How it works
A booster pump is used to convey the ready-mixed beverage to the GEA Venturi saturator, so that the reduction in pressure in the part of the saturator that has the smallest cross-section generates a partial vacuum and this results in the desired suction effect for pulling in CO2. Automated optimization keeps the flow velocity through the saturator within a predesignated working range. The short duration of increased flow velocity guarantees a fine distribution of CO2 gas, and its homogeneous mixing into the product.
CO2 is supplied from a pressure tank to the saturator. The constant overpressure of the pressure tank helps to control beverage carbonation and the complete process also supports a loss free CO2 supply.
Beverage carbonation is effectively dependent on the tank pressure, which is adjusted according to the desired CO2 setpoint of the specific beverage, and is only slightly higher than the saturating pressure of the product. Temperature compensation adapts the pressure in the tank to the saturation curve. The system is dimensioned according to the required flow rate of the overall process.
It is also possible to process non-carbonated products on a production line through the DICAR-C.
GEA DICAR-C aseptic carbonating system
The GEA DICAR-C technology can optionally be designed and installed as an aseptic system that exhibits the same features and functionality as the non-aseptic system. The focus here is on the choice and design of the individual components - which have to meet all requirements for aseptic processing - as well as the ability to sterilize the complete system, including the CO2 supply. The DICAR-C aseptic carbonation solution can be configured to produce non-alcoholic beverages as well as alcopops, sparkling wines, hard seltzer and other products.
The aseptic system employs sterile valves and a sterile filter to supply the CO2. The complete system can also be steam treated. A thermo siphon (TS) unit is installed on the base frame of the system. In this TS unit, sterile steam, which is fed in from outside the system, is cooled down in a controlled manner. The resulting condensate is then used to rinse the double-acting mechanical pump seals. The TS system fulfils all the tasks of a locking system, such as leakage compensation, lock fluid circulation through a thermo siphon effect, pressure build-up in the lock room, and prevention of dry running.
Advantage of aseptic carbonation
When installed as part of your aseptic filling processes, GEA aseptic carbonation technology can help to save on both investment and energy costs, as it allows pasteurization to be carried out at a lower pressure, which can reduce energy requirements for the pumps.
Key features and benefits of the DICAR-C carbonation system
- Achieves highest possible concentration of CO2
- Product-specific CO2 content control
- GEA saturator designed to ensure efficient CO2 dissolution
- No CO2 loss during carbonation in continuous process
- GEA Venturi saturator helps to ensure fine dispersion of CO2
- User friendly operation
- Versatile carbonation module can be combined with the GEA DICON® in-line blending unit, and with the GEA DIOX-2 water deaerating unit, as part of the single unit GEA DIMIX-C continuous mixer, for the production of carbonated beverages
- Recipe management system
- Option to configure as an aseptic version
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Related Products
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GEA has developed the DIOX two-stage deaeration systems for use by the juice and soft drinks industries.
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