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Feature article: ZETA's integrated approach is inspiring the food industry

13. September 2021 by Andreas Pompenig Automation, Biotech, Feature article, Process Expertise

From process development to fully automated plants

ZETA has profound expertise in process engineering and in-depth product know-how in the food industry. The company has established itself as a strong industry specialist in various food segments with numerous successful projects and satisfied customers.

ZETA experts draw on decades of experience in the fruit processing industry, aroma production and biotechnological food production. Whether it is batch systems or continuous process lines, at ZETA, the focus is on ensuring aseptic process management and all quality-relevant product parameters.

Efficient heating and cooling systems, homogeneous mixing and low product losses when changing recipes play a major role in the planning of these process systems.

Hygienic design and the ability to clean easily go hand in hand with a high level of user-friendliness - of course in compliance with all national and international regulations, safety and hygiene guidelines.

ZETA experts draw on decades of experience in the fruit processing industry.

Technical challenges in product manufacturing?

The right solution will be found in the ZETA TechCenter!

Many years of experience and proven engineering competence make ZETA a sought-after contact for companies in the food industry, for example, when it comes to procedural challenges in manufacturing or processing. ZETA experts work in close cooperation with the customer to create suitable solutions. Looking for the best technical solution to admix a powder that is difficult to wet, a producer of high-quality dietary supplements contacted ZETA engineers.

The new customer from Germany was already heavily involved in a feasibility study in the ZETA TechCenter and was soon convinced of ZETA's professionalism. The problem: Collagen hydrolysate should be mixed into water as a hard-to-wet powder and brought into solution, with minimum formation of dust, lumps and foam. ZETA took on the preparation of the test series as well as the organization of equipment and material. Original raw materials were used. On the basis of a YTRON powder dispersion system, a technical solution was developed that more than met the customer's requirements for product quality in the test.

The success of the feasibility study prompted the customer to commission ZETA with implementation for industrial production. This included the service package from engineering, production and automation of the entire preparation system. In addition, the system was commissioned by trained ZETA engineers.

Contact Alexander Lausecker - Head of Sales Area Eastern Europe

The time from project start to commissioning was just 12 months. From the preliminary tests in the Innolab "TechCenter ZETA" to achieve the desired product quality to the finished plant - ZETA offers an integrated approach that focuses on the customer's needs at all times.

Ansprechpartner: Alexander Lausecker
Head of Sales

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High-value engineering, construction and automation of the entire system by ZETA

A nutritional supplement with positive effects for skin health is produced and bottled on the preparation system. The preparation system consists of a process container with a working volume of 1000 L and, in addition to the powder feed, also includes a pasteurization unit. A CIP system ensures the ability to clean. The customer wanted a fully functional, easy-to-use and safe system - these expectations were met to the fullest satisfaction by the ZETA team.

Complete automation of the plant

ZETA's integrated approach to project implementation included process development, engineering and plant construction as well as the complete automation of the plant. A suitable automation concept was created, which enables maximum flexibility and multi-user use with the generation of different production processes for different products. The system is extremely user-friendly, and recipes are created in a simple and well-structured manner.

The ZETA team was able to prove its ability to react appropriately and flexibly to unforeseen situations during the commissioning of the system. Travel restrictions due to the Covid-19 pandemic prevented the customer from being present on site. In order to be able to commission the system on time, ZETA engineers managed the customer's team remotely. They provided special software and a camera system for remote commissioning. Special situations require innovative solutions: The partner in Germany equipped with video eyeglasses was, so to speak, the eyes and hands for the ZETA team in Graz and was guided step by step through the commissioning process.

ZETA's integrated approach leads to maximum customer satisfaction

The time from the start of the project to the commissioning of the system was only 12 months. The implementation of the project was characterized by excellent cooperation with the customer, in which the ZETA team carefully addressed all individual customer requirements. From the preliminary tests in the ZETA TechCenter to achieve the desired product quality through to the finished system - ZETA offers an integrated approach in which process development, value engineering for the design of a highly efficient system, its production and its automation come from a single source. The result is maximum customer satisfaction.