Pure pleasure. Protadur food gases from Westfalen.

Transcription

1 Pure pleasure. Protadur food gases from Westfalen.

2 Protadur. Our gases for your food. The brands' brand Protadur is Westfalen's brand name for all pure gases and gas mixtures used in the production and packaging of food products. That's a broad scope ranging from spray cream and pressurised beer barrels through to frozen pizza. Everywhere, our gases ensure longer life, more appetising appearance or smoother manufacturing processes. These after all determine the pleasure a product delivers, how convenient it is, and ultimately your success as a manufacturer in the food industry. Our gases all have one thing in common. You can rely on them absolutely to comply with the strictest safety standards. All Protadur gases meet the necessary approvals, specifications and EU regulations as well as the specific standards of the industry (see page 18). And that's the case all the way through the supply chain: from manufacture - generally in our own facilities - to your production. Something sure to please both you and your customers. More than a name Protadur isn't just a product, or a brand, or a family of gases. Rather, it is an end-to-end system, a complex sequence of flawlessly interfaced elements. From packaging to freezing, from gas cylinder and road tanker through to control units and regulators, everything comes from us and is subject to the most stringent control. Which as Protadur gases are food additives, is just as it should be. We never compromise at Westfalen. Westfalen and gases Today Westfalen is a modern mid-sized industrial and service company, our gases the product of more than 90 years' experience as a family business. Our promise: our energy takes you further. That's a promise supported by our over 1,400 employees in our three businesses gases, energy supply and service stations throughout Germany and reaching into Europe. Responsibility isn't just a marketing concept at Westfalen - it's a state of mind. We're satisfied only when our products make your life and work easier. We see ourselves as a true partner to industry. But for all that, every production process ends with a satisfied customer. And nowhere is the customer's opinion more important than in food products they enjoy every day. We are Westfalen - and we're Westphalia folk And that shapes our behaviour and actions. Stubborn, yes. But only when it comes to the quality and reliability of our products and the satisfaction and trust of our customers. Down to earth? Naturally - because without strong roots, our company cannot grow. Picky? Absolutely, because we can't allow the slightest imperfection into your business. And our tenacity ensures we'll work with you to find the best solution. And we won't stop, until we've found you the perfect mixture or ideal storage option. 2

3 Contents: Protadur, Westfalen Supply, Added value Products, Applications Packaging, Protection Refrigeration, Freezing Service, Benefits The Protadur brand name derives from the Latin words protegere (to protect) and durabilis (sustainable). Appropriate. Because that's exactly what characterises food gases from Westfalen. Westfalen - Westphalia folk - are obstinate. But only in terms of taste there's no argument when it comes to quality. 3

4 Our supply chain for your safety. As part of our HACCP (Hazard Analysis and Critical Control Points) system in accordance with DIN EN ISO 22000, all processes are monitored in a dense network of control points, which also include microbiological tests. Production and filling are performed in our dedicated filling facilities. The traceability of Protadur food gases is permanently ensured - seamlessly. With a separate container fleet for food gases identified with the "glass and fork" symbol, Westfalen is fully compliant with EU Regulation 1935/2004/EC. Tankers The tankers used for transporting cryogenic liquefied Protadur gases require individual approval, which must be regularly renewed. Before loading, both vehicle and driver are checked to ensure they have the correct permits - without which, loading cannot proceed. Cylinders We have a dedicated cylinder fleet for Protadur food gases. Before being filled for the first time, every cylinder is neutralised, preventing contamination by moisture or by undesirable components in the atmosphere. Residual pressure and non-return valves prevent contamination by external influences. Safe delivery - only by appropriately authorised tankers. Static tank installations. After filling our tank installations for the first time with Protadur gases, we take a sample. Only once the analysis results have been accepted is the installation given final approval and the Protadur product designation granted. If requested, we will regularly analyse the installation. We can also inspect your existing tanks to check suitability for Protadur. Dedicated filling facility, dedicated cylinder fleet, one-of-a-kind safety: Protadur Approval and identification of a tank installation for Protadur. 4

