean Cox M. Winemaking with a Decanter Centrifuge. Am. J. Enol. Vitic., Vol. 35, No. 2, (1984).
– Hamatscheck J., Mäuser B., Meckler O. Decanters for juice extraction from grapes for
winemaking. The Australian Grapegrower & Winemaker, 380: 36-40, (1995). – Schneider R. Nouvelles techniques d’extraction des moûts: exemple du décanteur centrifuge.
On « Les vins blancs de la démarche marketing à la vinification. » Ed. France Agricole. Ch. 12, pp 158-163 (2013).
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Concepto
© Alfa Laval Source: Alfa Laval www.alfalaval.com
Slide 5
Moderador
Notas de la presentación
The, as we named, Decanter, is a horizontal centrifugal separator able to separate liquid phase from solid phase from a raw material with high content of solids. In the winemaking process, it can be used for the production of white wine and rosé wine and also for red wine after thermovinification or directly on the fermented paste. The first publications related to the use of Decanter as an applicable technology in the oenology started in 1981 with Foster and Dean Cox where it is described as a tool for press juice clarification. In the 90’s, an article on the use of decanter for grape juice extraction for winemaking has been published in the Australian Grapegrower & Winemarker with Hamatschek, Mauser and Meckler. Finally in 2013, Schneider catalogued the decanter technology as a new technic of juice extraction for high quality wine production. This technology didn't have a large diffusion in the wine sector due to the level of investment needed to compared technology. The juice obtained with the decanter present the characteristic of having a very high turbidity compared to the low suspended solids. It was so needed a successive clarification in order to send the juice to the fermentation. Today with the use of adequate adjuvant, adding on the mash, it is possible to obtain in continuous and in a short time a clear juice ready for fermentation. This process named Foodec Centrifuge is object of an Italian patent set by Alfa Laval (and a pending international patent). The professor Roberto Ferrarini participated actively in its development and today many articles have been already published.
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Decantación estática Flotación
Centrifugación Filtración
+ Recuperación de fondos (5-25% de
mosto)
100% mosto < 1-2% solidos 600-1000 NTU
Cosecha manual Despalillado Extracción centrifuga Clarificación del mosto Fermentación
El Decanter para la extracción de mosto
• Mano de obra • Tiempo • Costos
• Bombeos y tuberías
• - Mano de obra • - Tiempo • - Lavado • - Espacio
• Mano de obra • Tiempo • Espacio • Costes • Sostenibilidad
Resumiendo: Las ventajas de utilizar el decanter en lugar de las prensas no siempre son suficientes necesitando, la clarificación posterior del mosto
Moderador
Notas de la presentación
Since about 20 years it has been introduced on the mkt a technology for juice expression based on decanter centrifuge: Continuous process Expression & clarification in the same equipment Need for further juice clarification before fermentation Minimum hold-up volume & time Juice clarification bottoms to be treated
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Foodec Centrifuge. La nueva línea de proceso patentada de Alfa Laval para extracción y clarificación simultanea de mosto
© Alfa Laval Slide 7
Proyecto de investigación realizado por Alfa Laval en colaboración
con:
• Spin Off de la Universidad de Verona (IT) – Perfect Wine
• INRA
• Enológica Vason
• Lindegas
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100% mosto < 1% solidos < 200 NTU
Foodec Centrifuge Fermentación Despalillado Cosecha
Foodec Centrifuge – Nuevo proceso Extracción y clarificación simultanea Concepto: El uso combinado de la centrifuga y de coadyuvantes especificos añadido a la pasta de uva permiten extraer y clarificar en una única operación
Cosecha mecanica
DECAZYM® DECAGEL ®
Moderador
Notas de la presentación
Since about 20 years it has been introduced on the mkt a technology for juice expression based on decanter centrifuge: Continuous process Expression & clarification in the same equipment Need for further juice clarification before fermentation Minimum hold-up volume & time Juice clarification bottoms to be treated
www.alfalaval.com Alfa Laval Slide 9
Foodec Centrifuge - Método Pruebas de laboratorio para la evaluación de los coadyuvantes
Medición NTU mosto
Sedimentado (piel, pepitas, solidos suspendidos)
Centrifugación pasta
Puesta a punto de aditivos:
- DECAZYM®
- DECAGEL ®
Ferrarini et al., 2014
Moderador
Notas de la presentación
Features and optional: Capacity range up to 30 t/h Mash thermal treatment Maceration unit Homogenizer systems Automatic control Safe equipment for extraneous bodies Gas protection available
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Clarificación simultanea - Turbidez
© Alfa Laval Slide 10
Turbidez del mosto - ensayo 1 Turbidez del mosto - ensayo 1
La grafica muestra los valores de turbidez del mosto después del procesado con Foodec Centrifuge. En el ensayo 2, después de 12 horas de funcionamiento en continuo el mosto obtenido tenia una turbidez media de 145 NTU. El mosto entonces ha sido inoculado directamente para la fermentación.
