Separators, Decanters and Process Lines

from GEA Westfalia Separator for

Citrus Processing

engineering for a better world GEA Mechanical Equipment

Contents
4 1. Introduction

6 2. Citrus Fruit as the Raw Product
8 2.1 Structure of the fruit

9 3. Processing
10 3.1 Extraction of pectin
11 4. Process Lines for the Production and
Recovery of Citrus Fruit Products
11 4.1 Juice and concentrate
16 4.2 Automatic de-pulping and de-bittering
18 4.3 Juice de-oiling –
“Top oil separation”
19 4.4 Pulp wash
20 4.5 Clear lemon juice
22 4.6 Natural cloudy peel products
23 4.7 “Comminuted products”
24 4.8 Essential oil
28 4.9 Citrus oil de-waxing
28 4.10 Aroma water
30 4.11 Alcohol from citrus peel
32 5. Systems for the Citrus Industry
32 5.1 Decanters
33 5.1.1 GEA Westfalia Separator  varipond ® –
reliable mastery of solids concentration
33 5.1.2 Drive systems
34 5.2 Clarifiers –
high product quality and yield
35 5.2.1 GEA Westfalia Separator  hyvol ®
and hydry ® generations of machines
cover the full capacity range
36 5.3 Separators
36 5.4 Hydrocyclone
37 5.5 Ceramic membrane filtration
37 5.6 Line and control system –
better from a single source

38 6. Summary

39 7. Bibliography

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GEA Westfalia Separator
1. Introduction
The history of industrial citrus processing
is relatively recent. Citrus fruits used to be
principally marketed as fresh fruit, because it was
not possible to preserve them and sell them in
a preserved condition. The citrus industry took
an upturn in the mid-1940s. This was primarily
brought about by the introduction of modern
juice extraction processes. Since then, the market
for fruit juice and the consumption of fruit juice,
and thus sales opportunities, are increasing
throughout the entire world.
Figure 1 details the quantities of citrus fruits
which are harvested. Figure 2 demonstrates per
capita consumption of fruit juice and nectar.

Fig. 1 Quantities
of citrus fruits
harvested.
The largest
manufacturing
countries of the
respective products
are printed bold.
 Liters

The increasing popularity of citrus beverages GEA Westfalia Separator has been heavily involved
with the consumer, together with the importance in developing a large number of new processes.
which food scientists attach to the citrus fruit, has Modern citrus fruit processing methods provide
led to an impressive development in this market. many possibilities for the application of clarifying
and separating technology.
Two technological developments were among
the most important reasons for this rapid The wide range of application possibilities is due
growth process. to the many different stages involved in citrus
fruit processing. The individual components
These developments were: which are recovered can, in turn, be used for
• Automatic juice extractors recovering a wide range of new products.
• Gentle concentrate production processes Each method poses very specific requirements
with respect to process engineering and
Nowadays, technical experts and engineers are machine equipment.
increasingly devoting their attention to recovering
new products from citrus fruit, to increasing This technical-scientific documentation details
the amount of valuable components obtained, the wide range of methods and technological
to improving the quality of these components stages of citrus fruit processing. In particular, it
and to automating and optimizing the will discuss the use of centrifuges for solving a
traditional processes. wide range of problems encountered in the fields
of separation and clarification.

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GEA Westfalia Separator
2. Citrus Fruit as the Raw Product

The processing method and procedure are Because citrus fruits grow throughout the year and
determined principally by the type of fruit and because the ripening period can last for a total of
the structure of the fruit. five months, the fruits obtained at one particular
harvest are different from fruits obtained at other
The fruit types can be roughly classified as follows: periods of the harvest, particularly with respect
to acid, sugar and pigment content. The different
Orange-fruit types: types of fruit, depending on type and ripening
• Sweet orange conditions, also differ in other respects (vitamin
• Bitter orange C, pectin, carotenoids, flavonoids, etc.).
• Mandarine
The characteristic properties of the raw product
Yellow-fruit types: exert a great influence on the final product. Today,
• Lemon the assessment of juice quality is simplified by
• Lime, limetta statistical indices obtained from genuine raw
• Grapefruit product samples.

The orange (citrus sinensis) ist the most important
basic product in the citrus industry, followed by
grapefruits, lemons and mandarines.
Following is a list of the main types of oranges
grown in the individual citrus fruit countries:
• Brazil: Hamlin and Pera
• USA: Navel in Florida, Valencia in California,
Jaffa and Pineapple
• Italy: Biondo Comune, Ovale
• Spain / Marocco: Navel, Valencia, Jaffa
• Israel: Shamuty, Valencia
Figure 4 shows typical analytical values for
orange juice.
The first stage of industrial processing of citrus
fruit is to extract juice from the endocarp.
The residues which are created in this process
are the basis for producing a wide range of
additional marketable by-products. Many of these
by-products come from those parts of the fruit
which several years ago were discarded as they
were not considered to be of any value.

Fig. 3 Orange plant

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GEA Westfalia Separator
Fig. 4 Standard
values for
orange juice
(AIJN – Code
of Practice)
 1

8
7
6

5
4
3

Fig. 5 Orange and section through an orange

1 Stern end (proximal) 5 Albedo (mesocarp)

2 Stylar or blossom end (distal) 6 Endocarp with septa (partitions)
3 Exocarp (flavedo) 7 Fruit axis (half hollow)
4 Oil cells 8 Seed (partially cut)

2.1. Structure of the fruit
The following is a simplified explanation of the are larger, less compact and very high in pectin
structure of the citrus fruit:
Peel (pericarp)
This is made up of two layers, namely the flavedo
and the albedo. The flavedo is the outer layer of
the peel. It is pigmented and relatively thin. In
ripe fruits, the flavedo contains the vesicles and
also the pigments which contain carotene. The
vesicles contain essential oils. The outer epidermis
is covered by natural wax. This layer of natural
wax prevents water losses and protects the fruit
against fungal infections.
Compared to the flavedo, the cells of the albedo
content. The albedo borders on the edible part
of the fruit.
Flesh (endocarp)
The flesh of the fruit is divided up into radial
segments. These segments consist of a large
number of juice sacs which are held together by
high-molecular adhesive substances. The seeds
are located towards the center of each segment,
near the fruit axis. Short vascular bundles connect
the seeds to the main (threadlike) bundles which
run along the main axis of the fruit.

There is a smooth transition between the flavedo

and the underlying albedo. The albedo is so called
because of its whitish color.

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GEA Westfalia Separator
3. Processing
There are two main production fields in industrial
citrus processing, and the differences between the
two are related to the geographical area where
the fruits are processed. In the Americas (Brazil,
USA), large quantities of fruit are processed into
standard products in a relatively small number of
very large companies.

In other countries with a more favorable

climate (Israel, Italy, Morocco, etc.), production
concentrates on a wide range of special products.
These products are made in medium-sized and
small companies.

