PROCESSING MACHINERY

(It all starts with excellent processing! )

TURNKEY PROJECTS

1. Puffed food (corn snacks) processing line (Double screw Extruder Inflating Snacks Food Processing Line)

Double screw extruder inflating snacks food processing line is foodstuff manufacturing equipment researched and developed on the basis of international advanced technology.

The performance and quality have reached the highest international level of the same line. From feeding materials, extruding & inflating, drying, flavouring to finished products are done one time with automation. We fill the gap of first-class food produced with extruded and inflated technology.

This processing line can produce all kinds of inflating foodstuffs, rice bread, rolling smacks, crackers, gruels, nutrient flour, and so on.

This processing line can be used to produce many kinds of shapes such as round balls, rings, flowers, heart shapes, starts, animals, alphabetic ABC or nos. 123, etc.

Output 120-150kg/h
Raw materials Rice powder, corn powder, millet powder, wheat flour, oats, buck wheat, beans, starch, etc

Main features:
a) Stable performance: adopting imported frequency or electromagnetic controlling system, high automation and smooth operation.
b) Long working life span: manufactured with special materials and technology.
Flow chart: Mixing – extruding – drying – flavouring

Installation: We will send our engineers to the buyer’s factory for a 10-day period installation and training to the operators. There is no fee for installation; all related expenses (electric accessories) will be on the buyer’s account.

List of equipments
No. Equipment Power Technical parameter Quantity
1 Flour mixer 4kw Output: 40kg/7min
Dimension: 1100x750x1300mm 1set
2 Screw conveyor 1.1kw Capacity: 100kg/h-300 kg/h
Dimension: 2000x550x2300mm 1set
3 LT65Double screw extruder Power : 36KW Main motor:22kw
Heating power:12kw
Feed motor:0.75kw
Cutting motor:0.75kw
Oil pump: 0.37kw Capacity:120-150kg/h;
Size: 3100*950*1850mm 1set
4 Air Conveyor 0.75kw Size:-1400*450*1900mm 1set
5 Three-layer dryer 27.75kw 3layer, Electric type 30kw, driving: 0.75kw, 5000x1300x1900mm 1set
9 Auto flavoring line Total power :2kw Electric power source :380V,50HZ
Conveyer:0.37kw
Trum:1.1kw
Capacity: 100-300kg/h;
Size: 5000x1500x12500mm 1set

2. Milk Processing

(a) Liquid milk processing
Milk is widely considered as one of the world's most valuable protein food. As a raw material, it is available in various forms, and it is processed into an ever increasing variety of nutritional products. Gte Ltd offers Dairy plants that include small milk processing equipments for handling milk in liter capacity of 1000 to 5000 litres per day. A number of products like ghee, butter, cream, toned milk, double toned milk and skimmed milk can also be manufactured. Milk is first received in a dump tank from the road milk tankers. It is then chilled in a chilling unit to 4ºC. This chilled milk is then pasteurized in a milk pasteurizer and cream is separated from milk in by the cream separator to get skimmed milk. Milk is standardized depending on the requirement of toned milk, double toned milk, skimmed milk or full cream milk. The separated cream is further processed to manufacture ghee and butter. The pasteurized skimmed milk, toned milk or double toned milk is sent for packing in pouches in the packing machine for various capacities like ½ kg, 1 kg pouches. The plant will be in operation for 20 hours in a day.

(b) Milk powder plant
Milk Powder is a processed dairy product made by evaporating milk to dryness. Drying extends the shelf life of milk apart from reducing the weight and volume and lowers the cost of transportation also. The initial solid in the milk varies from 7.5% to 12% depending upon type of milk and the final moisture in the powder, ranges between 2.5% and 5%. Since drying is an energy intensive process, Gte Ltd offers the solution to make the process energy efficient & cost effective.

Milk Powder Plant Consist Of:
· Multistage Evaporator
· Two/Three Stage Dryer

Process Discription
Milk is concentrated up to 45-48% solid concentration in Multiple Effects Falling Film Evaporator with TVR/MVR System. Evaporation of water takes place under vacuum conditions and at low temperature. A Five Effect Falling Film Evaporator with TVR over 3rd effect will have specific steam consumption of 0.12 kg/kg whereas a seven effect plant with TVR over 4th effect gives specific steam consumption of 0.09 kg/kg which is equivalent to energy consumption in MVR evaporator.

During drying in spray dryer, the excess water present in free form between the particles of the dry solids gets evaporated easily. Whereas last stage of evaporation demands more energy as water contained in pores and capillaries of the solid particles need to be evaporated. These last drops of water are removed from milk solid in a Vibro Fluid Bed Dryer which requires less energy for removal of balance moisture.

The combination of multiple effect evaporators, spray dryer with fines recirculation system and use of a 'Vibro Fluid Bed Dryer', produces instant quality powder.

Lecithination System
We also offer lecithination system integrated with the milk powder plant to manufacture whole milk powder. Addition of lecithine produces instant quality WMP.

Gte Ltd supplies energy efficient plants which produce instant powder of highest quality.

Quality Parameter of Milk Powder

 Unique Features of Power Plant
· Low Power Consumption
· Maintenance Free Design
· Lower  T ensures Gentle heat treatment of product
· PLC Operator Plant available with 100% Automation
· Production of INSTANT QUALITY POWDER
· Flexibility in Controlling Powder Quality
· WINCH driven special CLEANING Lift
· Negligible DEPOSITION of Powder in Chamber
· Less DOWNTIME for Maintenance
· EXPANDABLE up to 100% Capacity
Sweetened Condensed Milk Plant
Sweetened Condensed Milk Plant is basically concentrated milk to which sugar has been added. The high sugar concentration in sweetened condensed milk destroys majority of micro - organism. It can be made either from whole milk or skim milk. Normally it contains 9% Fat, 43% Sugar, 22% SNF and 26% Moisture and is packed in 397gm tins or in barrels for industrial use.

The manufacturing process consists of the following stages
· Standardization
· Sugar Addition
· Evaporation
· Cooling
· Lactose Seeding and Crystallization
· Packaging in sterilized Cans
· Storage.

Process
To manufacture sweetened condensed milk the pasteurized milk with added sugar syrup is taken to the evaporator and concentrated to desired level of concentration. The product is then cooled in such a way that lactose forms very small crystals in the supersaturated solution. After cooling & crystallization the sweetened condensed milk is packed in pre-sterilized cans or in barrels.

Evaporated Milk Plant
Evaporated Milk is a sterilized product. The product has a large market in tropical countries. It is used where fresh milk is not available. It is also used in cooking and as a Coffee/Tea Whitener.

Process
The manufacturing process for the evaporated milk involves precision standardization of the fat content and the dry solids contents. This is followed by heat treatment which partly destroys the microbes present in the milk. The heat treated milk is then fed to an evaporator, where it is concentrated up to 26% (8% Fat and 18% SNF). The milk is then homogenized (homogenizer) before being cooled. Checks are carried out on the coagulation stability of the milk before it is packaged in the sterilized cans. The product is then placed in an autoclave for sterilization. Finally the cans are cooled before storage.

The different stages in the production of evaporated milk are:
· Standardization
· Evaporation
· Homogenization through homogenizer
· Cooling & Inspection
· Packaging
· Sterilization
· Cooling
· Storage.

Malted Milk Plant
Malted Milk is a powdered food product made from mixing of standardized milk, malt extract with wheat flour, and cereal grains in such manner as to secure complete hydrolysis of the starchy material, which is evaporated until it forms a high viscous solution which is then dried in a Vacuum Tray Dryer / Vacuum Band Dryer.

The manufacturing process consists of the following stages
· Blending of ingredients like malt extract, milk or milk powder, grain flour etc in required proportion.
· Concentration of the slurry in evaporator.
· Vacuum Drying of the concentrate.
· Pulverization of the dried product.
· Packaging of malted food.
· Storage.

Casein & Whey Processing Plant
Whey comprises of 80-90% of the total volume of milk entering in the cheese making and casein manufacturing. Whey contains soluble proteins, lactose, vitamins & minerals.

Sweet whey is produced when cheese or casein is precipitated by rennet. Acid whey is produced when mineral acid is used to precipitate cheese or casein.

Soy milk Plant
Soy milk and its related food products are getting popular throughout the world due to their nutritional and medicinal qualities.

Soy milk is high in protein and low in fat and carbohydrate and contains no cholesterol.

Soy milk is an excellent food for babies, children and the elderly people including pregnant and lactating women as it contains vegetable protein that is very easy to digest.

Continous Soy Milk Plant
The plant has been designed for handling 100 liters of Soy milk per hour from 15 kg/hr Soybeans.
The plant is a skid mounted one and requires only 15 sqm area. Only one skilled operator and one helper are sufficient to operate the plant.

