Bilfinger GREYLOGIX foodtec has become an established partner for complete and problem solutions for automation and plant engineering projects in the area of milk and food industry. Many products in our daily lives are produced by means of spray drying. These range from milk powder over instant coffee up to vaccines. The manufacturing process here is very complex. The high temperatures can cause fires or even explosions in the plant during the drying process. The relatively high age of many plants increases this risk even more.

20-Strong-Department for Safety Technology

Against this background, Bilfinger GREYLOGIX sees great business opportunities in this field and has formed a 20-strong special department over the last years. They deal with all safety aspects regarding these problems and at the same time they bring forth technological developments. „Safety and safety technology are playing an increasingly important role“, says Matthias Buch, general manager at Bilfinger GREYLOGIX foodtec GmbH. „We recognized that and developed a comprehensive package with many simple but ingenious solutions. In addition, we will invest further in new developments.“

Comprehensive Safety Package for Spray Towers

For a safety-related upgrade the age of a plant is not the only decisive factor. The legal safety requirements also have steadily increased in the past years. Hence, modernization is required in a lot of existing plants. Bilfinger GREYLOGIX foodtec offers a comprehensive package for the safety of the spray drying plant – from the analysis of the current situation over the concept for improving the safety coordinated with the authorities up to the installation of the components. Furthermore, the company also provides comprehensive services and maintenance, if desired.
The safety team at Bilfinger GREYLOGIX foodtec consists of experts in plant engineering, engineers from the process technology and professional project managers as well as employees from the area of technical documentation. The package resulting from this wealth of experience comprises different modules, which significantly increase the safety during production. This way, not only are the single components compatible with each other, but also with a lot of third-party systems. The companies which are using the innovative Bilfinger GREYLOGIX safety solutions in milk processing include among others Uelzena eG, Molkerei Rücker, and Deutsches Milchkontor.

Carbon Monoxide (CO) Detection System „detex“

An innovative module of the portfolio is the carbon monoxide (CO) detection system „detex“ for the spray drying, which has ensured a safe production of milk powder for three years by now. It monitors the spray dryers for glowing embers, which, in the worst case, can lead to an explosion in the plant. detex is equipped with a dual-channel analysis module. The benefit: The absolute measured values of both the air intake and the exhaust air are available at any time. Thus, it is possible to clearly recognize perturbing effects outside the process and minimize unnecessary production stops.

Cooling System „vertex“

In case a plant needs to be shut down immediately and cooled down to a non-critical temperature range, the cooling system „vertex“ comes into play. Vertex prevents superheating of the air intake flowing to the drying chamber independently from the mains supply voltage and cools the air down in a controlled manner. The basic principle is based on evaporative cooling, which is achieved by a fine spray of water into the air intake duct of the drying chamber. The energy removed from the hot air through this process reduces the air’s temperature to a non-critical value – without damaging the powder present in the drying.
Despite all precautions, the chance of fire or even an explosion can never be fully ruled out. In order to ensure greatest possible protection even in such cases, Bilfinger GREYLOGIX offers explosion protection systems as well as customized fire extinguishing systems.

Trapped-Key Interlocking System for Maintenance Accesses

Even when working in the plant itself, the safety can be increased in a highly effective way. Bilfinger offers an innovative trapped-key interlocking system for maintenance accesses. It ensures that the closed accesses remain locked until it is safe to open them. In the same manner, it prevents dangerous operating conditions when the accesses are open. For this, a locking mechanism is installed at each maintenance access, which can be opened only with a key specifically designed for this mechanism. When the plant is in operation, the keys are in a key board which has an electronically monitored slot for each key. If a key is removed, the plant will be locked against unsafe operating conditions and will be shut down in a controlled manner.

Since the market is set on new and innovative solutions in terms of safety, the objective of Bilfinger GREYLOGIX is to further grow and invest in new developments as well as to continuously bring forth technological development. The dedicated team brings a lot of experience and innovational spirit to supply highest quality standards to the customers.

Regarding this, you can read the interview with Olaf Literski, the expert for CO-detection in spray towers at Bilfinger GREYLOGIX.