Ceramic Membrane Crossflow Filtration Technology Mr Paul Baggio WEA Aug. 2012 NZ

• WHO ARE DELLA TOFFOLA

• EXPERIENCE IN WINE FILTRATION • CROSS FLOW DEVELOPMENT 90’s

• CERAMIC CROSS FLOW - PACIFIC STARTED IN AUSTRALIA 2000 – One of the First Cross flow suppliers specific wine • • • • •

SOLD FIST CROSS FLOW 2002 - 200sqm STILL OPERATING TODAY ! Over 10 years old 48 cross flow units operating in NEW ZEALAND & AUSTRALIA ONE OF THE LARGEST CROSS FLOW MEDIA FOOTPRINTS OF ALL SUPPLIERS ONE MACHINE PURCHASED IN 2003 over 700 million litres processed

• We do not just guarantee 10 years of membrane life - we also guarantee membrane performance!

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Overview of filtration technologies • Traditional filtration (dead end) • Cross-flow filtration

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What does Cross-flow filtration offer over Traditional filtration?

• Cross-flow Filtration Technologies • Evolution of Cross-flow Filtration Technologies • • • •

Spiral membrane Polymeric membrane Ceramic membrane Polymeric membrane v Ceramic membrane

• Advantages of Our Ceramic membrane • Design construction & design advantages

• Operational Differences – Hollow Fibres vs Ceramic • Product Quality Considerations • Health & Environmental Impact Considerations • Automation • Customer Feedback • Questions

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Traditional filtration processes (Diatomaceous Earth and filter pads/sheets) use dead-end filtration techniques • Flow in these systems is direct perpendicular to the filtration surface. • Typical industrial application of dead-end filtration include the sterile filtration

of sugar syrup, water, beer and wine products. 

There are several processes that have high concentrations of particles or macromolecules – that rapidly compact on the filter surface when a deadend filter is used causing filtration flux to drop to what are non commercial levels of capital employ.

Feed

Gel Layer

Filter Filtrate Flow Filtrate Time

FILTRATION RATE SLOWS AS MATERIAL BLOCKS THE FILTER. FILTER MEDIA & SOLIDS DISCARDED TO WASTE.

Feed

Retentate Filter Filtrate

Filtrate Flow Gel layer Time

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Tangential Flow 1.5m/sec with a trans-membrane pressure for wine 1. 5 2.5 bar pressure

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Factors that impact velocity include;

• Diameter of membrane, Bore channel • • • •

Pump Size/kW Viscosity/SG weight of product, Membrane porosity Membrane Granulometry/symmetry

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Single filtration step to remove solids and microorganisms.

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Reduced handling = IMPROVED QUALITY

• Reduced losses (losses for earth filtration are typically 4-8% dependant on number of filtrations required through coarse – medium – fine. Cross flow can deliver losses less than 0.05% to .0005%) • No filter media consumables and waste costs • Multi purpose – suitable for range of applications from cellar to final bottling applications

• Low labour input – ability to run unattended • Improved OH&S – no diatomaceous earth

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Cross-flow systems today are primarily Spiral, Ceramic or Polymeric membranes.

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Membranes maybe organic (polymeric) or inorganic (ceramic) material.

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Della Toffola today sell Spiral and Ceramic membrane cross flow. • If the price of polymeric membranes do not fall the Evolution/future of wine cross flow filtration rests

with Spiral or Ceramic membrane filtration. 

Organic (polymeric) membranes are constructed from polymers such as • Poly sulphone • Poly Ether sulphone • Poly Vinyl Ether Sulphone

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Inorganic (ceramic ) membranes are made of various materials, such as • Aluminum oxide • Zirconium oxide

• Tungsten TAMI patented 

Cross flow membranes manufactured in a range of porosities tailored to address various applications.

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The tightest porosity is reverse osmosis (RO), then nano-filtration (NF) then ultra-filtration (UF) and micro-filtration (MF) technology.

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CMF (Cross flow micro-filtration) is the preferred technology for the wine filtration

 Organic

Polymeric Spiral membrane (flat sheet polymeric)

 Organic

Hollow Fibre membrane tubular Polymeric

 Ceramic

membrane candle

• Ideal for low NTU entry load

•Best price! Best entry investment •Very good uniform porosity

•Density of porosity also managed very good •Widely used for many applications water filtration & desalination plants. •Application in wine industry, final pre-bottling only of low viscosity products. Or SME winemakers.