The technology used for processing raw products

in the production of juice is virtually identical
throughout the world. The freshly harvested,
healthy and intact fruits are stored in silos after
they are delivered to the processing plant. They
are then washed, sorted according to size and Fig. 6 Process technology
processed into juice.
Centrifuges or decanters are appropriate
Various extraction systems are used for
separating systems for a continuous cost-
recovering the juice. The systems of
effective process in the production of juice,
the JBT and BROWN companies are
concentrate, pulp wash, aroma, cloudy peel
frequently found. However, the Italian
products, pectin, alcohol and essential oil.
INDELIATO, BERTUZZI and other machine
manufacturers are also encountered on a
regional basis.

The extraction systems produce three intermediate

products (percentage values in relation to the raw
product):
Juice / Pulp 45 – 55 %
Peel 45 – 55 %
Essential oil 0.2 – 0.5%

Fig. 7 Intermediate products obtained during citrus fruit processing

The above percentage figures are only
approximations. They can fluctuate depending on
the type of fruit, the country in which the fruit is
grown and also the climatic conditions.

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GEA Westfalia Separator
 Citrus fruits

Juice and cells Peel Peel oil Comminuted products

Juice Cloudy peel products Essential oil

Cells Pectin Terpene

Concentrate Cattle fodder Flavonoide

Pulp wash Hesperidin

Dehydrated products Naringin

Segments Alcohol

Aroma Natural pigment

Candied peel

Fig. 8 Products which can be obtained from citrus fruits

3.1 Extraction of pectin estimated at approximately 35,000 tons of which

Citrus fruits occupy a special position, as they
have an unusually high concentration of pectin
substances in the flavedo and albedo (about 25
percent moist mass of the whole citrus fruit).
The pectin obtained from the citrus peel is used
mainly as a setting agent in the food industry,
but is also used in pharmaceutical and cosmetic
products. Global production of pure pectin is
70 percent comes from citrus peel. The pectin
process from GEA Westfalia Separator provides
today’s producers with an extraction process
which is gentle on the product and efficient.
More process technology information can be
found in a separate brochure on this specific topic.

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GEA Westfalia Separator
4. Process Lines for the Production and
Recovery of Citrus Fruit Products
Fig. 9 Diagram of juice extraction from whole fruits,
using extractor JBT
4.1. Juice and concentrate
There is a significant difference in the processing
of citrus fruits as compared to the processing of
pomaceous fruit, stone fruit and small fruits.
When extracting the juice from oranges,
grapefruits, lemons and limettas, the objective is
to obtain the best possible separation of juice, peel
and peel oil. It therefore does not make sense to
completely crush the fruit and press the resulting
mash. For this reason, special machines were
developed for extracting the juice from citrus fruits.
Each fruit can be processed individually with
these machines.
The peel contains the valuable peel oils. These
peel oils are the principal factors which affect the
taste of the juice. The proportion of oil in the juice
should be between 0.01 and 0.03 percent if the
juice is to have a balanced taste and if the juice is
to be preserved for any length of time. Depending
on the technology used, the oil is recovered in
advance (BROWN) or in the extractor (JBT).
Modern juice extraction processes make use of
two basically different extraction methods which
are described as follows:
BROWN method
In this method, the fruits are cut in half. The juice
is then extracted from each half by means of a
rotating squeezing head. This system is simply a
mechanized and automatic version of the simple
manual lemon press found in every kitchen. The
fruit holder replaces the hand, and the rotating
squeezing head replaces the pointed section of
the lemon press.
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GEA Westfalia Separator
 1 2 3 5 6

F
W
T
N P
U
4

7 10
D

H
D
K

8 9 11 12

Fig. 10 Process for the production of juice and concentrate

1 Extractor 9 Heater H Cooling water

2 Finisher 10 Buffer tank J Juice
3 Collector tank 11 Pump K Concentrate
4 Mohno pump 12 Evaporator N Cells
5 Hydrocyclone P Pulp
6 Clarifier B Vapor condensate T Emulsion
7 Buffer tank D Steam U Sand, solids
8 Pump F Fruits W Water

The orange juice is discharged from both
extraction systems with approximately 11° Brix
and a pulp content of between 20 and 25
percent (by volume). The pulp is then reduced
to approximately 10 – 12 percent (by volume) in
downstream finishers (horizontally-mounted
screen drums). Coarse trub particles such as cells,
rags and other fibrous materials are separated into containers (single strength juice). However, it
out in these finishers. Centrifuge systems
can then be used to reduce the trub particles
to almost any desired residual level. All
intermediate stages of residual solid level
can be achieved by varying the throughput
during the process of centrifugal clarification. In
this way, it is possible for the product to be adapted
at the stage of juice recovery to suit the specific
requirements or expectations of the consumer.
The fruit juice which is recovered is then subjected
to heat treatment (pasteurization or flash
pasteurization) and is subsequently directly filled
is usual for this pre-clarified juice to be evaporated
in order to obtain concentrates. Approximately
10 – 12 tonnes of fruit are necessary to produce 1
tonne of concentrated orange juice with 65° Brix.

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GEA Westfalia Separator
 60

50
Clarification performance in m3 / h

40

30
8 %
6 %
20
4 %
2 %
10

0
GSC 45 GSE 75 GSE 125 GSC 150 GSE 200 GSE 300

Fig. 11 Capacities of various clarifiers used for pulp reduction as a function of clarification efficiency.
The value shown here refers to machines without continuous pulp removal.

The centrifugal pre-clarification of the raw juice
permits the production of juices with a high
degree of cloud stability since centrifuges classify
trub particles according to particle size. All coarse
trub particles, which have a strong tendency to
sediment, can be separated off. Only the extremely
cloud stable fine particles remain in the juice. The
risk of deposits forming is therefore reduced to
a minimum.

Fig. 12 Separator GSC in juice production

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GEA Westfalia Separator
Italian method
If a solid content below 1 percent (by vol.) is
desired, a 2-stage process using a decanter can be
provided. The juice is heated in a tubular heater
to between 75 and 85° C before entering the first
clarification stage. Pre-clarification is carried
out in a decanter, and subsequent clarification
is performed by a clarifier in the second stage.
This method is used principally in Italy. It is not
necessary to use an upstream finisher when the
Italian method is used.

F
T W

P
1 2 3 4 5

H
B
K
D

11 10 9 8 7 6

Fig. 13 Process for the recovery of low-pulp juices (“Italian method”)

1 Extractor 9 Buffer tank H Cooling water

2 Buffer tank 10 Pump J Juice
3 Pump 11 Evaporator K Concentrate
4 Tubular heater P Pulp
5 Decanter B Vapor condensate T Emulsion
6 Buffer tank D Steam W Water
7 Pump F Fruits
8 Clarifier

* The capacity figures listed above are based on a pulp content in the decanter feed of 25 percent (by vol.) and 3 percent (by vol.) in the decanter discharge.
** For clarifiers, the pulp contents are 3 percent (by vol.) in the feed and 0.5 percent (by vol.) in the discharge.

