GEA Processing equipment

Flexibility in processing performance for meat,

poultry, fish and vegetables
Test your ideas before you invest
If you want to try creative ideas or new recipes either
before or after you invest in a machine or marination line,
we can help you explore the options at our Technology
Centre. Together with our application specialists, you can
test and fine-tune the brine-preparation, injection,
tenderizing, tumbling, massaging and defrosting process
steps for an optimum balance of cost and quality.
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Creating new business

opportunities
In a market where customer preferences, economic trends and
global competition influence how you operate, you need to turn
challenges into opportunities. GEA performance-focused solutions
give you the flexibility to produce a variety of processed foods to
quickly anticipate new market trends.

Lowering your operational costs With you all the way

Optimizing your investment in GEA equipment for processing To extend the operational life and optimize the efficiency of
meat, poultry, fish or vegetables by focusing on the factors that your GEA solutions, we can provide training, maintenance
affect your business, now and in the future. These are the programs, equipment and software upgrades, performance
foundations of Lifecycle Performance. Your products will be benchmarking, diagnostics, applications expertise and factory
varied, appetizing, affordable and safe – at a lower cost per integration services.
portion or per kilogram. And your processing lines will be
flexible, cost-effective and lean. Single machines or complete lines
Whether you need individual machines to complement your
existing equipment or a complete line to launch a new product
or extend capacity, GEA is your ideal partner. Our machines use
a standard operator interface to simplify training, and are easily
integrated into your line and factory automation infrastructures.

Performance-focused processing

Variety Cost effectively produce a wide range of appetizing foods by a combination of forming, coating, frying, cooking, grilling
and freezing.
Efficiency Combine flexibility with benchmark performance in terms of capacity, productivity, yield, automation and sustainability.
Safety Meet and exceed haccp/ssop sanitation and food safety requirements and enjoy cleanability that saves time and costs.
4 GEA PROCESSING EQUIPMENT

One machine for varied particle sizes and

presentations
To give you the flexibility to switch from handling fine particles
to whole muscles, and to create varied presentations, the GEA
MultiFormer is designed to grow with your business. You can
start with a standard configuration, then add accessories like a
stick insertion unit or paper interleaver as your needs grow.

Natural shape, good structure retention and low

give away
Increase the ‘quality perception’ of your products, for example
by whole muscle formed products with a natural shape and
almost original look. Using GEA forming machines, you can
quickly change over from emulsified products to whole muscle
formed products as well as benefit from exact weight with very
low give away, high yields and excellent retention of product
structure.
 GEA PROCESSING EQUIPMENT 5

Forming, the shape of satisfaction

Eye-catching, fun, convenient, appetizing or traditional – forming
adds appeal to your food products. From mouth-watering burgers to
meat replacement and trendy whole muscle products, GEA forming
solutions give you extra ingredients for improving business results –
variety, capacity, yield and versatility.

Consistent, hygienic results Variety in form and presentation

Designed around your production needs, our interchangeable You can choose from an extensive range forming machines and
forming plates deliver consistent quality results, and can even forming plates for meat, poultry, fish, vegetables and cheese.
shape whole muscle pieces with a constant weight and size. To And if you need to stand out even more, we can also help create
help increase your productivity and food safety, we have custom two- and three-dimensional forms. Whatever the
developed a maintenance-friendly approach to machine ingredients, recipe or product size, a GEA solution can form it
cleaning. You can also change tools and substrates in minutes into a vast array of shapes and presentations.
rather than hours, facilitating non-stop production even with a
mix of high volume and niche products.

Forming equipment

GEA FreshFormer Easy-to-use, versatile, lowest cost per Kg, minimum product residue after product change-over, ideal for smaller
batches of fresh meat with many product change-overs.
GEA MultiFormer High capacity, extreme versatility, very wide choice of materials and shapes, wide range of accessories.
GEA MaxiFormer High capacity drum former, with optimal beltloading, excellent shape retention and weight accuracy.
Accessories Stick inserter, paper interleaver, ball rolling unit, tray transverse conveyor.
Innovation takes product quality to new levels
Imagine a tempura system that ensures very low shear for
unbeatable fluffiness, or a crumb coating system with a unique
circulation system that eliminates crumb damage. The GEA
TempuMixer and GEA CrumbMaster® are just two examples of
how our innovative technology developments enhance the
quality and consistency of your products.

