Food and Baverage, Brinox

www.brinox.eu

FOOD & BEVERAGE

Technology that delivers

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30 Years of INNOVATING “More than 30 years of experience in the food and beverage industry are a guarantee of our flawless process systems.”

We are an innovative European company specializing in fast, efficient, cost-competitive, and personalized process systems.

We focus our knowledge and competencies on developing and producing high-tech equipment that meets the most complex requirements of the pharmaceutical, food and beverage as well as chemical industries.

Our long-term vision is to become Europe’s leading provider of unique, personalized process solutions.

Our more than 250 motivated and highly educated employees follow the company’s values, which are based on our customers’ requirements regarding: ¬ quality, ¬ innovation, ¬ flexibility, ¬ reliability.

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Personalized solutions FOR Reliable Operations “The food and beverage industry is constantly increasing its requirements regarding the design of hygienic technological equipment, aiming to achieve the highest food safety. At Brinox, we are ready.�

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FOOD AND BEVERAGE INDUSTRY COMPETENCIES “We offer turnkey solutions to our customers in the food and beverage industry: from conceptual design through to implementation and automation.”

COMPLETE TECHNOLOGICAL SOLUTIONS

We provide our customers with a range of complete solutions, starting with a concept, the design and production of process equipment, and finishing with its assembly, installation and start-up. Our process systems are fully automated. Prior to shipping it, we assemble, wire up and test the process equipment in our own testing center, which significantly reduces the time needed for onsite assembly and start-up, whilst increasing the reliability of the whole process system.

We bring our customers benefits in the following areas: ¬ project design and implementation (according to hygiene standards, e.g.

HACCP), ¬ production of key equipment (classical welding, orbital welding, robotic welding, grinding and polishing, cleaning and passivation of equipment before shipment or after delivery),

Concept

Detail design

¬ automation of process systems (ensuring that all events are repeatable and traceable, history…), ¬ documentation in compliance with the legislation (e.g. dimension protocols, protocols of surface roughness, non-destructive testing, endoscopy, welding log books), ¬ certificates (e.g. welding certificates for welding procedures, individual welders; certificates for the production of pressure equipment, ISO 9001 and ISO 14001).

At Brinox we constantly monitor and follow the latest requirements, standards and technological trends in the food and beverage as well as other industries, and make sure to regularly incorporate them in our solutions, thereby always providing our customers with the most advanced process systems.

Implementation

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Dairy Industry “Our path here at Brinox started more than three decades ago in the dairy industry. That is why our most extensive experience is with milk processing.”

RECEPTION, STORAGE, AND HEAT TREATMENT OF MILK

Reception of raw milk ¬ vehicle and driver identification (RFID technology), ¬ gravitational reception of milk with a deaerating system and a volume measurement system, ¬ cooling systems for keeping the milk temperature below 6° C, ¬ data recording.

Storage of raw milk in automated storage rooms Our activities here include: ¬ design and fabrication of valve clusters equipped with our own (Brinox) valves or valves made by third-party manufacturers, ¬ execution of piping connecting valve clusters with milk tanks (orbital welding is also available), ¬ fabrication of milk tanks in accordance with different standards (e.g. PED, ATEX, IPPC, HACCP), ¬ complete automation.

Heat treatment of milk Milk is prepared for further treatment or packaging: ¬ milk pasteurization, where the system’s capacities can be tailored to each individual customer, while all key parameters of the process are automated and recorded, enabling historical data to be reviewed (a HACCP requirement), ¬ separation, standardization, homogenization and deaeration of milk, ¬ pasteurization and storage of cream.

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Dairy Industry “Food safety matters – Brinox ensures the control of all production parameters from the raw materials to the shelf.”

FERMENTATION OF MILK AND MEMBRANE TECHNOLOGIES

We design and manufacture process systems for fermented milk products such as yoghurts, kefir and cheeses (e.g. quark and feta). All these products are based on heat treated (pasteurized) milk.

YOGHURT

Fermentation

Along with pasteurized milk, yoghurt is the dairy industry’s most widespread product.

Yoghurt production technology has been in the spotlight at Brinox for decades, and the following are the processes we particularly excel in:

¬ metering/dosing of pitching cultures, ¬ fermentation in special fermenters with a built-in heating/cooling system, ¬ rapid cooling of fermented products, ¬ in-line dosing and mixing of various ingredients, e.g. fruit paste into yoghurt.