Fig. 14 Sample of types and capacities of decanters and clarifiers used for pulp reduction in the production ot citrus juice
(“Italian method”)

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GEA Westfalia Separator
Separators with continuous de-pulping
In an alternative process configuration, the pulp
is discharged from the clarifier bowl by means of
a special centripetal pump. This reduces the load
on the disk stack. The intervals between the solid
ejection cycles are considerably lengthened. The
clarification efficiency of the centrifuge is vastly
improved. Consequently, higher throughput
capacities and / or residual pulp contents in the
juice of 1 percent (by vol.) can be obtained.

Automatic pulp evacuation Fig. 15 Lemon pulp

The machines can be provided with an
additional automatic system. A sensor measures
the consistency of the concentrated pulp and • Longer solids-ejection intervals
determines whether to recycle the pulp into • Compact pulp with high level of
the feed line or to send it to the solids tank. A dry substance
regulating valve optimizes the counter pressure in
the discharge line and thus the consistency of the The following chart (figure 16) illustrates the
pulp for the purpose of minimizing juice losses. process for continuously discharged pulp.

The advantages of this method of reducing the It must be noted that continuous pulp discharge is
level of citrus pulp are as follows: only possible with specially designed separators.
• Low level of residual pulp content in the The models GSE 125, GSE 200 and GSE 300 are
clarified juice suitable for this application. These machines can
• Minimum juice losses be retro-fitted in existing plants.

1 Tank
2 Pump
3 Solids tank
4 Clarifier
5 Flowmeter
6 Reversing valve
7 Pulp sensor
8 Pressure sensor
9 Control valve

Fig. 16 Automated continuous pulp discharge

* The capacity figures listed are based on a residual pulp content in the separator feed of between 10 and 12 percent (by vol.).

Fig. 17 Capacity data of clarifier

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GEA Westfalia Separator
4.2 Automatic de-pulping and de-bittering
De-bittering and acid adjustment of
citrus products
Depending on the raw material used and on the
desired end product, the extracted juice may have
to be de-bittered or de-acidified. To achieve this,
citrus juice is processed with adsorption plants
in order to improve the quality and value of
the product.
Adsorber columns containing resin reduce the
bitterness and acidity respectively.
Perfect operation of the adsorption plant requires
a juice with a pulp content below 1 percent.
Fig. 18 Feed to separator
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GEA Westfalia Separator
Centrifugal separation technology allows gentle
product treatment for this purpose.
De-bittering (“adsorption”)
In the adsorption process, the juice is sent through
a column containing an adsorbent polymer resin.
Polymer resin adsorbs the bitterness (e. g. limonin
or naringin).
De-acidification (ion exchange)
In the ion exchange process, the juice or fruit
extract is sent through a column containing an
ion exchange resin. In this way fruit acids are
exchanged onto an absorbent medium.
In both cases, when the capacity of the resin has
been exhausted, the resin has to be regenerated
so that it can be reused. Stainless steel columns
are used to contain the resins. For continuous
processing, equipment with twin alternating
columns is used. One adsorber unit is processing
while the other one is regenerating.
To comply with the desired product specification it
is often necessary to recycle (part of) the previously
separated pulp after de-bittering / de-acidification.
The most efficient way of doing this, is to reduce
the pulp level prior to the adsorption process to
below 1 percent by means of a centrifuge. The
excess pulp obtained from the separator is added
back later at the desired level.
 1 Separator
2 Supply tank
6
3 Pump
4 7 4 Adsorption unit
5
2 (column 1)
5 Adsorption unit
(column 2)
6 Resin purification
7 Tank
Juice with 0.05% oil 8 Pump
Juice with
9 Mohno pump
max. 1% pulp

3 8

Excess pulp
e. g. with 10% pulp content
1 9

Fig. 19 Citrus de-bittering process

Fig. 20 Processing of citrus juices with a separator (left) and adsorption unit (right)

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GEA Westfalia Separator
4.3 Juice de-oiling – “Top oil separation”
Juice de-oiling is a special application for the
production of nfc juices (not from concentrate).
Depending on the extraction system used, more
or less high quantities of peel oil enter the juice.
When producing concentrate, this oil is evaporated
which presents no problem. In the production of
nfc juices, however, this oil cannot be thermally
separated. Due to the fact that the oil remains
in the juice, an unpleasant, astringent taste may
develop. This makes it necessary to separate the
oil in order to obtain a high-quality juice. The oil
content is reduced to maximum 0.035 percent (by
vol.). Some producers demand values smaller than
0.03 percent (by vol.).
This limitation of the oil content can be
achieved by appropriately modifying the
extraction systems. However, in most
cases a compromise has to be accepted
in terms of yield and hence the economy of
the process. For this reason, there is a growing
interest in centrifugal polishing of the oil from
the partially pulped juice.
The oil content is centrifugally separated gently
so that values between 0.02 and 0.03 percent (by
vol.) can be obtained (based on feed oil contents of
0.1 percent (by vol.). Product losses are minimal.
1 4
J O P O Oil discharge
2 3
Fig. 22 Process for juice de-oiling
GEA Westfalia Separator
The machines used are separators (liquid-liquid
separation).
These machines are adapted to the very small
contents of light phase (citrus oil). The separated oil
is generally not used because of the low quantity.
In addition to the ESE 140 and ESE 230 models,
there is a demand for even larger machines as
a result of rapid market growth. GEA Westfalia
Separator responded by presenting the ESE 500
for the high capacity range and by successfully
putting this separator into operation.
The separator type ESE 500 offers feasible
economic possibilities for producing large volumes
of nfc.
* The figures are based on an oil content in the separator feed of
maximum 0.1 percent (by vol.) and of maximum 0.035 percent
(by vol.) in the discharge.
Fig. 21 Guide values for processing orange juice with
1 – 8 percent (by vol.) pulp
1 Fresh juice tank
2 Feed pump
3 Separator
4 Buffer tank
5 Pump
6 Plate heat
D D exchanger
J Juice
J P Solids
D Steam
5 6
18
 1 2

F
W
T
J
3 4 5 6

P
J P

11 10 9 8 7

Fig. 23 Process for the production of pulp wash

1 Extractor 7 Scroll mixer F Fruits

2 Finisher 8 Finisher J Juice
3 Scroll mixer 9 Storage tank P Pulp
4 Finisher 10 Pump T Emulsion
5 Scroll mixer 11 Clarifier W Water
6 Finisher

4.4 Pulp wash
In the production of pulp wash, the cells which
have been separated out by the finisher are treated
in a multi-stage counter-current washing system.
With the aid of scroll mixers and finishers, it is
possible to extract up to 90 percent of the valuable
juice components such as fructose, fruit acids,
minerals, carotenes, etc., from the cells.
The pulp wash obtained in this process has a Brix
content of between 4 and 5° and still contains a
high proportion of trub particles. These can be
separated out with the aid of clarifiers. The pre-
clarified product is concentrated to 60° Brix in
an evaporator.
Pulp wash can be marketed as a product in its
own right. It is also usual and allowed in some
markets to mix orange juice with the pulp wash
before the concentration process. The maximum
amount of pulp wash which may be blended with
the first-class juice is governed by the statutes and
standards in each individual country.