Okara Dryer
Okara is the residual fibers after extraction of milk from soy bean. It contains about 80% moisture and can be dried by a drying system to get dried product with 4%-12% moisture content.

The dried Okara can be used as a source of good fibre and can be used in making Biscuits, Sweets.

Tofu (Soy Paneer)
Tofu can be made by acidification of Soy Milk by use of lactic acid. The paneer obtained is washed and pressed to get Tofu.

Tofu can be packed in vacuum packages to extend its life upto one month.

Flavoured Soy Milk
Soy milk can be formulated by addition of sugar and flavour to produce flavoured soy milk. Varieties of flavours like Chocolate, Vanilla, Coffee, etc. can be used to produce tasty flavoured soy milk drink. The flavoured Soy milk produced can be sterilized in a sterilizer and can be marketed. The life of sterilized soy milk will be six months.

Soy Milk Powder Plant
Gte Ltd also offers suitable multiple effect Evaporator to concentrate soy milk upto 22% followed by Spray Dryer for manufacture of Soy milk powder.

Instant Soy milk powder can be made by addition of lecithination system along with Spray Dryer.

Technology
Gte Ltd has invested in advanced training to promote knowledge in the area of technical development, research and production, creating preconditions for innovations. Thus Customers are assured that Gte Ltd will respond to their specific needs in a quick and reliable manner.

Hi-energy efficiency and Hi-purity exhaust process developed by Gte Ltd have helped to reduce the load over nature. Gte Ltd guarantees that all matters relating to your project will be taken into consideration to ensure tailor-made solutions suited to your needs.

Services
Gte Ltd aims at achieving Complete Customers Satisfaction. We assume responsibility not only for the supply of equipment but also for installation and commissioning. We provide training to your plant operators and make them understand Do's and Don'ts regarding all aspects of process and machinery. We act as procurement office for spare parts and undertake everything needed for successful operation of dairy plants.

3. Fruits & vegetable processing projects
Fruit Juice, Pulp & Concentration Plants
The study, design & manufacturing of these processing lines are the result of many years of efforts devoted to research of processing methods focused on preserving organoleptic, physical and aromatic characteristics of the processed fruit in order to produce a juice of high quality in color and clearness.

Fresh juices are best in taste and colour and are best to be consumed fresh. The efforts to preserve them and to ensure their quality, various techniques are to be adopted. This includes various process and preservation methods. The most important aspect is to ensure such methods which helps to retain these properties to the maximum extent.

Gte Ltd offers complete lines for fruit processing and concentration. These plants are for processing of fruits like mango, orange, apple, pears, etc. and for making juice concentration, paste, jam, jelly, ketchup, etc.
The plant size ranges between 1 Ton/day to 200 Ton/day or even more depending on availability of fruits.

The most important steps involved in processing of juices and beverages are:
· Selection and preparation of fruits
· Extraction of Juices
· Straining, Filtration and clarification
· Blending Pasteurisation.
· Filling, Sealing and sterilization
· Cooling, Labelling and Packing
For Juice Concentration, vacuum evaporation is another step in fruit processing line. The final concentrate can be filled in aseptic bags in drums for export purposes.

Clear Juices can be formulated, blended and spray dried at best conditions to convert them into readily soluble powders.

Gte Ltd offers multiple fruit processing plants for production of juices / pulps.
· Apple, Pineapple
· Mango
· Tomato
· Papaya
· Guava
· Berry
· Grapes
· Oranges
· Lemon

Multi Fruit Processing Line

Reconstitution plant for - Juice, Ketchup & Puree
For economic transportation of fruit Juice concentrates and reduction of volume, two thirds of the water from juice is extracted through evaporation process and the resultant concentrate is transported to factories, where the same amount of water or vitamin contents that was extracted before, is again added back or reconstituted. The process is called the Fruit Juice Reconstitution System.

Unloading of paste from aseptic drums into a tank with an agitator

This is the transfer of paste to a formulation tank where the other ingredients are added for dilution.

The formulation can be done for tomato juice, puree and ketchup. For juice and puree, the dilution will take place in the formulation tanks and passes through the pasteurizer before filling and packing is done.

For ketchup preparation, sugar desolation and other ingredients will take place in separate tank. These ingredients are pumped to the blending tanks which have been filled with the paste. Heat is supplied through steam in the Jacket and all the ingredients are processed to confirm the ketchup requirements. The formulated ketchup is then pasteurized and packed into paper packet or glass bottles.

Fruit Juice powder plant
Converting Juice into powder can be a solution for long shelf life and easy packing and transportation.

Gte Ltd offers juice powder processing plants of various capacities to suit the client requirements.

Tomato processing plant For Manufacturing Tomato Ketchup/Puree/Paste
Gte Ltd offers complete process line on turnkey basis to produce the following end products from tomatoes. Tomato processing plant gives variety of tomato based dishes which you can enjoy any time.
· Tomato Puree from tomato processing plant
· Tomato Paste from tomato paste processing plant
· Tomato Ketchup/Sauces from tomato ketchup puree plant
· Tomato Juices from tomato juice processing plant
Packing lines can be offered depending upon the requirement like Product in glass bottles, Cans, Drums, etc. Manufacturing process involves most modern technology of vacuum evaporation using forced circulation evaporators/scrapped surface evaporators. Evaporation plants are versatile in nature and can concentrate other juices also.

Salient Features
· High yield upto 90% of juice
· Low energy cost.
· Low temperature evaporation resulting improved quality of products.
· User friendly.
· Semi automatic and fully automatic systems available.
· Both hot break and cold break systems available.

Vegetable / fruits dehydration plant
In International market, it is surprising but true that agricultural products are not processed and get wasted due to lack of cold storage. Vegetables/fruits can be stored for long time periods provided they are dehydrated to reduce water content. In this way, we can store and export them like ginger, garlic, onion, chilly, etc.

Process Description
A unit has been made to dehydrate vegetables/fruits at low temperature with air re-circulation arrangement. Batch size is approximately 100 kgs. And drying time is about 2-6 hours depending upon types of vegetables.

Batch Size : 40-100 Kgs.
M.O.C. : All product contact parts SS-304
Batch Time : 3-6 hours depending upon moisture to be removed

Specifications
Description Quantity (Kgs) Time (Hours)
Cauliflower 100 8
Spinach 40 6
Chilli Coriander 40 4-5
Fenugreek Leaves 40 3
Cabbage 40 6
Green Mango 50 6-8

Plant and Machinery
1. Electric Heater : 1 Set (12 KW)
2. No. of Blowers (0.5 KW) : 2 Nos
3. No. of Trays : 12 trays (600 x 800 mm)
(2 columns, 6 trays in each column)

Infrastructure & Facilities
Space : 1.8 x 1.2. x 1.2.m
Manpower : 2
Electric Load : 13 KW

Coconut milk processing plant
A large number of products can be manufactured from coconut. Desiccated coconut, coconut cream, Coconut milk and spray dried Coconut milk powder has a good market not only in Asia but also in Africa and other continents. Fresh coconut water, coconut water concentrate and coconut vinegar are also used extensively.

Desiccated coconut is supplied in small and bulk quantity. Deflated desiccated coconut is also in demand for various food preparations.

Coconut cream and coconut milk finds its application in various food preparations as a substitute to milk. Milk is extracted from raw kernel in tradition methods. Then it can be made available in cans and ascetic packages.

Spray dried coconut milk powder has advantage of long shelf life, less storage places required and lower cost of bulk packing.
Instant coconut milk powder, desiccated coconut powder along with vinegar from coconut water is a highly feasible project.

Unique design ensures
· High product quality.
· Compact design.
· Easy operation and automatic control.
· Minimum manpower required.
· Low operation cost.
· Low and high fat powder.

3. Other Processing Projects
Instant coffee plant
Coffee
Coffee is a brewed beverage prepared from roasted seeds, commonly called coffee beans of the coffee plant. Due to its caffeine content, coffee has a stimulating effect in humans. Today, coffee is one of the most popular beverages worldwide. Approximately 90% of world coffee production is represented by the species Coffea arabica; about 9% by the species Coffea Robusta; with minor production from the species Coffea libericia. Most processed coffee available in the market is differentiated in terms of aroma, blend and flavour which comes from the way it is processed. Processing coffee to a perfect blend and taste is an art and requires excellent techniques of extraction, roasting, concentration, aroma recovery, spray drying and agglomeration.