5 Your added value. Tank installations at Westfalen plants Our tank installations are inspected at regular intervals by an independent body to ensure they meet Protadur standards. Gases coming from the manufacturing process are also subject to annual microbiological testing. Along with our in-house analyses, this system ensures the absolute "cleanliness" of our storage facilities. Our manufacturing facilities Westfalen's manufacturing facilities are registered with the competent authorities in accordance with EU food hygiene legislation (Regulation 852/2004/EC). Suppliers to Westfalen Group Our suppliers are required to comply with our specifications. All components meet the criteria defined for Protadur. We accept only suppliers having guaranteed product traceability and established monitoring procedures. Suppliers' road tankers also have to undergo annual inspection by an independent body as per Commission Directive 231/2012/EU. Traceability Laboriously produced, fastidiously stored, food-safe for you. The origin and history of every Protadur delivery is systematically recorded, ensuring at all times traceability in accordance with Regulation 178/2002/EC. Certificates Pure diversity. Our Protadur gases and gas mixtures cover all food industry applications; on the following pages you'll find the ideal solution for your production. In choosing Protadur gases, you are absolutely assured of compliance with all applicable legislation; something we are happy to confirm to you by supplying an individual certificate for each delivery. Freezing and cooling Chopping/ mincing Hydrogenation Ripening Surface hardening Packaging ¾ The Declaration of Compliance (in accordance with DIN EN 10204) certifies compliance with the product specification. Preserving Carbonating Pressurising Foaming Stabilising Water treatment ¾ The Test Report (in accordance with DIN EN 10204, 2.2) certifies compliance with the order by stating the results of non-specific tests (batch analysis). ¾ The Inspection Certificate 3.1 Specific Inspection (in accordance with DIN EN 10204, 3.1) certifies compliance with the order by stating the results of specific tests. 5

6 Our best for your production. Protadur E 290 In the food products industry Protadur E 290 or CO2 carbon dioxide is a real all-rounder. It cools, protects, carbonates and also makes some manufacturing processes possible. Its specific properties are what make it so versatile: it's colourless and odourless, taste-neutral, oxidation-inhibiting and nutritionally safe. It also has bacterio- and fungistatic properties, meaning it inhibits the growth of fungi and bacteria. Carbon dioxide can be obtained by industrial or biogenic processes or from natural sources. Versatile in application Protadur E 290 is primarily used either on its own or as part of a mixture for protective atmosphere packaging. In liquid form or as dry ice snow, it is used for chilling or cryogenically freezing a wide range of food products. There are also two particular applications for Protadur E 290 in the beverage industry. Mixing carbon dioxide with water produces carbonic acid (H 2 CO 3 ) known as carbonation, this process creates the desired "fizz" in many soft drinks. By contrast, in the brewing industry carbon dioxide is added to the bottle or barrel rather than the beer. That's because according to the German Purity Law, the carbonic acid in beer can only be that produced through the natural fermentation process. Using gas at gentle pressure to pressurise bottles and casks facilitates filling without excessive foaming. Single cylinder 8 l 6.0 kg Single cylinder 13,4 l 10.0 kg Single cylinder 50 l 37.5 kg Bundle 12 x 50 l 450 kg Liquefied in tanker for static tank installations Freezing and cooling Packaging Carbonating Pressurising 6

7 Protadur E 941 Only nitrogen is almost as versatile as carbon N2 dioxide: as Protadur E 941 it's used in a wide variety of applications in the modern food and beverage industry. The main component of ambient air, nitrogen too is taste-neutral, colourless and odourless, reaction-inhibiting, non-flammable and nutritionally safe. At Westfalen nitrogen is produced by cryogenic air separation. Simplified stabilisation Protadur E 941 is also used in the beverage industry to stabilise PET bottles when bottling non-carbonated drinks. This facilitates bottling and makes the bottle itself easier to grip. As a bonus, at the same time the nitrogen pushes atmospheric oxygen out of the top of the bottle. Protecting, chilling, surface hardening Protadur E 941 has three main food industry applications. One is protective atmosphere packaging either on its own or mixed with carbon dioxide for all sorts of different products. Its rapid cooling effect makes nitrogen ideal for cryogenic chilling and freezing, especially in meat and sausage processing. Hardening the surface of the product improves mechanical slicing, while a controlled supply of cryogenic liquefied Protadur E 941 helps to maintain a uniform temperature during cutting processes. Delivering a smooth finish in the beverages industry as well both in processing and in logistics: Protadur E 941. Single cylinder 50l m 3 Single cylinder 50 l (300 bar) m 3 Bundle 12 x 50 l m 3 Bundle 12 x 50 l (300 bar) m 3 Mobile container 175 l container-specific Mobile container 600 l container-specific Liquefied in tanker for static tank installations Freezing and cooling Packaging Surface hardening Chopping/ mincing Stabilising 7