The capacities of pulp wash clarification are

roughly equivalent to the capacity of normal
citrus juice clarification. This is true
if the pulp content does not exceed
10 to 12 percent (by vol.) upstream of
the centrifuge.

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GEA Westfalia Separator
4.5 Clear lemon juice
The production of clear lemon juice used to be
very difficult, time-consuming and associated
with a high level of risk in terms of quality.
Using traditional methods, the clarification
process involved allowing the juice to stand.
Several weeks were frequently necessary for
this process. In view of the lengthy amount
of time necessary for the sedimentation
process, the juice had to be protected
a ga i n s t ox i d a t i o n a n d a l s o a ga i n s t
u n d e s i r a b l e m i c r o b i o l o g i c a l a c t i v i t y.
Today it has been possible to reduce process
Fig. 24 2-stage plant with GSC separators
times to between approximately 6 and 8 hours.
This has been achieved by making use of
traditional pre-clarifiers combined with modern
high-performance clarifying centrifuges (g force:
15,000) and also by making use of newly developed
enzyme preparations.

With this product, the actual process of recovering

the juice is identical to that encountered in
connection with other citrus fruits. After the juice
is discharged from the extractor, the solids are
reduced by means of a finisher and pre-clarifier.
A maximum pulp content of 2 percent (by vol.)
in the discharge of the preclarifier is desirable.
The pre-clarified juice is then heated to between
25 and 40° C (optimum enzymation temperature,
depending on the pH value of the juice). It is not
easy to choose a suitable enzyme preparation and
optimum reaction conditions for reducing pectin
at pH values of around 2.8.

The juice is treated with enzymes in the

downstream reaction tank. The correct enzyme
dosage depends on the desired reaction time. If Fig. 25 Spin test specimen
the process does not exceed three hours, then it
is not necessary to add SO2. If the process does
exceed three hours, then adequate protection
against oxidation must be provided by adding
SO2 in quantities of up to 500 mg / kg. When the
enzyme reaction has finished (this is checked by a
quick alcohol test), then the product is refined with
Kieselsol. This process causes the fine trub particles
which are still in suspension to agglomerate.
The Kieselsol dosage which is necessary depends
to a great extent on the efficiency of the pre-
clarifier which is installed downstream of the
finisher. The lower the residual pulp content in
the juice, the lower the consumption of Kieselsol.

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GEA Westfalia Separator
Fig. 26 Process for the production of clear lemon juices

1 Extractor 11 Enzyme tank F Fruits

2 Finisher 12 Pump H Cooling water
3 Collecting tank 13 Clarifier J Juice
4 Pump 14 Tank K Concentrate
5 Hydrocyclone 15 Pump P Pulp
6 Clarifier 16 Evaporator T Emulsion
7 Tank U Sand, solids
8 Pump B Vapor condensate W Water
9 Heater D Steam
10 Tank E Enzymes

For clarifying the juice, the Kieselsol is mixed
intensively with the product. The mixing
equipment is then switched off and the mixture is
permitted 30 minutes reaction time. The very fine
particles coagulate during this period. In the fine
clarification process, the fined juice must be fed
smoothly into the centrifuge, avoiding excessive
shear forces. Gravity feed or specially chosen
smooth-action pumps are suitable for conveying
this product.
Poorly designed pumps lead to the mechanical
destruction of coagulated trub particles (principle
of ultradispersion), thus providing a poor
clarification effect.
The clear juices are usually then further processed
into concentrates.
Instead of the high performance centrifuges a
membrane filtration plant can be used. More
information on this topic can be found in chapter
5.5. Capacities of high performance centrifuges
and membrane filters will be communicated
on request.

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GEA Westfalia Separator
4.6 Natural cloudy peel products • Centrifugal pre-clarification by means
Cloudy peel products are obtained principally from of decanter: Reduction of solids to
citrus peel. However, the basic product may also be approximately 1⁄4 of level in feed
a mixture of peel and pulp. The product which is • Centrifugal clarification by means of clarifiers:
obtained from the peel by extraction with water is Reduction of solids in decanter discharge to
concentrated from an initial level of 4 to 5° Brix to a less than 1 percent (by vol.)
final level of approximately 50 ° Brix. It contains the
natural components of the original material. The The products obtained from this process are used
product is cloudy, but at the same time it exhibits as basic products in the soft drink industry. The
extreme cloud stability. The cloudiness is most important property of this product is its
attributed to the effect of pectins, polysaccharides excellent cloud stability. It is also very important
and waxes and the essential oils. for the beverage industry as an aroma, trub and
coloring agent.
Cloudy peel products can be obtained via a number
of methods. However, processes which make use
of pectolytic, cellulytic and proteolytic enzymes
and which permit enzymatic liquefaction of
the original material appear to be gaining the
upper hand.

Various process parameters must be maintained

in order to obtain an optimum product. These
parameters include:
• Degree of size reduction: Uniform particle
size of comminuted peel to ensure optimum
cell disintegration
• Mixture ratio: Ratio of comminuted peel
to water
• Enzyme type: Cf. data of enzyme producers
• Enzyme quantity: Cf. data of enzyme
producers
• Enzymation temperature: Cf. data of enzyme
producers * For the decanters, the indicated capacities are based on a pulp content
of between 35 and 40 percent (by vol.) in the feed and between 8 and
• Mixing intensity: Use of low-speed paddle
10 percent (by vol.) in the discharge.
mixers ** For the clarifiers, the indicated figures are related to between 8 and
10 percent (by vol.) in the feed and approximately 0.5 percent (by vol.)
in the discharge.

Fig. 27 Types and capacities of centrifugal clarifiers and

decanters for the production of cloudy peel products

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GEA Westfalia Separator
 1

2
W
3

U U

4 5 6 7 8 9
16
10

18 17 15 14 13 12 11

Fig. 28 Process for the production of cloudy peel products

1 Peel silo 10 Vibrating screen B Vapor condensate

2 Hammer mill 1 1 Pump D Steam
3 Mixing tank 12 Tank E Enzymes
4 Mohno pump 13 Pump H Cooling water
5 Enzyme tank 14 Heater K Concentrate
6 Metering pump 15 Clarifier U Solids
7 Reaction tank 16 Tank V Peel
8 Mohno pump 17 Pump W Water
9 Decanter 18 Evaporator

4.7 “Comminuted Products” The following are then set:

A special product group is represented by the • Acid level, using citric acid
so-called comminuted products. These are used as • Juice level, using juice concentrate
intermediate products for soft drinks and also for • Aroma, using oil
other applications. They are used as a component
in intensively-pigmented, viscous, and clouded The process of homogenization is performed in
products and also products with a colloid mills and high-pressure homogenizers.
high degree of cloud stability. In this The basic products for soft drinks which are
p r o d u c t i o n p r o c e s s, c l a r i f i c a t i o n o r obtained in this process are preserved by means
removal of trub particles are not necessary. of pasteurization or by adding preservatives.
The most important item of equipment is the
disintegrating machine which completely crushes
and mashes the whole fruit.