Gte Ltd has supplied coffee extractors, instant coffee powder plants, aroma recovery systems, evaporators, spray dryers and agglomerator to quite a large number of instant coffee manufacturers in Africa and the systems are running successfully. With core competency lying in the field of evaporation and drying technology, Gte ltd has collaborated with leading manufacturers of green coffee cleaning, blending, roasting and grinding equipment manufacturers to supply instant coffee plants on turnkey basis. We have also collaborated with leading companies for supply of continuous freeze drying equipment for production of freeze dried coffee. Coffee produced from our plants have excellent aroma due to our extensive knowledge and experience on coffee. Gte Ltd offers the most energy efficient soluble coffee processing technology and is in a position to supply upto 15TPD instant coffee production plant. Coffee plants with smaller capacities are also available e.g. 50 kg/hr, 100 kg/hr, 150 kg/hr, 200 kg/hr, 250 kg/hr of instant powder production capacities. Gte Ltd has already designed, engineered and supplied a few complete plant on turnkey basis and is negotiating for more.

The process in brief:
1. Cleaning & blending of green coffee
The first step is thorough cleaning of defective beans and separation of nails, stones, dirt & dusts. Blending of beans is carried out before roasting by installing volumetric feeders at the outlet of the silos. Through this process various kinds of blends are obtained depending on the taste and demand of the market.


Roasting of coffee beans develops the flavor and aroma which depends on various physical & chemical changes which occur during roasting. Degree of roast & roasting temperatures are very important and plays an important role in deciding the flavor and colour of the final product..

Green coffee cleaning

2. Roasting & grinding of green coffee
The third step is extraction of ground coffee through a continuous process in a pressurized vessel with hot water. To get a better yield seven batteries of counter column extractor cell is used featuring extraction under closely controlled system. Extraction is greatly influenced by factors like type of green coffee beans, degree of roast, type of grind, ratio of coffee to water & mode of heat input.

Coffee extraction

3. Clarification system
The extracted coffee solution is passed through a centrifugal clarifier to separate the insoluble solids.

Clarification unit
4. Aroma recovery cum concentration system (ARC system)

This is done after clarification extracted coffee liquor is passed through the aroma recovery cum evaporation plant. In the plant, the volatile aroma is stripped off from the coffee before it enters the evaporator. Based on the boiling points of the aroma constituents Gte Ltd has developed a new technology for the extraction of this aroma without diluting them with the water vapours so the result is more pure and concentrated aroma. This technology is called the ARC System which stands for AROMA RECOVERY CUM CONCENTRATION SYSTEM which is integrated with the evaporation system. In the evaporator concentration of the extract is done through multi-effect evaporators with TVR systems for concentration up to 50-55%. It is possible to concentrate the extract further up to 65-70%, to reduce the load on freeze drying system.

Aroma recovery unit

5. Coffee concentration
the next step is concentration of the extract through multi-effect evaporators with tvr systems upto 50% concentration is achieved.

Evaporation section - Part 2 calandrm section

7. Spray drying system
the concentrated coffee is then converted to instant coffee powder by spray drying. Drying is done under controlled conditions to protect and preserve aroma and flavor in the coffee.

Spray drying section

8. Agglomeration system

Lastly, the Spray dried powder can be converted into soluble (instant) granules in an agglomerator tower by Re-wet agglomeration technique. This technique results in the formation of bigger sized porous particles and reduces the bulk density thereby increasing the instant ability of the powder. Hence when a spoon of this agglomerated powder is put in water, it disperses completely due to the osmotic pressure of the liquid.

Agglomeration section
9. Packing & filling

The instant coffee powder is then taken to the tote-bins for storage and packing. For filling into tins or jars, vacuum operated filling system is used. For filling into sachets, a form fill-sealing machine is used. The filled containers/flexible packing are packed in the shipping cartons and sent for dispatch to the finished goods warehouse.

Unique features of instant coffee plants
• integrated evaporation and aroma recovery system, both of which can be controlled from one plc.
• saves lot of energy as pre-heating is carried out with generated vapours in the evaporator.
• the system provides aroma at a higher concentration and is not diluted with water vapours.
• availability of concentrated aroma allows higher concentration feed to spray dryer, which increases productivity.
• unique agglomerator design ensures stronger particle with less fines.
• aroma recovery system consists of rotating stripper column which makes it sturdy and easier to handle.
• evaporators are most energy efficient. In a 5 effect plant with tvr the specific steam consumption is 0.12 kg/kg, i.e., 1 kg of steam evaporates 8 kgs of water.
• flexibility in agglomerator for obtaining required bulk density

unique evaporator design ensures:
• highest energy efficiency.
• high product quality.
• compact design.
• easy operation & automatic control.
• low operation cost.


Unique spray dryer design ensures:

· Flexibility in controlling powder quality and production of instant powder.
· Less down time for maintenance purposes.
· Possibility of expanding capacity upto 100%.
· Gte Ltd has supplied more than 50 spray dryers; the biggest one is having a powder output of 38 TPD.
Freeze drying system
Instant coffee powder is usually made by evaporation of coffee extract upto 40-45% concentration by use of an evaporator followed by spray drying at a high temperature (180-220 °C). This results in change in appearance, colour, loss of aroma and taste.

However, use of freeze dryer retains aroma, improves appearance and taste because freeze drying takes place at a low temperature which minimizes heat damage and retains volatile components (aroma). It also increases the shelf life of the dried product as compared to standard drying practices.

Freeze-drying involves dehydration of food products at low temperature and pressure. As a result only the moisture is removed, leaving the molecular structure intact. The end product is light in weight with least or no change in volume. Worldwide freeze-drying technology is considered as the ultimate amongst all other dehydration methods. Hence this technique is currently being used for the production of instant coffee.

In a freeze drying system, concentrated coffee (42-45%), is first freezed and then exposed to a low partial pressure (4.6 mmHg) of water vapour when ice sublimes directly to vapour leaving behind dried coffee.

Freeze drying is an expensive process in terms of capital, expenditure and operating cost but results in excellent product quality.


Freeze drying of coffee involves four steps:
Pre-freezing coffee concentrate up to -5 / -10 °C followed by foaming.
Freezing of the prefreezed coffee liquor at -50 °C in a blast freezer.
Sizing of the freezed coffee particles to a granular size of 3X3mm.
Sublimation of the ice in a vacuum freeze dryer (VFD) under vacuum (0.5 torr) and controlled temperature.

Gte Ltd has developed this technology successfully in their R&D laboratory, where a pilot plant has been set up for demonstration.

Advantages of freeze dryers are:
· Continuous plant, which needs less space.
· Most energy efficient.
· Minimum heat damages, which helps in retaining good appearance and colour of the product.
· Retaining most of the Aroma due to the use of most innovative Aroma recovery.
· Quick and complete re-hydration due to porous structure (Instant)
· Less man power requirement (fully automated)

Instant tea plant
Gte Ltd has designed this plant to manufacture instant quality tea from leaves. Tea Extraction Plant provides a fine quality of tea. The process in tea processing plant includes extraction, separation of waste, evaporation and spray drying.

Plant size can vary from a minimum of 5 kg/hr of instant tea to a very large capacity like 1000 kg/hr.

The plant is made complete in Stainless Steel wherever product is in touch. The space required for a plant of this size is 500 sq. yard.

Fresh Green leaves of the plant Camellia Sinensis is one of the main raw materials for this instant tea production. This type of plant is available throughout the year in abundance.

The Process
· Instant tea is manufactured from black tea by extracting the brew from processed leaves, tea wastes or undried fermented leaves.
· The extract is concentrated under low pressure and dried to powder by any of the processes including freezing, drying, spray-drying and vacuum-drying.
· Low temperatures are used to minimize the loss of flavor and aroma.
Instant green tea is manufactured by similar methods but hot water is used to extract liquor from powdered leaves. Instant tea needs to be stored in airtight containers or bottles, because they absorb moisture very quickly.
Refined iodised salt processing plant

Introduction
Main source of salt is rocks, sea and lakes. Maximum consumption of salt is in its natural form after being produced from sea or directly from rock. But with time, awareness of uses of salt has grown manifold and the demand of refined iodised salt is increasing tremendously during the last few years. Refining not only helps in increasing purity of salt but also improves flow-ability and use of anti-caking agents helps in keeping quality too. During refining and drying process, iodization is done which is important for human body to avoid various diseases. Refined salt is further graded for various applications like kitchen salt, table salt and industrial salt.

Salt refinery is mainly of two types:
· Mechanical Refinery.
· Vacuum Refinery

Mechanical salt refinery
Crude Salt is fed into the feeding hopper of suitable capacity and it is then transferred to a belt conveyor. This belt conveyor will be fitted with a magnet to remove rubbish metal and will also be provided with a belt weigher with totaliser. Crude salt is pre-washed in special washing system. This is then fed to the feed in hopper of the wet mill for grinding. Wet mill is used to grind the salt with the help of saturated brine solution. This mixture is then passed to the slurry tank that is fitted with a slow speed agitator.
This slurry is then pumped through centrifuges, high pressure pump, centrifugal pumps, axial flow pumps, gear pump to the wash tank by a slurry pump, wherein dirt is removed from the slurry. The overflow from the wash tank is collected in a clarifier wherein brine is clarified and re-circulated in the plant. This is then pumped to the hydro cyclone by a slurry pump for thickening of the slurry.

