Technology/IT | IDM
8 2017 | international-dairy.com · 31
Computer analysis shows how pressure-resistant LifeTec filters are because of their
special liners (fig.: Donaldson)
At drinktec, Donaldson will introduce a
new range of high-capacity sterile filters
for aseptic processes (photo: Donaldson)
highly resistant polypropylene. It encloses
the actual filter medium and provides the
necessary support for the pressure stability
required. A rhomboid structure ensures that
the compartments, in comparison to the
conventional square structure, are considerably
more stable when exposed to shock
and resistant to torsion – which makes unintentional
damage of the filters during installation
and removal almost impossible and
extends the service life of the filters.
Different filter media made of PP, PTFE or
PES are available, these depth and membrane
filters are selected appropriately, depending on
the purpose of use. The retention rates range
between 0.2 μm and 100 μm. With a total of
seven connections, the LifeTec filters fit in existing
standard housings. In addition, the user also
benefits from a lower pressure loss: It is possible
to either save energy for generating pressure or
use less filters in an accordingly smaller housing.
High throughput
According to Löbbert, the LifeTec filters are
characterized by good retention and, in particular,
high flow rates at a defined pressure drop
as well, which, in the LifeTec PES WN model,
means (in specific numbers) 17 litres/min at
100 mbar and a lower retention rate of 0.2 μm.
The permissible components according to EC
and FDA standards withstand more than 100
sterilization cycles, are regenerable, come with
comprehensive documentation and are 100 %
tested for their integrity as membrane filters.
In addition the filters are always individualized
and can be unambiguously traced via their
QR code or bar code. In addition to facilitating
handling, these codes allow the staff in the
dairy operations to convey all necessary information
to a database. One scan during installation
or removal is sufficient for this.
In dairies, LifeTec filters are installed in the
water area, e.g. for processing, rinsing and
CIP or ingredients water. They can also be
used for whey filtration.
Fast delivery
Whereas in the past it took six to eight
weeks for a defective filter or a filter which
is no longer regenerable to be replaced by a
new filter, Donaldson can now perform the
delivery of the replacement within a few
days. Considering that fewer companies can
afford costly storage of parts, this is naturally
an enormous relief.
This becomes possible thanks to a new production,
which is organized in the so-called single
piece flow. Peter Schaaf, Plant Manager of
Donaldson in Haan: "We received a great deal
of inspiration from automotive industry. The
production is carried out in such a way that
we also can produce small quantities rapidly
and efficiently. The basis of the entire operation
is an IT-controlled flow of parts organized
according to the Kanban principle; the components
are incorporated and immediately
individualized for manufactured components.
These components then directly undergo the
integrity tests in production." Donaldson does
not maintain a significant inventory of the
LifeTec filters, but produces them according
to the orders from the customer.
René Stoffels, the Production Manager, who
designed and started the new production of
LifeTec, explains the principle of the processes:
"The manufacturing of the LifeTec components
is carried out in a Category 7 clean room
starting with a pleating machine, which combines
the support and filter medium layers.
The liners manufactured by a third party are
provided with a QR code, from this point on
the components are then individual production
items. After several work steps, the individual
components are configured according to the
order in the above-mentioned sizes, connected
firmly to one another and prepared for the
tests. These take place in a self-constructed
line in the throughput processes and no longer
in batch processes as was done previously."
Donaldson provides insights into the processes
of LifeTec production in a YouTube video.
According to Schaaf, customers are welcome
to visit the plant, because: "We produce components
for sensitive food manufacturing sectors,
because transparency is a top priority for us!"
New to drinktec:
Sterile air filter
Donaldson will present a new range of sterile
air filters for aseptic applications at the
drinktec trade fair. The (P) series operates at
a separating limit from 0.003 μm with a very
low Delta P. It is resistant to ozone and H2O2
VPHP and it is stable at temperatures of up
to 200°C. This gives the user a high degree of
flexibility in terms of plant design. In the case
of bacteria and viruses, the filters provide an
LRV > 9. For nanoscale particle even retention
values of >10 have been measured.
According to Donaldson, this makes the
(P) series superior to comparable filters by
a factor of 500. The filters of the (P)-SRF X
and V series are resistant to aerosolized CIP
chemicals in tank ventilations.