8 Protadur E 938 Argon makes up about 0.9 percent of ambient Ar air, and is manufactured by Westfalen in three air separation plants as Protadur E 938. As a noble gas it provides protection against microbial and oxidative product changes and is used primarily to drive ambient air out of product packaging. Like helium, it is used for particularly delicate products. Single cylinder 50l m 3 Bundle 12 x 50 l m 3 Mobile container 175 l container-specific Mobile container 600 l container-specific Liquefied in tanker for static tank installations Protadur E 942 The medical use of "laughing gas" is widely N2O known, but as Protadur E 942 dinitrogen monoxide is also used in the food industry. This compound of nitrogen and oxygen is colourless and water-soluble, and has a pleasant, slightly sweet taste. Protadur E 942 is therefore often used as a propellant, for example aerating spray cream, or to produce the desired creamy consistency. Packaging Protadur E 939 Helium is obtained from natural gases. As a He noble gas Protadur E 939 is used to package products which are particularly susceptible to changes in consistency, flavour and shelf life, making Protadur E 939 the ideal choice for ensuring the quality of dairy products and very delicate flavours. Single cylinder 50l m 3 Bundle 12 x 50 l m 3 In compressed gaseous form by trailer for static tank installations Packaging Appearance and consistency are often key and are always a treat with Protadur E 942. Single cylinder 50 l kg Bundle 12 x 50 l kg Foaming Protadur E 948 Pure oxygen is a component of ambient air and O2 is obtained in air separation plants. As Protadur E 948, oxygen is colourless, odourless, heavier than air and supports desirable oxidation reactions. In the packaging of fresh meat, especially beef, the gas inhibits the growth of anaerobic microorganisms. 8

9 Oxygen is also used as a propellant for foaming instant desserts or spray cream. Single cylinder 50l 10.6 m 3 Single cylinder 50 l (300 bar) m 3 Bundle 12 x 50 l m 3 Bundle 12 x 50 l (300 bar) m 3 Mobile container 175 l container-specific Mobile container 600 l container-specific Liquefied in tanker for static tank installations Packaging Foaming Protadur E 949 Hydrogen may be the oldest element, but in H2 food industry terms is still relatively young. We produce Protadur E 949 through a process known as steam reforming. Its primary use is in the hardening of fats by hydrogenation. In margarine production the double bonds in the fatty acid chains of the fat molecules are saturated with hydrogen, resulting in a higher melting point and turning liquid oils into solid fat. Single cylinder 50l m 3 Bundle 12 x 50 l m 3 In compressed gaseous form by trailer for static tank installations Protadur mixtures (C-Gases) Protective atmosphere packaging often involves the use of precisely defined mixtures of different gases. Protadur nitrogen-carbon dioxide and oxygen-carbon dioxide mixtures cover a broad range of applications. Special recipes are however needed in certain cases. We can either manufacture these individually to customer specifications or produce the required mixing ratio on-site in a gas mixing plant. Protadur mixtures always comprise pure Protadur substances. In other words: you can be certain they comply with all applicable regulatory requirements, including traceability. Protadur C 20 The Protadur C 20 gas mixture CO2 N2 comprises 20% Protadur E 290 and 80% Protadur E 941. This nitrogencarbon dioxide mixture is used primarily for packaging meat and sausage products, pasteurised or frozen ready meals and certain dairy products. Protadur C 20 is also used for preserving wine and sparkling wine. Single cylinder 10 l m 3 Single cylinder 20 l m 3 Single cylinder 50 l m 3 Bundle 12 x 50 l m 3 Hydrogenation Preserving Packaging 9