23
GEA Westfalia Separator
 4.8 Essential oil
Citrus peel contains essential oils. These oils are
formed in the cells of the so-called oil glands, and
they are some of the most important by-products
obtained from the processing of citrus fruit.
Essential oils are in demand as taste and aroma
agents for the food industry and for the production
of odorous substances. Several methods are
available for recovering essential oil.
Juice and oil are extracted in one process step
where JBT extractors are used for processing citrus
fruit. The peel of the fruit is cut and squeezed
during the processing procedure. This releases
the oil which is contained in the peel. The oil is
obtained from the flavedo during this mechanical
treatment. The valuable essential oils are then
washed out and separately collected during this
process step.

1 Extractor
1 2 4 2 Vibrating screen
3 Pump
4 Tank
5 Pump
T 6 Hydrocyclone
W 7 Separator (first stage)
F
J 8 Buffer tank
U 9 Mohno pump
13
12 10 Separator (second stage)
3 5
11 Pure oil tank
12 Automatic filter
W
13 Treatment tank
14 Pump

14
F Fruits
J Juice
O
O Essential oil
W 6
O T Emulsion
U Solids, sand
W Water
U U

U W
11 10 9 8 7

Fig. 29 Process for the recovery of essential oil

24
GEA Westfalia Separator
In other juice recovery methods, either the
peel of the citrus fruit is pricked before the
extracting process and the oil which appears is
washed away with water (BROWN), or the outer
section of peel (flavedo) is rasped before being
mixed with water and then further processed
(INDELICATO). The first stage configuration is based on an emulsion with an oil content of
0.8 – 1.2 percent (by vol.).

The oil-water emulsion obtained in modern fruit Fig. 30 Essential oil concentration (first stage) with separators
processing lines contains approximately 70 to 90
percent of the essential oil naturally present in
the peel. The peel wash water contains between
2 and 5 kg essential oil as an emulsion per
100 kg of raw material processed, depending
on the type of fruit and the processing
technology used.
Fig. 31 Polishing of essential oil (second stage) with separators

One of the most important criteria in oil recovery

from peel wash water is the efficiency of the
downstream phase separation system.

25
GEA Westfalia Separator
Depending on the type of fruit, the proportion
of oil in the wash water is between 0.5 and 2.0
percent (by vol.). In the concentration stage (first
stage), this oil is generally concentrated up to 70
to 85 percent (by vol.). At the same time, relatively
coarse solids fractions are separated off. Figure 30
shows the first separation stage with separators
and capacities.
The total volume of oil contained in the peel wash
water can be efficiently recovered as clear essential
oil with a suitably rated 2-stage centrifuge system.
The process of phase separation is described in
detail in section 5.3. In the polishing stage (second
stage), the remaining water is removed and the
very fine solids particles are separated off.
The second processing stage with separators and
capacities is illustrated in figure 31.
Under certain conditions, the polishing separators
of the second stage can be provided with a “self-
thinker” control system ensuring bowl ejections
are triggered at the optimum fill level of the
solids holding space. Figure 32 illustrates the
corresponding system.
Depending on the type of separator, the pure
essential oil discharges either under gravity
or is pressure-discharged via a centripetal
pump. It is then collected in a tank. A smooth-
T O Essential oil
O U Solids
U
W
1 2
Fig. 32 Diagram of the “self-thinker” control system
26
GEA Westfalia Separator
action displacement pump delivers the
essential oil into an overhead tank. It is then
conveyed to a de-waxing stage. The level of liquid
in the overhead tank and thus the delivery head
of the pump are kept constant by means of an
overflow. This also provides a constant pressure
for the partial stream diverted off to the separator.
This partial stream is also called the impulse oil.
The quantity flowing into the separator can be
set by means of a throttle valve. The impulse
oil is recycled into the sediment holding space
of the separator. When the sediment holding
space is optimally filled with water and solids,
the flow of the impulse oil is blocked. This causes
the pressure in the impulse oil line to rise. The
pressure switch in the impulse oil line registers
the pressure differential and triggers the solids
ejection signal.
The operation of this “self-thinker” control system
is not time related. A timing unit is not required.
The advantages of this “self-thinker” control
system are as follows:
• A high level of reliability
• Solids are ejected from the bowl only when
the optimum level is reached
• Solids not ejected at inappropriate moments,
e. g. if product feed is interrupted
• Optimum oil yield
1 Separator
2 Collecting tank
4 3 Pump
4 Overhead tank
5
5 Needle valve
O
5 T Emulsion
W Water
3
This “self-thinker” control system is suitable for
plant automation and is used in the USA.
The following technical process parameters must
also be observed in order to achieve optimum
yield values:
• Use of smooth-action pumps for conveying
product (avoidance of shearing forces)
• Addition of water in correct quantities during
extraction or during pricking reduced (essential oil has a bacteriostatic
or rasping
• Avoidance of excessively high temperatures
(danger of evaporation)
Cost-effectiveness and waste water disposal
considerations resulted in a large number of
companies recycling water discharged by the
separators back into the process after appropriate
treatment.
The advantages are as follows:
• Reduction of water consumption
• Quantity and pollution level of waste water
effect even in low concentrations)

100% essential oil contained in citrus fruit

Emulsion
recycling

Extraction

Up to 25%
in the peel

Pre-screening
of light emulsion 1% in the trub
(de-pulping) particles

Separator,
first stage 2 – 6%
(concentration) in the water

Separator,
Approximately
second stage
2% in the water
(polishing)