Dust-free work environment

In addition to the labor-saving and space saving aspects, the
GEA MultiDrum also provides a very high degree of process
control. It enables you to accurate control the pick-up percentage
and creates a perfect homestyle appearance. To help keep your
work floor dust-free – as well as reduce waste and assist cleaning
– you can choose our unique GEA MultiDrum and GEA OptiAir
combination.
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Complete control over your

coating processes
The right coating adds value to your products. And now, in line with
the trend towards healthier eating and lower fat intake, you need
more accurate control over coating parameters. The GEA battering,
breading and pre-dusting solutions give you this control – plus the
capability to cost-effectively produce an appetizing variety of
products.

Total control over coating Operational flexibility

To fine-tune the coating process, GEA solutions give you total Coating efficiency is enhanced by optimizing operational
control over the quantity of coating material used, optimizing flexibility, providing accurate process control and ensuring ease
the degree of pick-up. with this level of control, you can of cleaning and maintenance. To cover the widest range of
precisely balance quality, yield and costs. We offer innovative operational requirements, we offer a choice of simple, manually
machines and configurations for all kind of wet and dry adjusted machines as well as fully automated solutions with
coatings. very accurate process control and little need for operator
intervention. The possibilities range from single pieces of
equipment to complete coating lines.

Coating Solutions

GEA MultiDrum & A coarse, high pick-up, golden coating on boneless and bone-in products. Perfect homestyle appearance,
GEA OptiAir reduced labor, dust free production environment, flour cost savings.
GEA OptiFlour® & Finely adjustable pre-dust, flour or breading pick-up, dust-free processing environment, flour cost savings,
GEA OptiAir suitable for heavy duty ‘seeded flour’ applications.
GEA CrumbMaster® Ideal for both fine and coarse crumbs ensures product consistency and quality, easy to clean, simple to operate.
GEA WetCoater & Efficient, even coverage of batter or tempura, easy to clean.
GEA TempuDipper
GEA OptiCoater & Versatile, even product coverage with batter or tempura, extra options to meet high product demands,
GEA OptiDipper extremely hygienic, recipe controllable.
GEA TempuMixer Fully automatic tempura mixer - industry standard in product quality, fluffiness, consistency and savings on
tempura mix ingredients, low product waste, easy and safe to operate, simple to clean.
GEA BatterMixer Versatile batter mixer, suitable for milk wash, adhesion batters and high viscous batters, simple to operate, easy
to clean. Manually supply of flour and water.
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Lower energy and operating costs

Reducing energy consumption, simplifying cleaning and
extending oil life will lead to considerable cost savings. The GEA
EasyFry scores on all three fronts thanks to its superior
insulation, hygienic heat exchanger and open sanitary design. It
delivers the highest heating capacity in the industry, while its
self-supportive sediment filtration system extends your oil
lifetime.

Tripling the life of your oil

Extending the life of your oil and reducing sediment to a dry
waste material is cost effective as well as environmentally
responsible. The GEA Oberlin Filter is a high capacity
continuously operating pressure filter that is especially suitable
for tempura coated and breaded products as well as non-coated
products like burgers and meat balls. It removes both sinking
and suspended/floating sediment immediately before it starts to
affect the oil, and therefore improves and stabilizes product
quality and flavor. It extends oil life 3 to 5 times and the
resulting sediment comes out as a dry cake containing no to
minimum oil.
 GEA PROCESSING EQUIPMENT 9

Perfect frying and oil management

Your deep-fried products need to be crisp, crunchy and golden-
colored, and GEA helps you achieve perfect results with a range of
frying solutions that guarantee attractive and tasty products – from
chicken nuggets and fish fingers to non-coated fried pork and
vegetarian products.

Enhancing taste and appearance External oil management

We ensure all our frying solutions provide you with efficient, As an option, you can add a centrally controlled external oil
cost-effective frying as well as safe, easy, low maintenance management system that is safe, flexible and includes storage.
operation. the machines are designed for high capacity and This ensures safe operation, minimizes the risk of oil mixing
reliability, and to help reduce your operational costs, we also errors, extends oil lifetime and simplifies operation. Combined
focus on low oil consumption. with the GEA Oberlin Filter or the GEA OilSaver oil filter, the
total oil treatment system ensures the right color, flavor and
reduces degradation of oil and product quality over time. This
results in maximized oil usage and balanced quality against cost.