10 Protadur C 30 Protadur C 30 comprises 30% CO2 N2 Protadur E 290 and 70% Protadur E 941. This nitrogen-carbon dioxide mixture is suitable for packaging sliced sausages and frozen ready meals and pizzas. Being heavier than air, Protadur C 20 is also particularly used for storing wine in the catering industry. Single cylinder 10 l m 3 Single cylinder 20 l m 3 Single cylinder 50 l m 3 Bundle 12 x 50 l m 3 Single cylinder 50 l m 3 Bundle 12 x 50 l m 3 Packaging Protadur O 100 Protadur O 100 meets the same requirements O2 as Protadur E 948, with the added advantage of also meeting those of DIN EN Chemicals used for treatment of water intended for human consumption Oxygen. Packaging Preserving Liquefied in tanker for static tank installations Protadur C 50 Protadur C 50 is a 50/50 mixture of CO2 N2 Protadur E 290 and Protadur E 941. In this recipe this nitrogen-carbon dioxide mixture is particularly suitable for pasta, bakery goods, cream and potato products. Single cylinder 20 l m 3 Bundle 12 x 50 l m 3 Packaging Foaming Protadur O 70 C 30 As its name suggests, Protadur O 70 O2 CO2 C 30 is a mixture of oxygen and carbon dioxide. In this combination it is used almost exclusively for packaging fresh meat. Water treatment Protadur Ethen 4 Protadur Ethene 4 is a mixture of C2H4 N2 4 percent ethene and 96 percent Protadur E 941 and is used for the precision control of ripening processes in fruit and vegetables. Treating produce with this mixture of natural gases triggers metabolic processes which allow fruit harvested before it is ripe to ripen evenly in a controlled manner. Bananas for example are harvested green, transported at a constant temperature and then ripened in a precisely controlled atmosphere once they reach their destination. Single cylinder 50 l m 3 Bundle 12 x 50 l m 3 Ripening 10

11 The freshness promise. The food industry today caters for every possible taste. The more specific the product, the greater the demands on packaging. Our food gases will help you meet these demands both in taste and in regulatory compliance. 11

12 Our solution for your packaging requirements. Food products are coming under ever greater scrutiny both in terms of regulatory standards and increased consumer awareness. While purity and safety are paramount, taste and appearance are important too. Protective gas packaging has proven itself from both perspectives. It keeps food fresher for longer, and the reliable exclusion of atmospheric oxygen inhibits changes in colour and taste and the growth of aerobic bacteria and moulds. You ve already discovered our Protadur product solutions on the previous pages. Now we'd like to tell you about the key applications. Sealed protective gas packaging An important criterion for the effectiveness of protective gas atmospheres is the selection of appropriate packaging films. The film must prevent the escape of protective gas from the packaging, and the entry of atmospheric oxygen, for the requisite period of time. The use of composite films for protective gas packaging is now well-established because of their good cost-benefit ratio. Gas flushing Gas flushing eliminates ambient air from packaging by injecting a protective gas. This system has proved particularly effective in combination with the widely-used form-fill-seal machines. The product is filled into the tubular bag, which is flushed with Protadur, and the bag then sealed immediately. Existing packaging systems can be quickly and easily retrofitted with a protective gas flushing system. Evacuation In evacuation with gas refilling, air is first removed from the open pack. The pack is then refilled with Protadur protective gas and immediately sealed. This method has proved particularly effective in chamber vacuum machines for edge-sealed bags. Wherever freshness is demanded, it s securely packaged under Protadur protective gas. Tried and tested for meat and sausage products: evacuation and refilling with Protadur protective gas. 12

13 Your freshness, our mission. Stabilising Still drinks such as water, juice or iced tea contain little or no carbon dioxide. When PET bottles are filled with these they become unstable, which makes them difficult to label and less easy to palletise and transport. In short, manufacturing and logistics become harder, on top of which consumers are less willing to accept impractical or unaccustomedly "soft" bottles. To overcome this PET bottles are stabilised with nitrogen. Immediately before sealing, liquid nitrogen is added. As this gasifies it expands 700 times, so increasing internal pressure and stability. As nitrogen is completely tasteless and odourless, the particular characteristics of the drink are unaffected by the process. In addition, since the added nitrogen reduces the amount of oxygen in the neck of the bottle, the product's shelf life is also increased. Carbonating The process of adding carbon dioxide to a drink is known as carbonation. In this process mixing carbon dioxide with water produces carbonic acid, the solubility of which is dependent on pressure, temperature and other dissolved substances. Protadur E 290 is used for carbonation when for example the natural content of carbonic acid is inadequate, or by adding CO 2 to create a refreshing drink. It is also added to drinking water in drinks dispensers. Protadur E 290 naturell can of course also be used to produce as natural a drink as possible. Sparkling refreshment mineral water is carbonated with Protadur E 290, the CO2 combining with water to form carbonic acid. Making non-carbonated drinks easier to carry and transport stabilising PET bottles with Protadur E