Ferrarini et al., 2015
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Sequedad del orujo
* Inra, 2011 ** Inra, 2014 *** IFV, 2013 **** Perwine, 2013 unpublished
Vendimia termotratada
Vendimia fresca para rosado Vendimia blanca
Decanter Prensa neumática
Moderador
Notas de la presentación
No significant differences between technologies
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Rendimiento
Slide 12
Data: Alfa Laval
Se consigue un mosto de una calidad única con un mayor rendimiento al no tener perdidas en el proceso de recuperación de mostos a partir de los fondos
Moderador
Notas de la presentación
Decanter has higher yield or in line with Pneumatic Press technology , considering Drain and Press juice from Presses; Decanter produces single fraction of homogeneous juice.
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Calidad del mosto y del vino • Catequina, protoantocianidina y polifenoles totales
comparable con el conjunto de mosto flor y
primera prensada obtenido mediante prensa
neumática;
• Potasa, calcio, conductibilidad y pH a niveles
comparables o mejores con un mosto flor obtenido
mediante prensa neumática;
• Perfil aromático de los vinos obtenido de mosto de
decanter y prensa no presentan diferencias
significativa.
© Alfa Laval Slide 13
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Control de la disolución de oxígeno
© Alfa Laval Source: Perwine, Inra www.alfalaval.com
Slide 14
Dosificación de aditivos Adición de nitrógeno en puntos claves
N2
Moderador
Notas de la presentación
In addition, it was possible to identify the critical points of the machine in terms of oxygen entrance. The protocol integrates different point of N2 injection on the module and sensors of oxygen pick up in the inlet and outlet of the equipment. Therefore, the trials were aimed to operate in a more inert atmosphere, by nitrogen injection. As an alternative, it is possible to inject antioxidant additives continuously on the mash. The system We compared the quantity of caftaric acid in the juice after the operation with a witness of must extracted in laboratory under anoxic conditions. Adjusting the doses of SO2 or combination of antioxidant such as ascorbic acid etc, we could demonstrate the high efficiency of antioxidant dosing and evaluate easily the adequate quantity for an optimal protection.
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Extracción y clarificación simultanea Beneficios operativos y sostenibilidad
© Alfa Laval www.alfalaval.com
Foodec Centrifuge con respecto a prensado y clarificación tradicional
• Reducción del 80% del tiempo para ir a fermentar
• Reducción del consumo de agua para proceso y lavado hasta el 86%
• Reducción del espacio de mas del 70%
• Eliminación del desfangado y de la flotación
• Reducción a un mínimo de las lías y de los fondos con eliminación de
tierra de filtración, riesgo por la salud y vertido
• Gasto energético comparable
Moderador
Notas de la presentación
After making some attempts to obtain detailed information on the resources from wineries and equipment suppliers it became apparent that detailed analyses would be problematic. We choose to analyze the process in one winery (Teanum, Italy) using traditional technology and decanter technology on equivalent line producing 7000 T/year of mash. We compared the innovative line with traditional way including pneumatic press, continuous flotation and vacuum filter for the tank bottoms treatment. Two significant critical points have been identified : Water consumption is drastically reduced, thanks to the number of cleaning cycle and needs. A press works in batch and typically will be cleaned three time a day. A vacuum filter needs process water which represent half of the yearly consumption. Second point is still related to the filter, by avoiding the production of tank bottoms, we can eliminate the filter and the aids consumption which represents 10 T a year for 70 000 hl of mash, and the consequences related (health risk and needs for transportation and disposal) In term of energy the balance is similar. Decanter electrical consumption is equal to the addition of the different equipment (press, flotation, filter). It becomes attractive if the winery used cold settling for clarification. In that case the calories consumption represents 320 Mcal/day saved for 7000 T/year capacity.