Frying Solutions

GEA EasyFry The easy way to fry a wide range of products, for medium-high capacities, high heating capacity, safe and easy to
use and clean, self-supportive oil filtration, recipe controllable.
GEA EasyFry XL High capacity fryer, industry standard internal sediment removal system suitable for high contamination levels,
ideal for flour coated and tempura coated applications, high belt speeds with no metal-to-metal contact, dual
sediment removal system.
GEA OilSaver Entry level oil filter, easy to use, runs with a filter media to collect the frying oil sediment.
GEA Oberlin Filter High capacity continuously operating pressure filter, ideal for tempura coated and breaded products as well as
non-coated products , improves oil lifetime 3 to 5 times, dry sediment easily disposable.
GEA Oil management Software controlled, safe oil storage.
systems
Three-phase cooking and roasting
Expand your possibilities. The GEA CookStar, 3rd Generation,
has unique three-phase cooking in a two-section configuration
so you can cook virtually any product at two different
temperatures in steam as well as in hot air. And the new GEA
CookStar Turbo adds impingement technology for even more
possibilities, better efficiency, greater variety and yield
performance!

Faster payback by increasing yield, capacity and

efficiency
Shorten the payback time by using a GEA belt grill to coagulate
products that are pre-calibrated in thickness before they’re
cooked in a controlled environment. The results are lower core
temperature deviation, more efficient energy use, increased
capacity, and higher yield due to better weight retention.
 GEA PROCESSING EQUIPMENT 11

Creating a satisfying eating

experience
Achieving the right appearance, flavor, texture and mouth feel for
the most satisfying eating experience depends heavily on the
cooking or grilling parameters. With GEA heat treatment solutions,
you can control the process for the desired degree of juiciness,
crispness and browning, as well as maximize yield and shorten
cooking times.

Extend your process flexibility And the short cooking times, high capacity, ease of cleaning and
In addition to providing you with the capability to cook, grill, ease of operation mean you benefit from higher throughput and
roast and smoke a broad range of products to perfection, GEA more uptime.
also extends your operational flexibility. We do this, for
example, by offering three-phase cooking solutions that combine How efficient is your process?
cooking, roasting and smoking. You can even cook products To increase your operational effectiveness and optimize energy
with color and texture. utilization, GEA heat treatment solutions are designed for
efficient airflow and use energy-to-demand methodology. In
Cooking performance addition, they enable continuous cleaning during production
Our section cooking systems with their unique airflow concept with efficient Clean-in-Place systems, and incorporate dewpoint
not only increases your yield and operational flexibility, they control to manage steam supply. The overall design is energy
also guarantee food is thoroughly cooked for optimum safety. efficient.

Cooking, roasting and grilling solutions

GEA CookStar 3rd Versatile two-section oven, high capacity and superb flexibility, hot air and steam, excellent for innovative
Generation new products.
GEA CookStar Turbo 3rd Three-phase cooking and roasting, designed for roasting, extreme versatility and improved yield, shorter
Generation cooking, very energy efficient.
GEA FlowCook Dual-zone in-line oven, short cooking time, optimum yield, versatile (steam & hot air cook, and roasting).
GEA TwinGrill Contact grilling for high performance, versatile, grills a wide range of products, high yield with excellent
energy economy.
12 GEA PROCESSING EQUIPMENT

Freezing to protect and preserve

your product’s quality
Once you have formed, coated and heat-treated the product, you
need to protect and preserve its quality, freshness, appearance and
weight. Our range of chilling and freezing equipment combines
performance, hygiene and safety with a flexibility approach to meet
your specific business needs. The operational benefits include short
freezing time, compact footprints and a choice of configurations
and handling capacities.

Freeze more in less space

If you need tailored configurations in a small format freezer, the
GEA spiral freezer series gives you this flexibility without
compromising freezing performance. It delivers a very high
yield too. For small capacities GEA E-Tec/P Compact package
freezer delivers excellent delivers excellent freezing
performance from a very small footprint.
 GEA PROCESSING EQUIPMENT 13