14 Freshness, colour and vitamin content. These are the product qualities consumers are looking for. With modern refrigeration and freezing technology and reliable Protadur gases, you can be sure of achieving the best possible results. 14

15 Our refrigeration expertise for your quality assurance. Modern eating habits would be unthinkable without refrigeration and freezing. Freshness is everywhere and is universally expected, whether in the restaurant or the supermarket. Fruit and vegetables go straight from field to blast freezer, ensuring they retain both flavour and vitamin content. For delicate products in particular, conventional preserving techniques such as warming or heating are unsuitable. Speed and moisture content or moisture loss are the key parameters. The goal is quality-assured sterility with no "drip losses". We'll help you achieve perfect results every time. Our solutions for your production The Protadur range contains two product solutions with uses in refrigeration and freezing or in processing fresh produce. On the following pages you'll learn the key points about ¾ the efficient use of our food gases for chilling processes ¾ using liquefied carbon dioxide / Protadur E 290 ¾ liquefied nitrogen / Protadur E 941 in your production ¾ our expert knowledge of process and systems engineering Surface hardening for your processes Using Protadur E 941 is a simple way of hardening the surface of fresh meat, ham, pies and cooked meat. This makes possible, or much easier, the mechanical slicing of products and increases the cutting capacity since the products have the perfect consistency when they reach the cutting machine. Benefits of surface hardening with Protadur nitrogen: ¾ Workflow-optimised surface hardening in a freezing cell ¾ Constant surface temperatures before slicing ¾ Optimal cross-section and precision-cut edges ¾ Reduced wastage Making the cut in industrial slicing: surface hardening of sausage products with Protadur E 941. For more information see westfalen.com 15

16 Our know-how for your processes. Cryogenic freezing Cryogenic freezing units use cryogenic liquefied gases such as Protadur E 290 or Protadur E 941 as thermal media. Unlike conventional freezers, which use air for indirect cooling, cryogenic refrigerants act in direct contact with the items to be frozen. Suitable for all freezers Protadur E 290 and Protadur E 941 are suitable for all common cryogenic chilling and freezing applications on established equipment, irrespective of production capacity or chosen technology: ¾ Large-scale belt or tunnel freezers ¾ Space-saving spiral freezers and chillers ¾ Plate freezers for free-flowing products ¾ Freezing cells for batch chilling or freezing ¾ Blast freezers or rotary freezers for smaller products Cryogenic cooling Variations in ambient temperature while chilling during the manufacturing process can cause problems. Cryogenic cooling using Protadur E 941 prevents the negative consequences of these temperature variations. Liquid nitrogen can be added flexibly and in precise quantities, allowing high processing speeds to be maintained or even increased. Product quality is improved because the technique minimises thermal loading and prevents moisture losses. In addition, the rapid chilling achieved with Protadur E 941 means that the product passes through the critical temperature range between 45 and 15 degrees Celsius so quickly that the growth of microorganisms is virtually eliminated. Other product-specific benefits ¾ Better protein breakdown for optimal water binding ¾ Better colour retention through elimination of atmospheric oxygen ¾ Long-lasting flavour stability The benefits speak for themselves: ¾ Higher processing speeds ¾ Reduced thermal loading ¾ Lower moisture losses Blast freezing - the latest process technology allows consistency, flavour and aroma to be preserved. 16