Drying & finished product handling section
The salt crystals from the centrifuge are dried in a Fluid-Bed Dryer. The crystals forms a layer on the perforated sheet present in the drying chamber of the fluid bed dryer and is dried by means of hot air from a thermic fluid air heating/Indirect air heating system. The fines are removed from the exhaust stream in the cyclone separator and are collected separately. Dry salt is from the outlet of the fluid-bed dryer and is passed to the sifter through a bucket elevator. The oversized salt is separated in the sifter and the over sized salt crystals is passed to the pin mill for further grinding and salt is passed to the feed in hopper of the blender wherein free flowing agent is added. This free flowing salt is then sent to the storage silo for packing.

Vacuum refinery
The process involves dissolving of salt in water and making a saturated solution of salt. The saturated brine is pumped out to a brine clarifier, where the insolubles settles at the bottom of the clarifier and clear brine solution is taken to a brine tank. In the brine tank required chemicals are added to precipitate out magnesium and calcium salts present along with the salt. The brine is then filtered and taken to the final brine tank. From this tank saturated brine is fed to the continuous evaporation plant where Crystallization takes place and slurry is pumped out to a concentrate tank. This salt slurry is then pumped to a hydro-cyclone battery to get a slurry concentration up to 50-60%. This slurry is fed to a centrifuge, and from the centrifuge salt cakes with 4-5% moisture comes out. The salt with 4-5% moisture is fed to a fluid bed dryer through a screw conveyor where the iodization is completed.

In the Vibro Fluid Bed Dryer, the salt is fluidized by hot and atmospheric air for drying and cooling the salt. The salt is then taken through a bucket elevator to a sieving machine. The oversize particles are collected and sent for re-dissolving in the final brine tank. To the crystallized salt is then added the free flowing agent in a screw mixer and finally sent to a storage silo.

The salt packaging is done from the silo by a FFS machine in 1 kg. Packs or it can be packed in bags as per requirement.
Honey processing plant
Honey being a biological substance and intended for food & pharmaceutical use needs greater attention in quality and its handling. The moisture content in honey plays an important role in deciding the quality of honey. Honey with more than 20% moisture is thinner in consistency. The moisture content in honey increases due to hygroscopic nature of honey in which the surrounding atmospheric moisture is absorbed by honey. If the moisture content is more than 20% the honey is liable to spoilage due to fermentation & granulation. Considering the present practice of collection, storage & handling of honey under uncontrolled conditions including climatic factors the honey needs processing, reduction of moisture and packing by utmost care to protect the valuable natural properties.

Composition:
Water (Moisture) - 20%
Fructose (Levulose) - 37%
Glucose (Dextrose) - 34%
Sucrose (Non Reducing Sugar) - 5.0%
Total Ash (Minerals) - 0.25%
Acids Organic - 0.20%
Proteins, Amino Acids, etc. - 1.50%
Other ingredients including pollen grains - 1.05%

Brief process description
· Liquification
· Pre-Heating and Straining
· Micro-filtration
· Inactivation of Yeast Cells (Processing)
· Vacuum Evaporation
· Cooling of Honey

Egg processing plant
Eggs are an excellent food containing many essential nutrients. The higher nutrients density of eggs relative to their calorie content makes them excellent food. Two large chicken eggs contains about 12 gms of protein, 1.2 gms of carbohydrate 11 gms of lipids and substantial amount of iron, phosphorous, vitamin A, E, K and most of the B complex vitamins. White portion of the egg contains almost 90% water, but contributes about 50% protein, niacin and riboflavin. Most of the vitamins and minerals are found in egg yolk. The yellow color of egg yolk is due to the presence of xanthophylls pigment.

Process:
Eggs are taken from the cold storage and weighed. Dirty eggs are sent to a washing machine before they are broken. Rotten eggs are removed by candling. Egg breaking can be done manually or by using continuous egg breaking & separation machines. A skilled operator can break 500 to 800 eggs per hour. In case of large handling fully automatic machines are available.

For processing egg whites, efficient separation of egg whites from yolks is of great importance as no yolk must contaminate the whites. Even a small amount of yolk oil in albumen greatly reduces the quality of the product. Modern machines can achieve the limits of yolk oil in egg white to the extent of < 0.02%, which is acceptable.
In the production process of whole-egg or egg-yolk powder, whole eggs/egg yolks are homogenized, filtered to remove membranes and fragments of shell pieces. Pasteurization will be done at 64 to 66°C, with a holding time of 2 to 4 min. This ensures inactivation of most of the microbes such as E. coli and Salmonella which can cause ill health, if not inactivation.

After pasteurization whole eggs (solids content 20 to 27%) or egg yolk (solids content 40 to 48%) are fed to the spray dryer. The drying-air inlet temperature ranges between 150°C and 200°C. Final powder has a moisture content of 2 to 4% and bulk density of 0.3 0.35 g/cm³. The powder is then packed suitably after subsequent cooling.

Coffee Creamer Plant
In some countries non dairy creamer / coffee whitener is used for whitening of coffee or tea.

Non dairy creamer / coffee whitener normally consist of:
· Maltose syrup - 60 to 64.5%
· Corn / Palm Oil - 30.8 to 35%
· Sodium Caseinate - 2.1 to 2.5%
· Emulsifying agent - 0.05%
· Moisture - 2.5%
The final specification of coffee creamer which is instantly soluble free flowing white powder is as under:-
· Moisture - 2.5 to 3.0%
· B.D - 0.35 to 0.5 g/cc
· Mean particle size - 150 µ (micron)
· Solubility index - 0.1 to 0.5

The manufacturing process has the following steps
· Mixing of ingredients
· Homogenization of mixture
· Spray drying

Plant operations
The canisters, stacked in layers on a pallet, are placed on a rotary table that discharges into a downward chute made of twisted metal rods.

The worker can manually place a scoop into each canister as it passes on through the conveyor. The row of cans pass beneath a rotary auger filler set to deposit the correct quantity of coffee. After filling, the canisters pass through a can seamer that applies a metal bottom. This is followed by ink-jet coder that prints the manufacturing date to the metal bottom.

After this, the twister sets the canisters upright on the conveyor that is conveyed to an applicator for plastic overcaps. Side belts move the cans through the unit and the over-caps are fixed on the top portion of the foil membrane. Finally, the cans are delivered to a rotating accumulation table.

Starch, glucose & its derivatives
Starch can be produced from various starch containing materials like maize, cassava / Tapioca roots, potatoes, wheat, rice etc. There are different technologies for each raw material for recovery of starch. Starch is mostly used for industrial purposes

Being a pure renewable natural polymer, starch has many applications, its significance as a polysaccharide being able to breakdown into their monomeric and or oligomeric components leading to production of Dextrose, glucose, fructose, maltose & sorbitol. In fact starch has become an important material for the sweetening industry, which was otherwise relying upon sugar cane and beet sugar.

The most common uses of starch is in the following industries
1. Food industries as glucose, dextrose, fructose, sorbitol, maltodextrin as filler and sweetener
2. Paper industry for sizing, pulp making & surfacing
3. Textile industry for pointing & finishing.
4. Ceramic Industry as binder
5. Adhesive & Abrasive industry as major ingredient.
6. Rubber industry as filler.
Production of Starch from Maize

Production of Starch Saccharides
Malt Extract Plant

Introduction:
Barley Malt & Malt Extract are the products of germination of barley grains & these products are designated as:
1. Food’s malt & Malt Extract.
2. Brewer’s Malt & Malt Extract.
3. Distiller’s Malt & Malt Extract.
Both the products are intermediate rather than final products and are being used as industrial raw material in the following industries:
1. Malted Milk Foods.
2. Breweries & Distilleries.
3. Pharmaceuticals.
4. Bakery & Confectionaries.

Usage
1. Malt & Malt extract are essential ingredients for the manufacture of nutritious foods having high value of vitamins, proteins.
2. Malt is used in beer manufacturing and it is about 85% of the total material used in brewering.
3. Malt has got its use in distillery industry and this incorporated it at a level of 10 to 15% of total starch bearing materials.
4. Malt extract syrup which is as product made out of malt, finds use in number of food, pharmaceuticals, bakery and biscuit manufacturing industries.
5. Malt extract powder is the new R&D development and can be used easily for almost all applications of malt.

Salient features:
· Low operation cost.
· Short residence time.
· Easy Cleaning due to absence of fouling and hygienic construction.
· Continuous Production without product hold up.
Spirulina Algae Powder Plant
Spirulina is one of the most balanced and the most digestible plant protein source. It contains various types of nutrients, vitamins and minerals which acts as an excellent source of healthy and nutritious diet.