Storage

Pure oil yield, up to 90%

Fig. 33 Mass balance of essential oil recovery during processing

27
GEA Westfalia Separator
4.9 Citrus oil de-waxing
Waxes in the citrus fruit peel form a natural
protective shield. In particular, these waxes
prevent the fruit from drying out.
In the technical process of recovering valuable
essential oil (cf. section 4.8), a proportion of this
wax enters the oil phase. The quantity of wax will
depend on the extraction system which is used.
These waxes are undesirable products. After the
clear oil has been stored for a certain time, the
waxes become insoluble and lead to a deterioration
in the quality of the oil and must be removed for
this reason. There are various methods which are
suitable for this process.
In most cases, the de-waxing procedure involves
storing the essential oil at low temperatures.
Depending on the temperature and type of fruit,
a period of up to two months may be required for
the total cold-sensitive wax content to precipitate
out of solutions.
Fig. 34 Evaporator station
28
GEA Westfalia Separator
4.10 Aroma water
Citrus juices are frequently concentrated in
multi-stage evaporators. Considerable quantities
of steam condensate and vapor condensate are
produced in this process.
Certain quantities of aroma components and
essential oils are lost in the vapor condensate.
These valuable fruit components occur almost
exclusively in the first evaporation stage.
For this reason, the condensate at this point is
also described as aroma water. Almost all citrus
factories recover the aroma water and subject it
to further treatment. The process of aroma water
recovery is useful and advisable for both quality
and flavor reasons, particularly in conjunction
with the citrus fruits grown in regions with a less
favorable climate.
The recovery process is as follows:
The aroma-containing condensate obtained in the
first evaporation stage is collected separately and
cooled down to ambient temperature. However,
oil components of the juice are also separated
out in the evaporator, and these are precipitated
with the condensate. This necessitates a process
of separating aroma water and oil. Separators
(2-phase separation) have proved to be particularly
suitable for this task. The separated oil-free aroma
water is used either for blending the concentrate
(cf. figure 36) or marketed as aroma water which
is surplus to requirements. The separated oil
is used in many applications, e. g. in the
cosmetics industry.
Fig. 35 Capacity of the separators used for the
recovery and treatment of aroma water
 1 2 4

D H
B
J J
K A

A, O

O A

5 6 7 8 9 10 11 12 13

Fig. 36 Process for the recovery and treatment of aroma water

1 Evaporator 9 Pump A Aroma water

2 Buffer tank 10 Separator with B Vapor condensate
3 Pump solid-wall disk type bowl D Steam
4 Blending tank 11 Buffer tank H Cooling water
5 Buffer tank 12 Pump J Juice
6 Pump 13 Tank K Concentrate
7 Cooler O Oil
8 Buffer tank

29
GEA Westfalia Separator
4.11 Alcohol from citrus peel
In light of continually fluctuating crude oil decanters. This process stage prevents the
prices, diminishing natural resources and strong
political dependence on oil exporting countries,
attempts to provide safe energy supply are one of
today’s mega trends.
Many countries are turning to the possibility of
introducing savings in traditional energy sources,
particularly crude oil. All imaginable alternative
energy sources are used for generating energy.
The recovery of energy from biomass, and in
particular from sugar cane, is now very important
in Brazil.
Solar energy can also be used indirectly by
recovering energy from the vegetable biomass
“citrus peel.” Large quantities of citrus fruit peel
are obtained in the course of citrus juice recovery
(up to 50 percent by weight of the fruit).
It is possible to use biotechnological methods to from this process is a very energy efficient fuel for
convert citrus peel into various forms of energy,
and principally mobile forms of energy.
For instance, it is possible to obtain alcohol from of environmental friendliness.
citrus peel as described below.
The de-oiled citrus peel which is discharged from
the extractor is disintegrated, neutralized with
lime (CaCO3) and conveyed to a special press.
The pressed peel is further processed into animal
fodder, as used to be the case in the past.
30
GEA Westfalia Separator
The press liquor is clarified with the aid of
occurrence of trub particles and lime deposits in
the downstream evaporator stage, ensuring that
the evaporator operates in a cost-effective manner
without malfunctioning.
The pre-concentrated press liquor is a
fermentable substrate. The fermentation yeast
can either multiply if oxygen is added, or, if
most air is excluded, it can produce alcohol from
carbohydrates.
In this biochemical process, the sugar content in
the press liquor is broken down into alcohol and
CO2. When the alcoholic fermentation process has
finished, the yeasts as well as other coagulated
solids are separated off in a nozzle bowl centrifuge.
The pre-clarified alcohol solution is then distilled.
The alcohol is separated and fractionated in modern
distillation columns. The bioalcohol obtained
combustion engines, both in terms of efficiency
and power yield. One significant advantage of this
fuel when compared with gasoline is its high level
Alcohol recovered from citrus peel is also used
in the chemical and pharmaceutical industries,
e. g. for plastics, chemicals and also as a solvent.
 1 4 5 6 9
V

X 2

Y
10
3 15 U
7 8
B
18 Z H

11
U

Z
19 16 14 13 12

17

H H
21 21

D D

20 20

Fig. 37 Process for recovering alcohol from citrus by-products

1 Peel silo 11 Evaporator B Vapor condensate

2 Hammer mill 12 Buffer tank D Steam
3 Sroll mixer 13 Pump G Alcohol
4 Conveyor belt 14 Fermenter H Cooling water
5 Vertical press 15 Rotary brush strainer U Solids
6 Buffer tank 16 Pump V Peel
7 Pump 17 Mohno pump X Lime
8 Decanter 18 Separator Y Animal fodder, slop
9 Buffer tank 19 Buffer tank Z Yeast
10 Pump 20 Distillation columns
21 Cooler

31
GEA Westfalia Separator
5. Systems for the Citrus Industry
9.1 Decanters
When clarifier operation is no longer feasible
due to high proportions of solids in the
suspension to be processed, decanters are
used. The decanter design is based on decades
of experience in centrifugal separation
techniques as well as intensive research and freed from any adhering liquid by centrifugal force.
development by GEA Westfalia Separator.
Decanters have been developed for
high clarifying performance and the
maximum possible degree of solids flights of the scroll to the other end of the bowl.
de-watering. Essential conditions for this include,
among others, high bowl speed and an enormously
high scroll torque in conjunction with a control
system to synchronize differential speed and
solids load.
In this process the product enters the decanter
through the feed tube and the distributor
conveys it into the separating chamber where it
is accelerated to operating speed. The action of
centrifugal force quickly causes solid particles to
sediment on the bowl wall.
The bowl is of a cylindrical / conical shape. In the
cylindrical section, this shape allows effective
clarification of the liquid, while in the conical
section, the solids are effectively dried.
32
GEA Westfalia Separator
The scroll rotates slightly faster than the bowl
shell and conveys separated solids continuously
towards the narrow end of the bowl. Due to the
conical shape of the bowl here, the solids are lifted
out of the liquid and, on passing through the
“drying zone” which is no longer filled with liquid,
The solids are then discharged into the collecting
chamber of the housing through openings in the
end of the bowl. The liquid flows out between the
Slight impurities remaining in the liquid are
spun out by centrifugal force as the liquid flows
through the clarifying zone and is pumped by
the scroll to the “solids discharge” point together
with the solids which have already been collected
in the feed zone. The clarified liquid leaves the
separation chamber under pressure by means of
centripetal pumps. Depending on the decanter
type, it may be driven by a 3-phase AC motor
for controlled torque starting or alternatively by
3-phase AC motors with a frequency converter.
This allows start-up current and current peaks on
start-up to be reduced. The power is transferred
by belts.
Fig. 38 Decanter GCE 535
5.1.1 GEA Westfalia Separator  varipond ® –
reliable mastery of solids concentration
This control system uses existing capacities so
accurately that maximum results are achieved for
minimal duty. GEA Westfalia Separator  varipond
means “variable pond depth with machine running.”
Even if feed concentration varies dramatically, the
system controls the liquid level in the decanter
bowl so accurately that the concentration of the
concentrated solids can be set to a constant value
and maintained.