Minimize weight loss, retain product quality configurations, including feeding from two separate lines on one
At all spiral levels in a GEA A-Tec, S-Tec or E-Tec/P spiral freezer machine. The sequential defrost option allows up to 14 days
your products are evenly surrounded by a horizontal air stream continuous running without stop for evaporator defrost.
at a consistent temperature. This Individually Quick Frozen Adjustable air speed (option) facilitates freezing of very light
(IQF) technique first of all ensures that crust freezing occurs products.
very quickly to close the product, minimize weight loss,
optimizes food safety and preserve structure and flavor. It is also Streamline your operations
an efficient freezing process, reducing the freezing time as well Like all GEA equipment, the stainless steel freezers are built for
as saving energy –contributing to a lower price per kilo. ‘cleanability’ and easy maintenance, so you can be sure of
perfect hygiene. A comprehensive range of accessories adds to
Layout and capacity flexibility the flexibility and helps streamline your operations. With
Whatever the shape and size of your products, our freezers have options such as PLC operation control with pre-programmed
configurations to suit your specific volume and floor space menus, you can achieve perfect results with minimal operator
requirements. You can specify feed and discharge intervention.

Freezing solutions

GEA A-Tec & GEA S-Tec For stringent hygienic requirements, fully welded floor and fully welded structure in product zone.
spiral freezer
GEA E-Tec/P spiral freezer Minimum freezing time, maximum yield, customizable configurations.
GEA E-Tec/P Compact Freezer fully prefabricated prior to shipping. Plug-in solution.
package freezer
Series of Tunnel & Carton Different solutions for every application.
freezers
14 GEA PROCESSING EQUIPMENT

Complete lines from a single

source
Specifying a complete GEA line solution has advantages in terms of
yield, flexibility and cost of ownership. Our machines are tuned and
balanced to work with each other, and we can advise on the best
configuration for your production requirements or type of product.
We offer solutions ranging from simple dedicated lines to fully
customized installations, including lines for sliced/diced products,
coated products, roasted products, uncoated fried products and
fryless fried products.

The flexibility to respond to trends Performance quarantee

A line solution helps you maintain consistent product quality by With the support of our Technology Center to test and refine
offering more control over process- and recipe management. The solutions, you benefit from optimized yield and performance.
balanced performance optimizes capacity, lowers energy costs. Our equipment meets very high hygiene requirements, and is
The flexibility of our lines and equipment helps you take reliable, easy to clean and operator friendly – all contributing to
advantage of product trends and consumer preferences – thanks a lower overall cost of ownership. When required, we also offer
to benefits like short change over times, and the possibility to performance guarantees, and after installation at your site, a
process a range of different products by making small changes GEA application specialist fine-tunes the line so it runs
to the line set-up. according to the performance guarantee.

Synergy to deliver a 2% yield increase

By integrating the line control and by fine-tuning each single
processing step for optimum performance in relation to all
others in the line, one of our customers using a GEA total line
concept for producing fully-cooked breast products enjoyed a
2% yield increase compared to a line comprising equipment
from various manufacturers. You can also benefit from this
synergy.
 GEA PROCESSING EQUIPMENT 15

Your partner for food processing

& packaging solutions
GEA performance-focused equipment and solutions for preparation,
marination, processing, slicing and packaging are developed to help
you reduce operational costs, increase processing efficiency, and
respond quickly to new opportunities

A global heritage
To ensure you get the best out of your equipment, we provide
comprehensive customer support through a global network of
sales and service offices, so you get local knowledge in your
native language. You also tap into the creative thinking and
technical know-how of an international organization that
comprises many specialized activities with long and successful
track records in their respective fields.

Contributing to your success

The total GEA Food Processing & Packaging range - the most
extensive available today - extends from stand-alone equipment
to complete production lines. Depending on your requirements,
we can plan, develop and build a complete new line, or simply
enhance your existing capabilities. You can even try out new
ideas, test recipes and refine processes at our Technology Center.
 008162EN_022017 © GEA Food Solutions The information contained in this brochure merely serves as a non-binding description of our products and is without guarantee. Binding
information, in particular relating to capacity data and suitability for specific applications, can only be provided within the framework of concrete inquiries. Subject to modification.
We live our values.
Excellence • Passion • Integrity • Responsibility • GEA-versity

GEA Group is a global engineering company with multi-billion euro sales and operations in more than
50 countries. Founded in 1881, the company is one of the largest providers of innovative equipment and
process technology. GEA Group is listed in the STOXX® Europe 600 index.

GEA Food Solutions Bakel B.V.

Beekakker 11 Tel +31 492 349 349 [email protected]
5761 EN Bakel, Netherlands Fax +31 492 349 416 gea.com