Therefore it is used as a food supplement and as a treatment for malnutrition. Beside this, spirulina algae powder is widely used for various commercial and industrial purposes. To cater the needs of several food processing and commercial industries, we design, manufacture and implement spirulina algae powder plants at affordable prices.

Manufacturing process of spirulina algae powder
to manufacture high-grade spirulina algae powder, many steps are required to be implemented which comprise:

1. Growing:
as a first step, spirulina algae are cultured in open-pond systems (which include raceway-type ponds & lakes) or in a closed system called photo bioreactor (which includes a pond covered with a greenhouse).

2. Harvesting:
in second step spirulina algae are harvested using micro screens, froth flotation, chemical flocculants, auto flocculation or other ultrasound-based methods.

3. Powder extraction:
In final and important step we extract algae powder from these harvested spirulina algae through different type of methods. All these three steps include nine processes:

· Filtration and Cleaning
· Pre-concentration
· Concentration
· Neutralization
· Disintegration
· Dehydration
· Packing
· Storage
· Quality control

By manufacturing spirulina algae powder plant, we facilitate all above processes in a proper manner without much effort and time. For this purpose, our experienced and professional experts fabricate specific machines in diverse standard ranges using advance technology. We also have the facilities to customize these spirulina algae powder plants as per the individual requirements of the clients.

Usage of spirulina algae powder
· For nourishment & treatment of various diseases- Spirulina algae powder is a great source of nourishment not only for human but also for aqua cultures, birds, pets & animals. It has higher protein compared to meat like beef, chicken, eggs and grains like soybeans, rice or wheat.
· For food processing & cosmetic industries- Spirulina algae powder is used as natural colors in a variety of food and cosmetic products. This powder is extensively used in food & beverage, ice cream, skin care product, shampoos & dyes manufacturing industries.
For commercial & industrial uses- Spirulina algae powder has diverse commercial & industrial applications. It is used as a bio plastic, feed stock, pharmaceutical, pollution control, CO2 sequestration, fertilizer runoff reclamation, sewage treatment and a multitude of different purposes.

5. Effluent treatment projects
Industries during the manufacturing process generates huge quantity of high toxic effluents which yield very high BOD, COD, TS and TDS level with black colored and odor effluent.

Based on the above mentioned fact, Gte Ltd has developed a Zero Liquid Discharge Effluent Treatment system by which it will be possible to overcome all the environmental problems .The concept and the treatment is based on the belief that all the BOD requirement should go down and the condensate coming out should not be polluted.
For reducing the above BOD, COD level of the effluent, Gte Ltd has suggested a technology of evaporation and drying.
Gte Ltd has developed a process for treatment of industrial effluent with economical operation and Zero Liquid Discharge to meet the stringent pollution control norms. Depending upon the type of effluent, various processes have been developed for the cost effective treatment of effluent. The technological solution is provided after complete research and trial run at our R&D Centre

Advantage of technology
· Totally integrated zero discharge system.
· By Product is marketable commodity in most of the cases.
· Complete use of condensate water.
· Compact plant requires very less space.
· No Scaling & Froth formation in evaporator.
· User friendly plant.

Zero liquid discharge effluent treatment solution for:
· Textile Industries
· Distilleries
· Pharma Industries
· Chemical Industries
· Paper Industries
· Tannery Industries
· Dye & Dye Intermediaries
· Edible Oil Refineries
· Electroplating Industries

Key features:
· Fully Customized Designed System.
· Highest Steam Economy.
· Lowest Operation & Maintenance Cost.
· Operator Friendly
· Easily Upgradeable.
· Applicable for CDM Benefit.
· Technology approved by CPCB. (Central Pollution Control Board).

Distillery effluent

ETP system for molasses based distilleries
Distilleries have been generating huge quantities of high toxic effluents and in spite of the best efforts made so far, a comprehensive treatment has not been possible. In most of the conventional technologies, the treated effluent also yields very high BOD, COD, TS and TDS level with black colored and odor effluent to rivers & natural water streams. Based on the above mentioned fact, a treatment by which it will be possible to overcome all the problems have been worked out. The basic thrust of the technology is to reduce the quantity by a maximum possible extent. The concept and the treatment is based on the belief that the entire BOD requirement should go down and the condensate coming out should not be polluted.

Key features of multi effect evaporator system:
· Fully Customized Designed System
· Highest Steam Economy
· Lowest Operation & Maintenance Cost
· Operator Friendly
· Easily Upgradeable
· Generation of Reusable Condensate Water

Zero liquid discharge section (flow)
distillery waste water handling by evaporation and drying
The technology is based on basic principle of reduction of quantity by concentrating the effluent and subsequently drying it to a Powder / Mixed Fuel form which can be used as an alternative fuel for boilers and as an organic / inorganic fertilizer for plant growth.

The evaporation process:
Distillery Effluent is fed to the vacuum evaporator to concentrate maximum up to 60% solids concentration. The total process is under vacuum and the vapors generated in the system are re-used to economize steam consumption. In order to reduce steam consumption in multiple effect evaporation system the thermal vapour recompression system is used. The thermal vapour recompression system use Vapours generated in the evaporator and compress it by steam and the compressed vapours are used as heating medium in the evaporator. Water recovered from the evaporator has low BOD value and can be recycled in the plant.

The drying process (Zero Liquid Discharge Section):
The resultant slurry (concentrate) is fed to the drying section for converting the liquid concentrate to powder / mixed fuel (mixing with Secondary Fuel e.g. Bagasse, rice husk etc.) form. The air heated by steam radiator or hot air generator is fed into the dryer. The whole system is designed to obtain the optimum results. The emissions from the dryer are within the norms specified by the Govt. of India. This powder / mixed fuel can be used as an alternative fuel to steam boilers.

Main thrust of the technology
The Basic thrust of the technology is to reduce the quantity of Effluent by a maximum possible extent in the first stage.

In many of this kind of processes foaming is a big problem, which carries away lot of suspended particles in the condensate water, which eventually increases the BOD of distillate. Our technology has taken care of this problem and the BOD levels are contained to an extent of 80 mg/l and the distillate produced is colorless and is reusable for other processes.

Key features (General):
· ZERO Liquid Discharge
· Low Operating Cost
· User Friendly
· Easily Upgradeable
· Less Downtime for Maintenance
· Applicable for CDM Benefit

Zero liquid discharge system (ETP) for grain based distilleries (DDGS plant)
GTE Ltd has designed and supplied DDGS plants to various parties in Africa. In today's business scenario it is imperative for one to address his attention on the economic and environmental aspects that concern the grain-based alcohol producing industries in Africa vis-à-vis processing of stillage obtained as the by-product after distillation.

Gte Ltd is the pioneer in Africa to have indigenously developed a proven, fully integrated technology for manufacturing Distillers Dried Grains with Solubles (DDGS) from whole grain stillage which is the residue obtained after alcohol has been separated by distillation of the fermented mash of feed stock and water.

Scheme for zero liquid discharge system ( etp ) for grain based distilleries :
The zero discharge system for grain based distillery effluent handling (DDGS Plant) consists of following main processes.
· Decantation System: To separate the suspended particles and thin liquor.
· Evaporation System: To concentrate the thin liquor in vacuum evaporator.
· Mixing & Blending System: To mix the Wet cake and the concentrate.
· Spin Flash Drying: To dry the mix to get dried powder (DDGS).

The Process (DDGS):
The grain stillage from the bottom of analyzer column of grain based distillery is introduced to a continuous decanter centrifuge. Suspended particles are separated as a wet cake from the decanter and thin liquor is further processed to the evaporation section.

The thin liquor from decanter is concentrated in multiple effects falling film vacuum evaporator to get maximum water evaporation per kg steam energy supplied. The total process is under vacuum and the vapours generated in the system are re-used to economize steam consumption. In order to reduce steam consumption in multiple effect evaporation system the thermal vapour recompression system is used. The thermal vapour recompression system use vapours generated in the evaporator and compress it by steam and the compressed vapours are used as heating medium in the evaporator. The concentrate obtained from the evaporator is stored and fed to the mixing section. The wet cake and the concentrate is mixed and blended to for a uniform mix. The so formed mix is fed to the spin flash dryer to dry the wet mix to get dried powder DDGS. Fraction of DDGS at 10% moisture content is re-circulated through the blending section so to reduce the water evaporation load on spin flash dryer.

The DDGS thus obtained is a high protein content product and can be used as cattle feed of good nutritional value.

Effluent treatment plant for textile dyeing industry

ETC system for textile dyeing industries

Textile dyeing industries need huge quantity of water for textile dyeing, which they normally pump out repeatedly from the ground or natural water sources resulting in depletion of ground water level.

