The Gerstenberg Schröder Nexus is a compact, high-capacity, high-pressure scraped surface heat exchanger designed for various high-viscosity applications within the Fats & Oils industry. It is designed for low energy consumption using CO2 as the highly efficient cooling medium, but it can also be used with the traditional Ammonia. It provides high crystallization performance, minimal downtime, and easy maintenance.
Nexus is designed to meet market demand for high-quality products combined with low-cost production. With Nexus you can produce everything from consumer margarine, industrial margarine, shortening and low-fat spreads to recombined butter and butter blends.
Nexus consists of up to 4 chilling tubes and individual cooling systems and can use CO2 or Ammonia as the refrigerant. It was one of the first scraped surface heat exchangers to use CO2 as the refrigerant, as it offers many advantages over traditional Ammonia including higher efficiency and kinder to the environment. Should you choose Ammonia initially, you can change the refrigerant at a later stage. The design is robust, reliable, and built to last as well as meeting our customers’ wide-ranging product requirements. Additionally, our solutions comply with the full spectrum of certification standards.
Function and Principles of Operation
Crystallization takes place in the scraped surface heat exchanger (SSHE) which is the heart of the crystallization line.
The product is pumped into the chilling tubes where it is cooled and crystallized. The scrapers in the rotor system are pressed against the chilling tube by constant centrifugal forces during rotation. This ensures that the crystallized product is very efficiently scraped from the interior tube surface.
up to 13.4 t/h
- Multi-purpose machine for a variety of product qualities and consistencies.
- Hygienic design suitable for the food industry. All product contacting parts are made in stainless steel AISI 316.
- Completely sealed, fully insulated, corrosion-free stainless steel casing guarantees years of trouble-free operation.
- Special, corrugated multi-layer chilling tubes for improved heat transmission value and prevention of internal build-up of compressor oil.
- The chilling tubes can easily be inspected and replaced.
- Optional rotor systems with scrapers in a selection of different materials depending on the application.
- Low energy production of crystallized fat products. Test results show that using CO2 at -10°C reduces energy consumption in the refrigeration system by approximately 25% compared to an Ammonia compressor at -20°C.
- Reduction in heat transfer costs. CO2 is a very efficient refrigerant which has an external heat transfer coefficiency which is 2-3 times higher than that of Ammonia and which will increase the total heat flux by up to 40%.
- Heat recovery system possible. When using CO2 as the refrigerant, it is possible to install and use heat recovery systems to save energy. The heat recovery can offer useable water at up to 90°C, which can be used elsewhere in the plant. Up to 70% of the energy can be recovered.
- CO2 as refrigerant - lower investment costs for CO2 refrigeration system compared with Ammonia.
- Minimum downtime as CIP cycles are fast and efficient, and maintenance procedures are simple.
- The low energy motors and the cast iron gear boxes yield maximum power while keeping noise levels to a minimum.
- Small footprint which optimizes the floor space and the piping requirements.