17 Our services for your safety. Mobile test freezer Would you like to see for yourself the benefits of cryogenic freezing before converting your production facilities or investing in new equipment? Then we're pleased to offer you a special service. Use our mobile SF 80 test freezer for nitrogen or carbon dioxide. Try out different gases, techniques and temperatures directly on your products. After a training session with our engineers, we will leave the compact unit with you for a week or so, or assist you with your freezing trials at our own premises if you wish. Your benefits: ¾ Provision of a mobile unit ¾ Compact, space-saving system ¾ Software recording and analysis of freezing speed ¾ Recording of refrigeration chamber and product core temperatures Mobile gas analysis In conjunction with our partner Witt, we offer you a special service: location-independent sample analysis of your food packaging using the tried-and-tested "Oxybaby" device. We can come to you, or you can send us your products for sampling. This mobile gas analyser with Bluetooth interface, USB port and barcode reader gives you your O 2 and CO 2 values quickly and conveniently. Your benefits: ¾ Independent and accurate comparative measurement on-site ¾ Minimal measurement gas usage makes it suitable for even the smallest packs All part of the service and a catalyst for innovation Westfalen s mobile test freezer. Always in use and virtually always to hand Oxybaby for mobile gas analysis. 17

18 What you can expect from us. Other product-specific benefits ¾ The greatest security of supply because Westfalen isn t just a dealer as far as possible we produce all Protadur gases ourselves ¾ High flexibility with an excellent variety of delivery formats and container sizes from 6 kg cylinders to onsite systems. ¾ Close proximity to your business and knowledge of the latest production and systems technology ¾ Advice and dialogue from skilled personnel with good food industry experience ¾ Reliability built on our 90 years' experience in the gas industry and the corresponding know-how - from production to logistics Our strongest commitment The regulatory frameworks relating to food gases are complex. Users and consumers have high expectations. Protadur won't let you down: Manufacture Westfalen complies with Regulation 178/2002/EC and the requirements of the European Industrial Gases Association (EIGA) and the German Industriegaseverband (IGV): ¾ "Guidelines for Best Manufacturing, Filling and Distribution Practice of Food Gases" ¾ IGC DOC 125/11 "Guide to the Supply of Gases for Use in Foods" Specifications The Protadur range meets (and exceeds) the requirements of Regulation 231/2012/EU and voluntary industry specifications. ¾ Industrial Gases Council Document (IGC DOC) 70/99 D published by the EIGA ¾ DIN EN 12876: Chemicals used for treatment of water intended for human consumption Oxygen Individual gas supply from one source. Approvals The approval of food gases is subject to the following regulations: ¾ The German Food and Feed Code (LFGB) ¾ European Parliament and Council Directive 95/2/EC on food additives other than colours and sweeteners, as amended by Directive 2001/5/EC (12 February 2001) ¾ The German Additives Admission Ordinance (ZZulV): Ordinance on admission of additives in foodstuff for technological purposes. (29 January 1998) Modern air separation plant in Hörstel. 18

19 What you only get from us. Real service Partnership and service are on everyone's lips these days. But at Westfalen we do what we say. Through our vast product range, from high-purity gases through to bespoke gas mixtures for individual customers. Or our flexibility in terms of production plants and delivery formats from cylinder logistics to future-proof engineering concepts. And our people, all ready to help with their specialist knowledge from receptionists through to engineers. Would you like to try us out? As you wish! Put our service promise and expertise to the test. We'll work with you to produce every food gas to your specifications. We'll be glad to talk to you in detail about the many and varied uses of Protadur, the various delivery options and applications and the legal requirements for food gases. Tell us what you need. Safety-trained our service team are available for you always, everywhere. Find your personal contact via the internet at For more information see westfalen.com 19

20 Gases I Energy supply I Service stations Westfalen Austria GmbH Aumühlweg 21/Top Leobersdorf Austria Tel Fax info@westfalen.at Westfalen BVBA-SPRL Watermolenstraat Aalst/Alost Belgium Tel Fax info@westfalen.be Westfalen Gas s.r.o. Masarykova Domažlice Czech Republic Tel Fax info@westfalen.cz Westfalen France S.A.R.L. Parc d Activités Belle Fontaine Rosselange France Tel Fax info@westfalen-france.fr Westfalen Gas Schweiz GmbH Sisslerstr. 11/P.O. Box 5074 Eiken AG Switzerland Tel Fax info@westfalen-gas.ch Westfalen Gassen Nederland BV Rigastraat 20/P.O. Box AT Deventer The Netherlands Tel Fax info@westfalengassen.nl Westfalen AG Industrieweg Münster Germany Tel Fax info@westfalen.com Westfalen Medical BV Rigastraat EW Deventer The Netherlands Tel Fax info@westfalenmedical.nl J T P-G -EN