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Sumando beneficios, se consigue reducir el coste de la producción del mosto hasta el 30%
© Alfa Laval www.alfalaval.com Slide 16
Technology
Food
ec
Cen
trifu
ge li
ne
Trad
ition
al w
ay
PRO
CES
S
Crushed grapes production (T/year) 7000
Yield after extraction (%) 78%
Yield after clarification (%) 78% 76%
Juice production (hl/year) 54600 53508
CAPE
X
Total equipment cost (€) 325000 245000
Amortization (year) 7 7
TOTAL CAPEX (€/year) 46429 35000
OPE
X
Enzymes (€/year) 7000 7000
Clarifier additives (€/year) 9975 4281
Tank bottom recovery cost (€/year) 0 12938
Electricity cost (€/year) 936 874
Cleaning and process water cost (€/year) 881 6324
Nitrogen (€/year) 737 241
Manhour cost (€/year) 25272 67392
Maintenance cost (€/year) 5000 3000
TOTAL OPEX (€/year) 49802 101809
Extraction cost (€/hl) 1,76 2,56
Extracción y clarificación simultanea Beneficios económicos
Moderador
Notas de la presentación
Economically, juice expression is a complex trade-off between quality and productivity that will vary between wine companies depending on their range and grades of products and other specific circumstances. Capital and operating cost information and juice and wine value at different points in production, of sufficient accuracy is very difficult to be obtained. We tried to adapt from a general discussion to an individual company with its specific circumstances with data given by Teanum winery in Italy and use same time of amortization. The new line presented a higher CAPEX compared to the sum of press equipment and flotation system and filter for tanks bottoms when we talk about a new investment for both cases. When it comes to Operating cost, we identified three main critical items for traditional way : cost for tank bottoms recovery (including aids, process water, cost of disposal), water consumption and consequently cost, and man-hour needs. Reporting the total cost of the pre fermentary steps by hectoliters of juice recovered, the new process line shows a reduction of 30%. Another exercise can be done by evaluate the juice quality and quantity. In this comparison we have an increase of juice recovered by 3,5% volume. In terms of quality, another perspective is open. Several fermentation tests were carried out with musts obtained from Decanter, both at industrial and lab level, in comparison with standard press must fractions (drain juice to 0,2 bar pressure and press juice from 0,2 to 0,9 bars) with clarification by flotation. It has been demonstrated that aromatic profile of wine obtained with this process is quite similar to the first juice presses. The phenolic content is higher compared to drain juice and in the standard compared to press juice and mineral and acidic extraction as well as conductivity and pH at the same level as for the drain juice. An economical analyze could be done case by case to estimate the extra value of the unique fraction obtained with this process. Data regarding the quality will be the object of a next publication.
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Foodec Centrifuge. Conclusiones
© Alfa Laval Slide 17
1. Reduce en un 80% el tiempo de extracción y clarificación del mosto. Aumenta entonces la capacidad de recepción de la uva;
2. Simplifica el manejo de todas las operaciones de extracción y clarificación con una única categoría de mosto de calidad;
3. Reduce las operaciones unitarias eliminando las tecnologías para la clarificación del mosto y la recuperación de los mismo de los fondos;
4. Hace mas sostenible el proceso en la bodega al reducir gastos de agua, energia y de tierra de filtración.
Moderador
Notas de la presentación
High yield of high value juice Extremely low solids content in the juice No more need for setting the correct division of juice fraction between «free run» and «pressings» Continuous throughput at relevant capacity (flexible to turndown capacity) Hold-up volume & time minimized; no dead time for unproductive operations (ie crumbling) Screw press can be used to max the total juice yield Very small footprint vs traditional method No more juice bottom and flitration aids
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Publicaciones • Ferrarini R., Rapilly C., Franzoso M. 2014. Plant and process for obtaining clear must from grapes
and for vinification. International Alfa Laval Patent. PCT 104125.
• Ferrarini R. et al., 2014. Alfa Laval Foodec Centrifuge: a revolutionary process for must separation. World Congress of Vine and Wine. November 9th -14th 2014 Mendoza (Argentina)
• Duquene et al., 2014. Positionnement du décanteur centrifuge en vinification en blanc et rosé. Revue Française d’Œnologie
• Ferrarini R. et al., 2015. Development and study of a new Decanter technology on the grape juice extraction and clarification. 66th ASEV National Conference June 15–18, 2015 Portland, Oregon USA.
• Rapilly C. et al., 2015. Présentation d’un nouveau procédé permettant l’extraction et la clarification simultanée des moûts. Revue Française d’Œnologie.
• Salmon J.M. et al., 2015. The centrifuge decanter: an innovative equipment for continuous must extraction for the elaboration of quality white and rosé wines. Enoforum.
• Nicolis E., 2015. Studio e sviluppo di un innovativo processo per l’estrazione e l’illimpidimento dei mosti. Enoforum .
• D’Andrea E. et al., 2015. La produzione in continuo di mosti limpidi. VQ - Vite Vino & Qualità.
• Guantieri V. et al., 2016. New process for production and simultaneous clarification of grape juice. 5th Oenoviti Symposium, Bordeaux 10th May 2016.
© Alfa Laval Slide 18
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Reconocimientos Foodec Centrifuge para extracción y clarificación simultanea de mosto ha obtenido el
© Alfa Laval Slide 19
Technological Innovation Haward 2015
Mención especial:
“Innovation Challenge - Lucio Mastroberardino“
Primer premio a la Mejor Investigación en enología Año 2016 - Assoenologi
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