• Low trans-membrane pressure

• Little – No backwash • Rapid decay in flow • Low chemical resistance • Low temperature tolerance • Short membrane life

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Improved trans membrane pressure

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• Fouling problems

Non constant flow rate • Flow rate is influenced by the product

temperature 

Backwash now possible • Limited 2 – 3 bars

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Tangential filter speed • Sheering

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Some CIP resistance

• Low of performance

• Yet reduced life expectancy

• Low flow rate

• Proprietary cleaning products  

Storage of membranes

• Block single fibre

• Proprietary bacteriastatic 

Low temperature • Over 50 – 60

oC

CIP damaging • Limited efficiency in CIP

Repairing the membrane • Complete module needs to be removed

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Porosity limited • Membrane integrity

plastic plug

ASYMMETRIC • The porosity increases • Reduced adsorptive effect • Increase loss of performance

SYMMETRIC • • • •

Porosity throughout the membrane Membrane structure Decreased loss of performance Greater CIP imposed

-Why Della prefers Ceramic membranes over Polymeric membranes

* Never the same wine at the inlet, Wine business very different to other beverage industries * Wine from same vineyard, different season, different varieties, many different challenges presents within the same season a different wine to the filter.

-Polymeric tubular membranes have very little room to move - 1.5mm – 1.8mm bore max acceleration Polymeric membrane - Performance best when the entry NTU concentration is constant such as water, beverage where pre treatments exists

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• Titanium backbone with ceramic bake

•Porosity dictated by bake time, easy to replicate •L=1178 D=25 39 channels d=2.5 surface area per strand = 0.5m2 •Ceramic product very thermal resistant -Minus 10 C to 100 C. • Best Uniformity and Density of pores over broadest range of products and operations • Flow dynamic and design of membranes allows for best self cleaning of the membrane during filtration

Wider bore of 2.2 - 2.5mm in Della Toffola Ceramics compared to 1.5 - 1.8mm of capillary systems. 1.5m/sec is an ideal velocity for wine products

This flow dynamic gives us a much wider scope for filtration of wine with a high viscosity or low temperature Wider bore also = less force required to move product through system (lower energy requirement and lower shear

Asymmetrical Organic Polymeric

Asymmetric Inorganic Ceramic

Symmetrical Organic Polymeric

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Solid composition: • Support • membrane

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Frame work • Titanium

Easier passage of flow through Asymmetric Media because of the composition of the strata = better flow = More efficient back flush

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Solid composition: • Support • membrane

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Frame work • Titanium

Greater mechanical strength = Wider operational range = Can be cleaned more aggressively without degradation of membrane = Can back flush at higher bar More efficient back flush regimes gives longer filtration runs clears gel layer on membrane for reduced shear of wine during filtration = Allows filter to run at higher pressure than any other system

-Value Benefits -Points of Difference over competing Technologies

- Ceramic membranes have a Guaranteed life of 10 years compared to competing technologies – viable life of 4 – 5 yrs. Operating life of a candle is already proven beyond 15 years! - To regenerate filter efficiency – interchange of entire modules not necessary, competitor must change whole modules -No cross contaminate/taint of membrane between wine products

- Consistent output of flow and quality over time - Suitable for carbonated products as standard build– sparkling wines & ciders

Comparative Flow Rates

20,500 20,000 19,500 19,000 18,500 18,000 17,500 17,000

Litres /Hour

16,500 16,000 15,500

Hollow Fibre

15,000

Ceramic

14,500 14,000 13,500 13,000 12,500 12,000 11,500 11,000 10,500 10,000 1

2

3

4

5

6

7

8

9

10 11

12

13

Hours

14 15

16

17

18

19 20

21

22

23

24

-- Designed to eliminate bacteria – hot/steam wash, peroxide wash, caustic 2%, faster regeneration back to peak filtration. 

- Longer filtration runs between cleaning – more filtering less stoppages for cleaning! Rinse every 16 - 24 hours 3.5lts/m2 & chemical clean every 70 to 90 hours. • Polymeric membranes by comparison require rinse wash each 6 – 7 hours @ 5lts/m2 & chemical clean every 24 hours • WHY? Difference better designed strata • CERAMIC is not absorptive – membrane is solid 6 bar back flash v 2 bar

-- Modular design - Compact Footprint -- Long lasting durable Stainless Steel housings

•Lowest cost to replace membranes – indentify individual candle easily and interchange or blank with stainless rod. •Reduced environmental impact – lowest water use, plastic is not biodegradable – Ceramic materials are •Versatility in investment decision making – • * Most efficient cross flow recover broadest range of solids, reprocess solid discharges 1500 NTU! Other filters discharge solid discharges to drain or RDV 1.*All types of wines, from any vintage, •*broadest range of delta change in solids change, •Bentonite 0.5g/lt, PVPP, kHT, Carbon

•- idiot proof!