In the dyeing process textile industries generate huge quantity of toxic effluent containing colours, sodium sulphate, sodium chloride, sodium hydroxide and traces of other salts. These are generated after dyeing and after washing of garments / fabrics. After dyeing the waste water produced is called Dye Bath water and after washing the waste water generated is called wash water. Dye Bath contains higher solids in the range 4-5% whereas wash water contains only 0.5-1% solids.

Based on the above mentioned fact Gte Ltd has developed a technology which can process such harmful toxic effluent water and transform it into reusable water. Thus the textile industries will have the advantage of using the same water in the dying process repeatedly; also the salt used for dyeing can be reused or sold in the market.

The technology offered by Gte Ltd can overcome all problems pertaining to environmental pollution in respect to textile dying industries.

The basic thrust of the technology is to convert entire quantity of effluent to zero level by separating water and salt using evaporation and separation technology.
The concept and the treatment are based on the removal of the entire COD/BOD and the condensate coming out to meet the fresh water quality requirement in the process.

Textile waste water handling by evaporation and solid separation basic principle:
The technology is based on basic principle of reduction of quantity by concentrating the effluent and subsequently separation of salt and water.

The evaporation process:
Textile Effluent is fed to the vacuum evaporator to concentrate up to 40% solids concentration. The total process is under vacuum and the vapors generated in the system are re-used to economize steam consumption in multiple effect evaporation system with thermal vapour recompression system. The thermal vapour recompression system use Vapours generated in the evaporator and compress it by steam and the compressed vapours are used as heating medium in the evaporator, in this way steam consumption is reduced. Water recovered from the evaporator has low COD/BOD value and can be recycled in the plant.

The resultant slurry (concentrate) is fed to the thickener and centrifuging section for converting the liquid concentrate to solid waste. The mother liquor from thickener and centrifuge is recycled back to evaporator.

The water separated out from evaporator is good enough in quality to recycle in the plant for Dyeing.

Key features:
· Zero Liquid Discharge
· Fully Customized Designed System
· Highest Steam Economy
· Low Operating Cost
· Less Downtime for Maintenance
· Generation of Reusable Condensate Water
· Operator Friendly

Effluent treatment solutions for pharmaceutical & bulk drug industries

Pharmaceutical and bulk drug industries emanate effluent which consists of high organic contents with high COD. Gte Ltd has developed a system to treat such effluent, through evaporation & drying technology & by removing the solvent from High COD stream, using stripper column. With the help of this technology, effluent concentrate is dried to a baggable powder with 6 -8% moisture content, which can be reused as a land filling / disposal.

Process description:
For the purpose of treating this effluent, Evaporation and Drying methods are used. A combination of Industrial Evaporators like Falling Film Evaporator, Forced Circulation Evaporator and the Industrial Dryers like Vertical Thin Film Dryer are used. Other auxiliary techniques such as centrifuging, filtration, incineration are also employed depending upon the characteristics of the effluent.
The effluent containing high amount of organics is heated in a reboiler and passed through a Stripper Column to strip off the maximum low boiling organic solvents and their vapours are condensed using a condenser. These condensed vapours are partially refluxed back to the stripper to enrich the column and rest of the condensate (solvent) is collected separately and can be incinerated in an incinerator for making the facility a complete zero pollution plant.

The output liquid stream from the bottom of the Stripper Column which is now almost free of low boiling solvents enters the Multiple Effect Falling Film Evaporator /forced circulation evaporator or combination of two for further concentration. After concentration in the Evaporator, we get a concentrated stream of effluent which can be then further concentrated or dried in different types of evaporators and dryers depending upon the actual composition of the individual stream. The condensate water obtained from the Falling Film Evaporator is of very low COD. In case further reduction in COD is desired, then various techniques can be used like activated carbon treatment or aeration with a high pressure blower for prolonged periods.

Finally, the whole of the effluent is converted into solid/sludge form so that it can be disposed using various ways like land filling.

Gte Ltd strong background and its research team at the Research & Development Centre tried and tested various techniques to bring down the COD of this condensate water so that it can be used back in the industry/ discharged with COD limits well within the range as specified by the Pollution Control Boards.

Key features
· User Friendly
· Easily Upgradable
· Low Operating Cost
· Zero Liquid Discharge
· Highest Steam Economy
· Applicable for CDM Benefit
· Less Downtime for Maintenance
· Fully Customized Designed System
· Lowest Operation & Maintenance Cost
· Generation of Reusable Condensate Water
· Conversion of liquid waste water to solid waste for TSDS facility.
· Removal of Solvent from High COD Stream using stripper column.

Zero liquid discharge effluent treatment solution for black liquor from pulp & paper industries
In pulp mills spent liquor produced during washing of pulp after cooking with Caustic is highly toxic and this cannot be discharged. So its treatment in recovery plant is must. Valuable inorganic chemicals recovery is also done to keep pulping cost under control.

Recovering inorganic chemicals is possible only by incineration of black liquor but since the liquor is in very dilute form containing as low as 8 to 10% solids, it is not economical to incinerate directly. For burning this liquor, it is evaporated in Multiple Effect Evaporator to the desired concentration i.e. 48% in case of conventional recovery or 25 % in case of non conventional systems and then subsequently incinerated.

In case of conventional method of recovery, inorganic chemicals are collected in molten form named smelt. The smelt when dissolved in hot water becomes green liquor which is nothing but maximum sodium carbonate. This Green Liquor is further treated with lime to produce sodium hydroxide which is reused in pulp mill for pulping fibrous raw materials.

In case of non-conventional method of recovery, liquor at 25% TS is further concentrated to 50 % in direct contact flue gas evaporator and burnt in fluidized bed reactor in which inorganic chemicals are recovered at pre-melting stage in the form of soda ash pellets which are sold in the market.

This is how pollution abatement and inorganic chemical recovery is achieved in pulp and paper industries.

Key features:
· Zero Liquid Discharge System.
· Produce Black Liquor Concentrate.
· Highly Energy Efficient (Evaporates 7 Kg of water / kg of steam for concentration upto 50% in Seven Effect Evaporator).
· Minimum Space requirement.
· Fully Customized Design System.
· Low Operating Cost.
· Less Downtime for Maintenance.
· Operator friendly.

Dye / dye intermediates industries
The effluent from the dye/dye intermediate industries containing a mix of organic and inorganic salts is treated using Evaporation and Drying Technology to separate the organic and inorganic salts. The organic salts are used as a solid fuel and the inorganic salt can be a marketable product. The scheme shown above depicts that the effluent is crystallized at first and after centrifuging, the concentrate from the centrifuge comprising organic salts is concentrated using evaporator and then the concentrate is dried using the Agitated Thin Film Dryer or Spray Dryer.

On the other hand, the inorganic salts obtained after centrifuging are melted and treated with Activated Carbon. After separation of carbon from the slurry, the resulting slurry is concentrated using an Evaporator. The concentrate from this evaporator is passed through Centrifuge to obtain inorganic salts with high purity. The salt obtained from the centrifuge now can be dried using a Fluidized Bed Dryer

Electroplating Industries
The effluent from the Electroplating Industries is generally low in solids content and contains metals like chromium and manganese in the effluent.

The effluent is preheated and then fed to the Multiple Effect Falling Film Evaporator for concentration. After concentration, the concentrate is dried using an Agitated Thin Film Dryer. This dried powder can be used as solid waste disposal or as a land fill.

The condensate obtained from the evaporator is clean and colourless liquid and it can be used back in the plant as soft water.

Detergent powder projects
detergent powder plant

Synthetic detergents, which are also known as syndets, were developed to overcome the difficulties faced while using soap as a cleaning agent. Soaps when used in hard water precipitate the calcium and magnesium salts, due to its effectiveness as a cleaning agent deteriorates. In addition, edible oil & fats which could be put to other uses are used as raw materials for the manufacture of soaps. These problems are circumvented in synthetic detergents that are highly stable in hard water and do not consume valuable and expensive oil for their manufacture.

Gelatine processing plant
(Edible / Industrial / Pharma)
Gelatine is derived from Degreased Crushed Bones (DCB) through acid treatment followed by alkaline process. DCB are first treated with acid for removal of inorganic salts in bone. The bones after acid treatment are referred to as Ossein.

Ossein is then treated with alkali for partial hydrolysis. During the partial hydrolysis, the collagen material is softened from the non-collagen. Non-Collagen gets removed with weak alkali solution. The temperature is controlled during maceration and liming to avoid any yield losses. Limed Ossein is then washed with water and then treated with dilute solution of weak acid. Ossein after weak acid treatment is taken for Gelatine extraction.