Fig. 39 Westfalia Separator ® varipond ®

Westfalia Separator  varipond  facilitates much lower
energy use, because adapting the g-force to feed
conditions and the associated reduction in speed
allows electrical energy to be saved. Abrasion on
the components is reduced and their service life is
increased.

5.1.2 Drive systems

GEA Westfalia Separator decanters have specially
designed drive systems.

2-gear drive
With this drive, the main drive motor drives the bowl
and the housing of the primary gear. An additional
secondary gear allows part of the power required
for the scroll drive to be provided by the secondary
motor. The current of this motor serves as a measure Fig. 40 2-gear drive
of torque-dependent differential speed control. The
drive is electronically monitored and can be
restarted. Downtimes due to overloading are
ruled out and smooth operation is guaranteed.
Decanters with this drive, which is patented in many
countries, are used when high torques are required
for maximum yields at low differential speeds.

Differential gear drive

The differential gear drive is recommended when
automatic control of scroll speed is required in
addition to bowl speed control. This is made possible
by the use of two gears. The secondary motor drives
the central inlet shaft and generates the differential
speed proportional to its own speed. A second inlet
shaft with no speed is connected to the housing. Fig. 41 Differential gear drive
This makes differential speed independent of bowl
speed. Differential gear drives are used primarily for
the lower differential speed range.

33
GEA Westfalia Separator
2.2 Clarifiers –
high product quality and yield
The expertise gathered from decades of experience
enabled GEA Westfalia Separator to adapt the
design of its separators to suit the requirements
of the juice industry completely. Self-cleaning
separators are used for juice clarification and
these naturally satisfy the requirement for a
continuous process.
The separators are equipped with a disk bowl and disk angle, disk diameter and number
sliding piston. The liquid is quickly and gently
clarified in a disk stack, the solids being spun
outwards into the solids chamber. Once the
optimum emptying point has been reached,
the sliding piston is opened hydraulically.
Once operating speed is reached, the solids are
suddenly ejected and the sliding piston returns
to the closed position. The clarified liquid is
taken away without foam and under pressure by Effects on clarification
centripetal pumps. If the liquid should not come
into contact with the outside air, these separators
can be supplied in a hydrohermetic (liquid seal)
variant.
Hydrohermetic variant
With these separators, the seal to the atmosphere
is achieved without using seals subject to wear by
means of an immersion disk arranged above the
product’s centripetal pump. This prevents the spun are the key factors.
product coming into contact with the outside air.
High-performance clarifiers
Separators of this series can be supplied with the
hydrohermetic variant. Use of new, high-strength
materials means that centrifugal forces 15,000
times those of the acceleration due to gravity can
be achieved. That way, solids particles up to an
order of magnitude of approximately 0.5 μm can
be separated.
34
GEA Westfalia Separator
The performance factor is calculated from:
• Bowl speed
• Disk angle
• Number of disks
• Disk diameter
Separators are designed for the greatest
possible effective capacity, but there
are limits. Bowl speed is limited by
the permitted material loading. Further,
of disks have to be matched to the
different products.
At a relatively high loading with solids in the feed,
e. g. in juice clarification, effective capacity also
depends on the size of the solids chamber and
possible ejection frequency.
There are many factors influencing the
efficiency of centrifugal clarification
of liquids. Both product-specific and
mechanical parameters have an effect. The
first group includes particle size, specific
density, viscosity and the proportion of solids in
the liquid to be clarified. In mechanical terms, it
is primarily g-force, equivalent clarification area
and the solids storage volume of the bowl which
On a specified separator, there are options for
improving the degree of clarification. Measures
frequently used include:
• Reducing capacity
• Adding fining agents to form particles
• Increasing temperature to reduce viscosity
• Diluting with water to reduce density
and viscosity
GEA Westfalia Separator hyvol® and A final feature shared by all GEA Westfalia
hydry® generations of machines cover the Separator hyvol® systems is their very fast ejection
full capacity range valves. The focus with these machines is on a very
GEA Westfalia Separator   hyvol ® and hydry ®  high hourly output.
machines are two families of separators. Both
cover the full range of capacities in the beverage The focus in developing GEA Westfalia
industry with optimum machine sizes for each Separator  hydry® separators was on achieving
application. GEA Westfalia Separator  hyvol® and the greatest possible dry substance content in
hydry ® separators have been optimized in terms the solids. With these machines, the greatest
of customer benefit and rapid integration in a content of dry substance is in the normal
user’s individual process. The principle of GEA range thanks to the GEA Westfalia Separator 
Westfalia Separator hyvol® is to provide maximum hydrostop ejection principle. The optimum solids
effective capacity for the specified volume concentration is reflected in very short pay-back
of investment. times, especially if, as in the juice industry, large
quantities of liquid have to be processed.
GEA Westfalia Separator   hyvol ® refers to a Product losses are extremely low. All GEA
separator with an ejection system for piston Westfalia Separator   hydry ®  and hyvol ®
valves. Use of the hydrohermetic feed minimizes separators are equipped with a belt drive. They
the negative impact of shear forces and guarantees are characterized by their ability to be put
optimum separating efficiency. to multifunctional use. The benefits of GEA
Westfalia Separator  hydry®  separators become
Separation performance and product quality are particularly clear when the objective is to clarify
consequently ideal. The hydrohermetic seal high-quality products. The minimized product
prevents the product from becoming contaminated losses can lead to a short pay-back time for
by ambient air. This seal simultaneously combines the lines.
optimum compatibility for CIP (Cleaning-In-
Place) with no need for maintenance.

Fig. 42 Clarifier GSC 150 with

GEA Westfalia Separator  hydrostop system

35
GEA Westfalia Separator

Fig. 43 Separator of the ESE series
5.3 Centrifugal separators
Centrifugal separators are used when a liquid
mixture has to be separated into its liquid phases
with simultaneous removal of solids.
This separator was developed for de-oiling citrus
juice and for separating citrus oil emulsions. It can
be modified in design in numerous ways so that it
can be adapted for various separation tasks.
The product enters via the product feed through
special rising channels in the disk stack of the
separator bowl. The positions of the rising
channels depend on the liquid component which
is to be recovered in the cleanest condition. If
for example in an oil-water mixture, this is the
heavy component (water), the rising channels are
close to the inner rims of the disks. For the light
liquid component (oil) however, they are close
to the disk periphery. If both components are to
be equally pure, the rising channels are in the
middle of the disk stack. Separating efficiency
and product quality can therefore be perfectly
customized.
36
GEA Westfalia Separator
In this case, both liquid phases are pressure
discharged. For this purpose, a double centripetal
pump is installed in the bowl top.
Both paring disks are immerged in the separated
liquid phases and discharge the liquids under
pressure. Solid particles sediment in the solids
holding space of the bowl. This design allows
3-phase separation. With its self-cleaning bowl,
the machine is suitable for fully automatic
CIP cleaning.
5.4 Hydrocyclone
Initial separation of coarse and abrasive solids
If the starting product for processing contains
a high quantity of abrasive and coarse
solids, these impurities need to be separated
off beforehand so that the continuous
separation process is guaranteed and
damage due to abrasion and other malfunctions
can be avoided on the separator.
It makes sense to use a hydrocyclone if the starting
product for processing is contaminated with an
increased proportion of sand.
This rules out any impact from separator ejection
cycles or fluctuations in solids content.
Discharge, clarified
liquid
Discharge, solids
Fig. 44 Diagram of a hydrocyclone
5.5 Ceramic membrane filtration
Filtration of juices
A filtration step is required to produce clear juices.
Colloidal trub material as well as particles have
to be removed to prevent the juice or concentrate
from subsequently becoming turbid. As more
stringent requirements are placed on the type
of membrane in these applications, the ceramic
membrane has been tried and tested in the field.