-Design Consideration

-Points of Difference over competing Technologies

Which allows operation and cleaning to be more versatile in all processes •

These membranes will operate between -5 to +90°C

•

Stored dry when not in use (or in caustic solution if preferred)

Have ability to be cleaned with caustic, phosphoric & nitric acid, or hot water. Giving best regeneration and no risk of contamination without degrading the life of the membrane •

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Able to isolate a single strand – Minimum Replacement to repair 0.5m.

Can supply housings part full of membrane but fully operational to allow increase in capacity over time. With reduced initial set up costs (room for growth) 

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TO CFKA Models can add additional pumps, membrane housing and backwash to existing frames utilising PLC and framework to increase capacity over time

-Performance Considerations -Points of Difference over competing Technologies

Technology offer retentate concentration rates of 80% +

Technology offer retentate concentration rates of 80% +

-Quality & Environmental Considerations -Points of Difference over competing Technologies

Crossflow reduces production costs without compromising quality

“Another main benefit of this technology for our site is better retention of colour and wine structure compared to alternative filters” NZ Sauvignon Blanc (Links Winery, July 09) - Single pass through CFKN170 directly off cold stab @ - 3°C

Della Toffola ceramic membranes are available in range sizes of 0.2 to 1.4 microns and bore diameters giving versatility to a wide range of products Durability of S/S housings & ceramic membranes ensures sterile cleaning can be effected between filtration runs Individual membranes can be isolated, providing reduced risk of contamination throughout housing if a single strand is compromised

Extensive trials have been conducted analysing bacterial count on exit wines. Yalumba Wines Over time as membranes degrades filtered wine quality decreases. With regeneration capabilities of the ceramics bacterial counts and exit NTU’s remain steady. Ceramics give the best repeatability over time

The environmental advantages of crossflow vs earth is well documented Reduced spent earth. - No spent waste associated with Ceramic X-flow – positive environment impact. - Elimination of the hazard to operator health and safety – no Diatomaceous Earth handling. - The ‘Green’ credentials of ceramic membranes add even further value - up to 5 fold reduction in membrane disposal compared to traditional systems and polymeric alternatives, which are non biodegradable and have a vastly shorter life span.

-Automation Considerations -Points of Difference over competing Technologies

CFKA Machine is equipped with 10-inch touch-screen color controls operator panel

Full control to program trans membrane pressure/backflow rate/wash cycle preferences /Empty cycles / set number of litres required to be filtered Auto alarm and shut down options when – no product is available/ set litrage are achieved / viscosity is too high / min flow rate is not being achieved / compressed air and nitrogen pressures are not sufficient for operation PLC graphic displays on screen status of the pumps, valves, pressures, instantaneous and mean flow rates, temperature, filtering time, litres filtered, viscosity and status of alarms

System for metering the detergent dosing and electron pneumatic valves for enabling and disabling the delivery of the alkaline, acid and neutraliser products used in the wash cycle

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Specific passwords can be set into the machine to allow various levels of access and operators ability to alter processing parameters

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Ceramics are robust and can withstand harsh chemical treatments. Should bentonite or tartrate cause damage to a membrane regeneration is possible

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*This ensures management have a strong protection over their investment on there investment

flow CFKI per specifiche -01.bmp

-Customer Feedback -Points of Difference over competing Technologies

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Ability to run 24 hour unmanned Operation

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1.1 million litre tank volumes processed within 26 hour period of time (i.e. compared to their 40m2 earth filter – Coat filter / 6 hour production / dump earth / wash - Coat filter / 6 hour production / dump earth / wash)

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Clean up to 100% over many years – CFKA340 filter processed over 70 million litres – CFKA680 over 280 million litres - no membranes replacement

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Reduced reliance on cellar shift operators who impact continuous filtration for any other filter media with lag in switching between processes

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Reduced centrifuge load - ceramic cross-flow has ability to take in higher NTU product reducing outputs of centros (= less centrifuge footprint & investment)

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Increased utilization rate of machines (from 500 to 700m2) as process demands increased without existing filter becoming redundant

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Retentate and other concentrate discharges can be filtered efficiently without downgrades or significant losses. Technology can be utilised across site for all products

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Labour savings / Earth savings = $10K operational savings per week per CFKA510

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Able to significantly extend life of final membrane cartridge filters on bottling line to 22 million litres – 4 times life

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Varietal aromatic whites successfully filtered directly off cold stab @ -2 deg C

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In the bottling hall have been able to automate filter to such a degree to match flow rates and run direct to the filler bowl – no buffer tank

-Thank You -QUESTIONS!