Milk preparation

We also provide completely customized solutions, such as:

¬ preparation of pasteurized milk for yoghurt production (clarification, separation, standardization, deaeration, pasteurization), ¬ mixing of powdered ingredients.

¬ pilot plants for the development of new fermented products and cheeses, ¬ plants for milk and cheese spreads.

MEMBRANE FILTRATION AND DRYING OF MILK AND WHEY We design and implement process systems for: ¬ membrane filtration of milk and whey (microfiltration, ultrafiltration, nanofiltration, reverse osmosis), ¬ drying of milk and whey (dehydrated milk, proteins, lactose), ¬ lactose decoloration (pharmaceutical lactose), ¬ GOS production.

Thermal treatment of milk ¬ thermal treatment and holding of milk at a prescribed temperature, ¬ homogenization, ¬ temperature regulation at the output for fermentation purposes.

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Dairy Industry “We have mastered the technologies for producing kefir for adults, but we are also especially proud of our solutions for producing kefir for children.”

FERMENTATION OF MILK AND MEMBRANE TECHNOLOGIES

KEFIR

Cultivation of kefir grains

FETA CHEESE

Due to its exceptional probiotic qualities, kefir is a very special dairy product, which is treated with great respect wherever it has been traditionally consumed. That is why our technologists and engineers focus on each and every detail when designing process systems to produce kefir. Our expertise is strongest in the following processes:

¬ preparation of mother cultures (kefir grains), ¬ preparation of production cultures based on the mother culture, ¬ separation of the kefir grain (the procedure is a result of our own R&D), ¬ prolongation of the shelf life of a product.

The entire process takes place in a highly hygienic environment.

Feta cheese is traditionally produced in the Mediterranean countries, and modern production is quite different from traditional methods. We use advanced filtration technologies, which ensure high efficiency.

Fermentation ¬ dosing of production cultures into pasteurized milk, ¬ fermentation in ultra-clean fermentation tanks.

Ultrafiltration concentrates the milk so whey does not need to be removed after fermentation: ¬ caseins are treated gently, ¬ whey proteins are preserved, thereby creating higher yields.

The whole process is closed and high levels of hygiene are ensured, significantly prolonging the shelf life of cheese.

Brinox provides modern quark production lines for classical production and with thermization unit(s) for baby food dairy products.

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BABY FOOD With complete & fully automated production, you can turn raw materials into the final product – baby food and infant ready meals.

We design, manufacture and install complete process systems for a baby food production plant: ¬ reception and dosing of fruit paste ¬ mixing with quark and additives – vitamins, aromas, different powdered ingredients ¬ heat treatment for extending the shelf life of a product (12 months) ¬ deaeration ¬ homogenization ¬ cooling ¬ hot filling ¬ CIP Based on our tradition and know-how we can control every stage of your manufacturing process, thus ensuring totally customized process solutions and equipment in compliance with health and safety standards.

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BEVERAGES AND AROMAS “Challenges! That’s why we are also active in other fields like the production of beverages and dry aromas.”

In the area of process solutions for beverages and aromas, Brinox offers its expertise in the following processes:

Fermentation and maturation of beer

Drying of aromas

¬ fermentation – temperature control and regulation (fermenters from 100 m³ to 350 m³), ¬ CO2 control and regulation, the whole process is closed, ¬ maturation and storage of beer in lager tanks, ¬ washing of the whole system (CIP) after the tanks are emptied.

¬ production and assembly of drying towers of various sizes, ranging from units used in laboratories to semi-industrial and industrial units, ¬ use of the “fluid bed drying” technology, a unique technical solution for aroma drying developed by Brinox.

Sugar dissolving (e.g. to be added to fruit juices or flavored water): ¬ direct dissolving of sugar without additional heating (sugar content up to 65° Brix).

The compact design of our system minimizes the footprint.

Spray dryer Dryers are used to produce a dry powder from a liquid or slurry by rapidly drying with a hot gas. This is the preferred drying method for many thermally-sensitive materials such as foods (milk and whey powder, vegetable and honey powder etc.) and pharmaceuticals.

The Brinox dryer is custom-made, designed in accordance with EHEDG guidelines, works at a high level of hygiene, and is reliable and cost-effective during production, cleaning and maintenance.

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CIP AND UTILITY SYSTEMS “When cleaning the process systems, our attention to detail becomes even more obvious as our outstanding systems are also much easier to clean, environmentally friendly and much more cost effective.”