Gelatine is extracted in the form of weak liquor, which is then filtered and passed through ion exchange (deashing system) for reduction of the dissolved ash(dissolved minerals) in the gelatine solution. This de-ionized weak liquor of Gelatine is then concentrated under vacuum to avoid any destruction to the basic tri skeleton structure of gelatine. So our gelatine processing plant or gelatine extraction plant is very useful.

Concentrated liquor is then passed through sterilization system followed by extrusion for making noodles to facilitate proper drying of Gelatine in the next stage.

Gelatine drying is very critical process since fast heating will melt the gelatine instead of drying and slow drying will result in gelatine moisture out of limits so Gelatine is dried very carefully with dehumidified air by gradual increase of temperature gradually to 60OC.

Dried Gelatine is then crushed to required mesh size as per the market demand. During Gelatine manufacturing DCP is produced as a byproduct. Which is a main constituent for the cattle and poultry feed.
General block diagramme depicting Gelatin manufacturing process from degreased dry bones

Unique design ensures
· High Product Quality.
· Compact design.
· Easy operation & automatic control.
· Minimum manpower required.
· Low operation cost.
· Easy Cleaning due to absence of fouling and hygienic construction.
· Continuous Production.

Herbal extraction plant
All the plants / herbs have very complex structure. Most of the active ingredients are present in the form of natural organic compounds.

The process of extraction for a particular compound or multiple compounds are dependent on the solubility of the rich components in an extraction media such as aqua (water) or organic solvent or a mixture of organic solvents by using the principle of physical separation and the property of solubility of those compounds in that particular extraction media.

The process and the plant design of extraction system is invariably different from product to product and component to component. It’s very difficult to generalize a process to extract isolated compounds from various herbs. From raw material to isolated compound, a series of processes will be involved. In the first step of process, the rich compound(s) can be extracted in a generalized manner with an extraction media. The second stage is followed by purification and isolation by various physical / chemical processes.

From a generalized extraction process, the rich herbal extracts can be used directly in herbal formulations for herbal, pharmaceuticals, food and cosmetic industries. Some of the herbal extracts can be used as natural dyes for textile, leather, food and cosmetic applications as coloring matters.

Process Technologies Available for:

A. Categorize Herbal extraction projects
For Herbal formulations / Food Industry:
· Instant Coffee
· Instant Tea
· Phyto Chemical Separation Systems for Steviosides, Tannins, etc.
· Protein Hydrolysates for Baby Food Formulations

B. General Herbal Extraction projects
· Natural dyes for textile dyeing industries.
· Tanin extracts for tanneries / leather industries.
· Katha extracts.

C. Organic Solvent Based Extraction Projects
· Formulation industries.
· Oleo Resins.
· Vegetable gums.
· Natural food coloring matters etc.
Herbal Extraction Process
Licorice Root Extraction Plant

Vegetable Dyes Plant
Gte Ltd offers vegetable/natural dye manufacturing plant. There is a big demand of vegetable/natural dye in the whole world as it is a replacement for chemical dye. Vegetable dye is used in textile as well as food industries.

The process involves extraction of colouring liquor from vegetable waste like onion peel, pomegranate (anar), mango (aam), harda, etc. and then concentration and spray drying to make powder.

This is a highly profitable project. Space requirement is only 300 sq. yard.
Centrifugal pump
The pump to take your products to dizzy heights

Application:
· Dairy Processing
· Food Processing
· Chemical Processing
· Salt
· Pharmaceutical
· Beverage Industries.
Gte Ltd pumps are of highest quality construction, manufactured from AISI 304/316 offering guarantee precision.

CP Series:
Centrifugal Pumps with Double Mech. Seals
· Water cooling arrangements.
· Suitable for use in vacuum Evaporators.
· These pumps can work under vacuum.
· Available with 1440 & 2800 RPM.
· These pumps have the capability to generate upto 80m head and capacity upto 160m3/Hr.
· Available with 0.5HP to 75HP 3Ph, TEFC Induction Motor.

TP Series:
· Transfer Pumps with Single Mech. Seals.
· Suitable for use in any transfer of liquid.
· Available with 0.5HP to 75HP 3Ph, TEFC Induction Motor.
· Suitable for Hydrocyclone.
· These pumps have the capacity to generate upto 80m head and capacity upto 160m3/Hr.

Special Features:
Centrifuges, high pressure pump, centrifugal pumps, axial flow pumps, gear pump
· Gte Ltd Pumps are of the Hygienic Construction with easy openable Impeller.
· It also offers centrifuges, high pressure pump, centrifugal pumps, axial flow pumps, gear pump
· These pumps are Energy Efficient and requires less NPSH to function without cavitation.
· Pump Impellers are made of SS-316 Casting and are thoroughly Balance on a Digital Balancing Machines.
· Suitable Elastomers are used with the above to provide optimum resistance for CIP, High Temperature and Chemicals.
· These Pumps are applied on products with viscosity upto 1500 centipose, like Apple Slurry, Concentrated Whey, Fruit Slurries, Dextrose, Maltose and other syrups.
· These pumps require Flooded Suctions.

Axial flow pumps
Keeping the diverse requirements of the customers in mind, our company is instrumental in presenting superior quality range of axial flow pumps. These axial flow pumps are suitable for high volume/low head pumping requirements especially when corrosive and abrasive solutions are involved. These are highly appreciated amongst customers for their mechanical reliability, extended service life and custom engineering.
Features:

· Multiple impellers selections for optimum performance and efficiency.
· Tapered bore stuffing box for longest seal life.
· Back pullout construction as standard on size through 22".
· Robust bearing shaft and frame for long life on critical and continuous duty services.
Application:
· Chemical industry.

New technology
Evaporator without a condenser, spray pond & cooling tower
Gte Ltd introduced an evaporator, where no condenser, a spray pond & a cooling tower is required. This technology will save lot of energy and shall also save cost in terms of recurring expenditure & infrastructure.

Gte Ltd is striving hard to bring tomorrows technology today. It’s only possible because of our in depth knowledge about the evaporation technology.

Industrial evaporators
Falling Film Evaporator
Use of falling film evaporator with multiple effects ensures high energy efficiency and is ideal for concentration of heat sensitive products, with low scaling tendency. Multi-effect falling film evaporator with TVR as well as MVR are designed by Gte Ltd and manufactured by appointed suppliers.
Applications:
· Milk
· Coffee
· Soy milk
· Apple Juice
· Tea extract
· Dye intermediates
· Distillery Waste Water Effluent with low TSS, etc.

Forced circulation evaporator
This is ideal for concentration of high viscous material and products with higher solids. This is also used as evaporative crystallizer. Sometimes these are used in series with falling film evaporator as finishing effect for achieving higher concentration. In this type of evaporator, liquid is pumped through heat exchanger tubes at high velocity (1.5-4.0 m/s) avoiding precipitation and creating high turbulence; liquid is then passed through vapour separator for separation of vapour and finally condensing the vapour in the condenser. Concentrated liquid is continuously discharged from bottom of vapour separator.

Applications:
· Brine evaporation (Vacuum Salt processing)
· Effluent concentration with High suspended solid.
· Fruits Pulp Concentration
· Tomato Paste
· Sodium Sulphate Crystallization.

Rising Film Evaporator
In a Rising Film Evaporator liquid feed enters from the bottom of steam heated tubes. The parallel movement of liquid and vapor along tube surface imparts effective water evaporation from the liquid feed. This type of evaporator is ideal for liquids which attain high viscosity or have fouling tendency.

Applications:
· Fruit Juice concentration.
· Sugar Cane Juice Concentration

Agitated Thin Film Evaporator
The agitated thin film evaporator is well suited for concentration of viscous and heat sensitive liquids such as gelatin, antibiotics, fruit juices, and solvent mix etc. The thin film evaporator reduces fouling and liquid residence time in the evaporator. In the vertical agitated thin film evaporator feed liquid is feed at the top of evaporator and is uniformly distributed in the form of thin film by the wiper blades on vertical cylindrical heat transfer area, inside the unit. Evaporation of water / solvent takes place as the thin film moves down the heat transfer area.

Scrapped Surface / Thin Film Evaporator
Scrapped Surface/Thin Film Evaporator is designed for evaporation of highly viscous and sticky products, which cannot be otherwise evaporated. These types of evaporators have been specially designed to provide high degree of agitation, effecting heat transfer as well as scrapping the walls of the evaporator to prevent deposition and subsequent charring of the product.

Applications:
· Tomato Paste
· Honey
· Solvent Recovery
· Milk concentrate (Khoa)
· Jam/Jelly.