Structure of Cross-Flow Filtration

With this method, the juice is guided along
the surface of the membrane at a tangent. The
permeate comes through the membrane and is
collected in a clear juice tank. A loop pump ensures
that the cloudy juice, the retentate, circulates in
the filtration circuit.

The volume of filtrate which flows off is replaced

by cloudy juice. The feed pump pumps cloudy Fig. 45 Ceramic membrane filter elements
juice into the filtration circuit. Part of the flow
of retentate is passed back into the process tank.
In the course of filtration, the solids become
concentrated in the retentate circuit.

Ceramic membrane 5.6 Line and control system –

The core element of these units are ceramic
membranes with a pore size of 20 to 200 nm. They
are extremely resistant to temperature, pressure
and chemicals, easy to clean and, compared to
polymer membranes, have a very long service life.
Only a ceramic membrane makes it possible to
concentrate retentate until there is no free juice
left. This allows operators to extend filter cycles
considerably and to minimize product loss.
Combining filtration equipment with centrifuges
Combining filtration with centrifugal separation
allows product losses to be minimized. A
separator or decanter is operated in a by-pass
circuit to filtration. This machine separates
spun-dried solids and thus slows down
concentration of solids in the retentate. the ideal automation solution from process,
However, it should also be pointed out that the
combination of filter and centrifuge depends on
the overall configuration of the processing line.
better from a single source
The two indispensable elements for solving a
process technology task are the line and its control
system. Only by matching these individually and
bringing them together can they be combined to
form a meaningful unit – and make an efficient
process technology line.
Besides individual machines, GEA Westfalia
Separator also automates complete process lines
with extensive peripherals.
A variety of components are used which can be
flexibly designed to suit customer requirements.
Our automation department works to develop
machine, drive and control technology. The more
complex a line, the greater the demands placed
on automation.

37
GEA Westfalia Separator
6. Summary
The most important process is the extraction of
the juice from citrus fruits. Such a process must
ensure reliable separation of juice, essential oil
and peel.
The pulp content of the juice is reduced in
downstream finishers. Centrifugal separation
technology is then used for setting the desired
residual pulp content. Centrifugal pulp reduction
of the juice enables the production of juices with
a high cloud stability.
The pulp, which is obtained during the production
of juice, and concentrate still contains valuable juice recovered from the peel. In order to obtain the
components. These valuable substances can be
extracted in a counter-current washing process.
The recovered pulp wash is clarified by means of
centrifuges and then concentrated in evaporators.
A further area of application is the production of
clear lemon juice. After finishers have reduced
the solids content, centrifuges are used for
pre-clarifying the lemon juice. Enzymes are
then added to the juice and the subsequent
precipitation ensures that the juice is capable of
being clarified. High-performance clarifiers are
used for the process of fine clarification. The
pure lemon juices which are obtained are mostly production. Clarifiers are again used for clarifying
processed into concentrates.
In addition, so-called cloudy peel products are also
obtained as a by-product during the processing
of citrus fruits. These products are made from
the peel. After the peel has been disintegrated
and extracted, decanters remove the solids from
the liquid. Once the solids have been reduced
in the liquid, centrifuges are used for polishing the company’s advanced centrifugal separation
the liquid.
The beverage industry uses this liquid as a basic
material. The peel of citrus fruits contains valuable
essential oil. During juice extraction, an emulsion
is produced as a result of squeezing or pricking
and simultaneous washing. Clear and valuable
essential oil can be obtained with minimum losses
by means of a 2-stage centrifuge system.
38
GEA Westfalia Separator
Waxes are precipitated when essential oils are
stored. These must be removed from the citrus oil.
A “winterization” process is necessary for this
purpose. The precipitated wax is then separated
off via a separator.
Essential oils and aroma components are
contained in the evaporator condensate which is
referred to as aroma water. Separators are used for
separating the oil from the aroma water.
Citrus pectin is a further by-product obtained
during the processing of citrus fruits. It is also
citrus pectin, the peel is blanched, dried and
stored before being conveyed to the extraction
process. Centrifuges are used for removing the
solids from the liquids in the extraction solutions.
The pectin which is precipitated by alcohol is also
recovered by means of decanters. A detailed pro-
cess technology description is found in the separate
brochure Extraction.
Citrus peel also contains substances which are rich
in carbohydrates. After appropriate pretreatment,
the peel can be conveyed to a fermenter for alcohol
the fermentation broth.
This paper illustrates the wide range of application
possibilities for separators, clarifiers and decanters
in the processing of citrus fruit.
In view of the company’s many decades of
experience in this complex field and in view of
technology, GEA Westfalia Separator can be
regarded as your competent partner in the citrus
processing industry.
7. Bibliography
1 AIJN-Code of Practice for evaluating the quality
of fruit and vegetable juices, edited by
AIJN (Association of the Industry of Juices and
Nectars from Fruits and Vegetables of the
European Economic Community), Avenue de
Roodebeck 30, B-1030 Brüssel, November 1996.
2 Bartholome, Prof. Dr. E.: Ullmans Enzyklopädie
der technischen Chemie.
3 Biekert, Prof. Dr. E.: Band 19, S. 237 ff.
4 Chen, C. / Nagy, S. / Shaw, Ph. E.: Fruit Juice
Processing Technology, AG Science,
Inc. Auburndale, 1993.
5 Citrosuco Paulista S.A., Firmen-Information,
Matao, Brasilien, The AVI Publishing Comp. lnc.,
1977, S. 12.
6 Cohn, R.: Über die vielfältigen Wege der
Citrusverarbeitung, Confructa-Studie 11,
Verlag „Flüssiges Obst“, Schönborn 1985, S. 178.
7 FAO-Database
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Westfalia Separator AG.
39
GEA Westfalia Separator
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(VdF), Bonn / Canadean Ltd., London u. a., 2008.
Authors of this technical / 
scientific documentation:
Dr. Stefan Pecoroni
Rüdiger Flocke
Wolfgang Günnewig
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