For the food and beverage industry, we design and produce utility systems that ensure appropriate hygiene of the systems after use or before changing the type of product. All of our solutions are completely customizable and include the following:

Cleaning of process systems (CIP) ¬ automatic operation and modular design in line with the system’s requirements, ¬ conductivity measurements for the automatic separation of cleaning solutions,

¬ measurement of the concentration of cleaning agents in order to constantly ensure the optimal concentration (acid, lye), ¬ system disinfection after final rinsing, ¬ ensuring the optimal temperatures of the cleaning agents, ¬ recovery of water from the final rinsing to be used for the first rinse of the next CIP cycle, when required.

Systems for reduced consumption of energy, water and cleaning agents ¬ reduced consumption of cold water and steam in milk-processing systems, ¬ reduced amounts of waste water, ¬ optimized CIP processes.

Treatment of process water ¬ chlorination, demineralization, ¬ filtering, ¬ reverse osmosis, ¬ sterilization.

Storage of cleaning concentrate ¬ reception and storage in line with environmental standards, ¬ automatic metering/dosing and distribution.

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Factory Acceptance Test (FAT) “Conducting a complete FAT in-house is our guarantee of the system’s expected quality and its flawless functionality.”

The modern and fully accessorized FAT testing facility in our workshop in Sora, Slovenia, allows us to run a full set of testing procedures with all required media on equipment prior to it being shipped to the final installation site.

Simulating real-life production conditions enables us to: ¬ debug the system prior to shipping it, ¬ anticipate troubleshooting in exploitation, ¬ speed up the installation and commissioning, ¬ provide the client with a quicker time-to market, minimize downtimes.

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Automation “Passing product control over to you.”

Working hand in hand with a customer, our Automation Department provides a complete automation solution according to the process system’s requirements: ¬ SW and HW Design & Documentation ¬ FDS based on our technological know how and experience ¬ Programming & Configuration ¬ FAT testing ¬ Start-up & Commissioning ¬ IQ&OQ ¬ Maintenance and change control We follow industry standards and guidelines:

¬ Information level: MS SQL and Reporting server, MS .NET, GE Historian ¬ The open concept allows us to integrate the solution into the customer’s environment The automation system provides: ¬ Advanced SCADA visualization, allowing manual equipment control at the lowest level (valves/motors, sensors) for maintenance and trouble shooting. ¬ Modular design with intuitive HMI, permitting the user to execute individual automated functions (phases, operations),

thus streamlining the introduction and optimization of new products. ¬ High process flexibility together with a high level of automation is achieved by using the S88.01 recipe system. ¬ Customers build their own recipes using the supplied library of phases/operations, thereby protecting their knowledge. ¬ The workflow process for approving recipes is based on E-signatures. ¬ Unit procedures are running completely on the PLC, eliminating the vulnerability of PC batch systems. ¬ Recipe, batch execution, audit-trail and

historian data provide a broad database for electronic reporting. Different comprehensive reports with integrated graphical charts can be generated (batch reports, raw material and utility consumption, equipment usage, …). ¬ 21CFR11 support with access control is based on Windows security. ¬ SCADA screens in English/Local language. ¬ Interface to other systems on the PLC level (utilities, waste, CIP, 3rd party units, e.g. fillers, separators, existing systems, safety systems,...) and on the Information level (MES, KPI).

¬ GAMP5 computer system validation ¬ FDA’s 21CFR11 requirements for E-signatures & E-records ¬ Process modelling based on ISA S88.01 We use recognized and general purpose tools: ¬ PLC level: Siemens, others on request ¬ SCADA: GE iFix, Siemens WinCC, others on request 25

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QUALITY ASSURANCE “State-of-the-art measuring equipment and motivated personnel guarantee the reliability of our process systems, which are also thoroughly documented.”

Our QA /QC Department is responsible for quality control in all stages of project development.

Only top-level measuring and testing equipment is used, making our testing lab one of the best equipped in all of Europe.

Certified management system Brinox d.o.o.

Slovenia

We have received the following certifications: ¬ ISO 9001 ¬ ISO 14001 ¬ ISO 27001 – in implementation ¬ OHSAS 18001 – in implementation ¬ ASME section 8 for welding of Boiler and Pressure Vessels ¬ AD 2000-Merkblat HP0 / EN 13445-4 / and EN ISO 3884-2 for welding of Pressure Equipment Directive 2014/68/EU ¬ PED 2014/68/EU Module A2, according ¬ to the PED directive that covers pressure vessels, reactors and heat exchangers ¬ EHEDG certification (hygienic design guidelines) for the DVEH double-seat valve ¬ Brinox is certified for welding austenitic steels of group 8 (8.1, 8.2) and nickel alloys group W34 (manual, robotic, orbital welding).