Vapour Recompression System (Tvr & Mvr)
The vapour is compressed to higher condensation pressure by means of either Thermal Vapour Recompressor (TVR) or Mechanical Vapour Recompressor (MVR), which results in steam economy. In TVR portion of vapour discharged from one effect is sucked and compressed using motive steam and the resulting mixture is used as a heating medium to bring down the specific steam consumption. In MVR the vapour is recompressed by using two stage compressors with mechanical seals. A typical five effect plant with TVR over three effects has a sp. Steam consumption of 0.12. & a seven effect plant with TVR having vapour suction from 4th effect has a specific steam consumption of 0.09

Expansion of Evaporator
Gte Ltd is capable of not only designing new evaporators but also enhancing the capacity of the existing ones. This results in improved operating conditions, increased capacity, lower specific steam consumption and saving in capital investment as well as operating cost. The capacity is enhanced by adding effects, thermo-compressors, etc. as the case may be.

Industrial Dryers
Gte Ltd supplies modern Drying Plants for Dairy, Food, Chemical and Pharmaceutical industries based on indigenously developed technology. As drying is an energy intensive process and dryers are expensive, we offer most economical Industrial Dryers matching the specific requirements.

Gte ltd supplies the following dryers:
· Industrial Spray Dryer
· Spin Flash Dryer
· Steam Tube Dryer
· Spray Nozzle
· Vacuum Band Dryer
· Rotary Dryer
· Vertical Thin Film Dryer
· Freeze Dryer
· Tumbler / Rotary Vacuum Dryer
· Fluid Bed Dryer
· Solar Dryer

Basic Features Of The System:
· Production Of Instant Powder
· Flexibility In Controlling Powder Quality
· Negligible - Deposition Of Powder In Chamber
· Less Downtime For Maintenance.
· Winch Driven Special Cleaning Lift.
· Expandable Up To 100% Capacity

Developments:
· Spray dryer with Nozzle Atomization & Disc Atomization.
· Modern Spray Dryer design with both types atomization in the same dryer to get desired quality of powder.
· Instant WMP Powder (Lecithinated)
· No sticking in the drying chamber even with Dairy Whitener.

Spray Dryer
· Gte Ltd Spray Dryers are relatively simple in operation which accept feed in fluid state and convert it into a dried particulate form by atomizing the fluid into a hot drying medium.
· Atomization is done using high pressure nozzle, high pressure air, two fluid nozzles or centrifugal disc atomizer.
· The heating of drying air can be through steam radiator or thermic fluid air heater according to the service conditions available.
· Direct or indirect fired hot air generator through oil or gas according to fuel availability with client.
· The unique Fines Re-circulation System produces highest quality of agglomerated powder.
· Apart from that it also offers spray nozzle, atomizer, diversion valve, blow through valve, pipes & fittings

Applications:
· Milk Powder
· Whey Powder
· Ceramic Slurry
· Magnesium Chloride
· Molasses
· Poly Aluminum Chloride
· Enzymes
· Catalysts
· Calcium Chloride
· Instant Tea
· Instant Coffee
· Ice Cream Mix Powder
· Bakers Yeast
· UF Resin
· Fruit Juice Powder
· Protein Hydrolysates
· Egg Powder
· Polyvinyl Acetate
· Dyes
· Detergent Powder
· Herbal Products
and other products

Criteria for selection:
· Physical /Chemical properties of the product.
· Production Capacity (Kg/Hr)
· Initial Moisture Content and final moisture required.
· Particle Size Distribution.
· Temperature & Drying Characteristics.
· Explosion & Toxicological Characteristics.

Freeze Dryer
Industrial freeze dryer retains aroma, improves appearance and taste because freeze drying takes place at a low temperature which minimizes heat damage and retains volatile components (aroma). It also increases the shelf life of the dried product as compared to standard drying practices. Freeze-drying involves dehydration of food products at low temperature and pressure. As a result, only the moisture is removed, leaving the molecular structure intact. The end product is light in weight with least or no change in volume. Worldwide freeze-drying technology is considered as the ultimate amongst all other dehydration methods. Hence this technique is currently being used for the production of instant coffee, instant tea, fruit pulp and other heat sensitive products.

Applications:
· Dehydration / Drying of food products.
· Instant Coffee Processing.

Tumbler Dryer / Sterilizer
These types of dryers are mostly used in pharmaceutical companies. This is a batch type dryer heated by steam (Indirect). This dryer can also be used as a sterilizer. Recovery of solvent from powder is possible using such dryer.

Application
· Talcum Powder
· Pharma Powders/granules
Fluid Bed Dryer
Versatile Drying method (Batch or Continuous Type) is used for drying various Liquid concentrates efficiently. It can also reduce the energy requirement of a spray dryer plant when used as a second stage dryer for production of instant quality powders.

Fluid bed dryer comprises of a top fluidizing chamber & a bottom air distribution chamber separated by a specially designed perforated plate.
The feed of wet materials is dried by intimate contact with hot air when the material is in a fluidized state. A vibrating mechanism can be attached to give a forward motion cum agitation to the product at a controlled rate. It is also used as second stage dryer for many products.

Applications:
· Milk Powder
· Cheese Powder
· Detergent Powder
· Fruit Pellets
· Dextrose
· Salt (Nacl)
· Agglomerated Powder
· Sodium perborate
· Herbal Powder
· Sodium Sulphate
· Different types of grains

Rotary Dryer
In direct heat Rotary Dryer, a continuous feed of wet particulate material is dried by contact with heated air, while being transported along the interior of a rotating cylinder / rotating shell acting as the conveying device and stirrer.

Gte Ltd supplies Rotary Dryers in co-current (Parallel) and counter-current operation. In the former, the wet material is exposed to the hottest air which enables heat sensitive or sticky material to be dried successfully.

In counter-current operation, dried material is exposed to the hottest air helping to achieve very low moisture content. The hot gas may enter at a very high temperature as high as 16000C.

Applications:
· Ammonium Sulphate
· Citric Acid
· China Clay
· Mineral Sand
· Sodium Sulphate
· Effluents mixture
· Coal dust and Coke
· Saw dust
· Mehndi/Henna
· Bagasse.

Steam Tube Dryer
Steam tube dryer is one of the indirect heated rotary dryers, which contains rotating shell, rows of steam tubes arranged in concentric circles and extended throughout the length of the dryer. Steam tubes are designed to transfer heat from steam to the material being dried. This is one of the most energy efficient dryers. The tubes and radial fights together serve to agitate the material and to provide required residence time.

Application
· Grains
· Germs
· Fibres

Spin Flash Dryer
Spin Flash Dryer is ideal for drying of wet cake, slurry, paste which is normally difficult to dry in other dryers. The material is fed by screw feeder through a variable speed drive into the vertical drying chamber where it is heated by hot air and at the same time disintegrated by a specially designed disintegrator. The heating of air may be direct or indirect depending upon the application. The dry powder is collected through cyclone separator / bag filter or with combination of both.

Application
· Amino Acid
· Pigments
· Starch
· Palm Kernel
· DCP
· Gluten
· Effluent
· Bleach Clay
· Organic Salt
· H-Acid
· Dye & Dye Intermediates

Vacuum Band Dryer
It is best suited for continuous drying of temperature sensitive and sugar containing products at low temperature under vacuum conditions. The dryer consists of a vacuum chamber in which conveyer bands of food grade quality are arranged. The band passes over the hot plates heated internally by steam or hot water. Feed product is spread on the moving band and is dried as it moves on the hot plates. Dried product is obtained at the other end.
It is best suited for continuous drying of temperature sensitive and sugar containing products at low temperature under vacuum conditions. The dryer consists of a vacuum chamber in which conveyer bands of food grade quality are arranged. The band passes over the hot plates heated internally by steam or hot water. Feed product is spread on the moving band and is dried as it moves on the hot plates. Dried product is obtained at the other end.

Application
· Malted food
· Extracts
· Fruits & Vegetables
· Gelatin
· Pharmaceuticals
· Beverage Mix
· Enzymes

Agitated Thin Film Dryer
This type of dryer is used for converting concentrated material to solid/semi solid form. This is designed with vacuum system / without vacuum system. Solvents/water is collected through condenser.

Feed is pumped to heat exchanger where it is scrapped/agitated through series of multiple blades on the inner surface of a vertical shell and shell is heated by steam. Due to vigorous agitation the heat transfer is fast and slurry is converted to solid/semi-solid form.

Application
· Effluent concentration and drying
· Solvent recovery and drying
· Fruits & Vegetables

Oil extraction machines
Oil extraction machines are meant for extracting oil from various seeds, nuts and other products. Designed by professional team, they are manufactured using premium grade materials and they meet all international standards. They have proven to be the most efficient, reliable and durable equipments available globally. Various models are available for different applications. Some of the seeds/nuts include cotton seeds, ground nuts (pea nuts), copra (coconut), mustard, canola (rape seed), palm kernel, sunflower, castor seed, Linseed, Sesame, Soybean, Maize-germ, Cashew nut shell, Walnut, Shea nut, Kardi, Tumba, Neem & other oil bearing seeds/nuts, etc.

 

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