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Business activities

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Regulatory compliance →

R&D →

Conceptual design →

We share our expertise with our clients in the field of regulatory compliance by auditing the existing facilities and equipment.

Using the right set of tools, we prepare customized plans for increasing the productivity of facilities and equipment in line with the cGMP requirements.

Each new project represents a new challenge for us. Employing a modern scientific approach, the most advanced tools and collaborating with established researchers and institutions allow us to transform each challenge into a tailor-made process solution.

Our experienced team of engineers and technologists is continuously working on new challenges so as to design the best conceptual solution that is cost-effective, high-performing and GMP-compliant.

Testing →

Assembly →

Automation →

Brinox’s qualification procedures ensure that its process systems and units meet all relevant standards and regulations and fulfil the URS. Brinox’s own testing facility and strict test plans allow extensive FAT prior to delivery, while Brinox’s engineers are a guarantee of successful SAT.

Our team of highly qualified fitters and implementing engineers provides professional on-site assembly of our process systems and units globally, be they manufactured by us or by third parties.

Using only the best tools and equipment available, they ensure the equipment is properly installed, guaranteeing its correct functioning.

In line with the requirements of the process system, we can provide a comprehensive automation solution that: ¬ is based on the ISA S88.01 standard for batch processes and the 21CFR part 11 guidelines on electronic records and signatures, ¬ is based on PLC-SCADA open solutions, ¬ takes the GAMP 5 guidelines on project life cycle into account.

Basic engineering →

Detailed engineering →

Manufacturing →

Quality control →

The main tool of basic engineering is the precise definition of the functionality of process systems and the links between them.

The process flow chart (P&ID diagram) is tailored to the customer’s needs and is the basic document for developing the system control schemes, the physical sequence of equipment and individual systems, and a platform for further safety and operational research.

Using the most sophisticated tools we design every process component, right down to the smallest details, anticipating any process problems and ensuring high levels of efficiency and productivity.

Our state-of-the-art machinery pool and excellent craftsmanship allow us to manufacture even the most complex process units and components. Having our own workshop not only gives us a high level of flexibility and adaptability to everchanging demands, but also guarantees the highest level of quality control and respect of budget and time constraints.

Our Quality Assurance Department uses the most advanced tools and equipment to continuously monitor quality levels within our manufacturing system, allowing any errors or disruptions occurring in the operation of our products to be discovered and remedied in advance with the help of mid-phase and endsystem checks.

Validation → ¬ uses established technologies for process management (Siemens, GE-Fanuc, Proleit), ¬ provides reporting, recipe management, and a connection with superior MES systems based on an integrated SQL database.

We offer our clients close assistance during validation procedures, offering complete documentation support, starting with DQ through to IQ/OQ. Our most experienced and skilled engineers and technicians train the client’s personnel up to a level that allows them to fully exploit the installed systems and units throughout their lifespan

Maintenance We provide our clients with: ¬ intervention, repair and assembly, ¬ spare parts for our equipment, ¬ engineer-supported interventions for any possible alterations, ¬ on-line support, ¬ preventive check-ups.

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Photo: © Marko Prezelj

Selected References: ¬ Coca-Cola HBC ¬ Frutarom ¬ Lactalis ¬ Lactosan ¬ Meggle ¬ Mlekarna Celeia ¬ Pepsico ¬ Pivovarna Laško ¬ Pivovarna Union ¬ Salford Group ¬ Sarajevska pivara ¬ Zott ¬ Žito

Brinox Deutschland GmbH Maria-und-Georg-Dietrich Str. 2 77652 Offenburg Germany T: +49 (0) 781 970 678 10 info@brinox.de

Brinox Ireland & United Kingdom Chambers House, Ellison Street Castlebar Co. Mayo Ireland T: +353 94 9026821, + 353 87 6264360 info@brinox.eu

ООО «БРИНОКС РУС» Кутузовский пр-т 9/2A, офис 98 121248 Москва Российская Федерация T: +7 499 243 71 55 russia.office@brinox.eu

F&B201709–EN

Brinox d.o.o.

Sora 21 SI-1215 Medvode, Slovenia T: +386 1 361 97 30 info@brinox.eu www.brinox.eu

Certified management system Brinox d.o.o.

Slovenia