Gusmer Enterprises, Inc. Bucher-Vaslin Cross Flow Filters 2014 East Coast Wine Seminars Agenda • • • • • • • What is cross-flow filtration? Review of design & applications What makes Bucher system unique? Cost and sizing Juice Lees Filtration Summary Questions What is Cross-Flow Filtration? • Definition: Method of clarification where product flow is parallel to the filter surface to minimize clogging and maximize efficiency •- Dead-end filtration •« Cake » clogging •Wine to be filtered (dissolved components, in suspension, microorganisms...) • Filtered wine (dissolved components) •- Cross flow filtration •RETENTATE: Wine to be filtered (dissolved components, in suspension) •PERMEATE : Filtered wine (dissolved components) •Cross-Flow Filtration : •Filtered wine tank •Wine to filter tank •Circulation pump •Feed pump •Capillary Membrane • Two internal diameters are available: with the same material and the same pore size. •1,5 mm ID for wine filtration: to optimize the area of filtration •3 mm ID for retentate or lees of the must filtration: to allow higher viscosity on the product to filter and to decrease the wine looses Filtration Targets Proteins Virus Dissolved salts Pollens Colloids Organic Molecules Sugar Hairs Bacteria Yeast Colloidal Silica Reverse Osmosis Microfiltration Nanofiltration Particles Filtration Ultrafiltration 0,0001 0,001 0,01 0,1 1 10 100 (µm) Flavy Cross Flow Micro Filtration FX Range Generalities 01/2009 What is a Micron? A “micron” is 1 thousandth of a millimeter Relative Particle Size • Red Blood Cell 5 µm • Fine Beach Sand 500µm ● • Bacteria Cell 0.65 µm • Yeast Cell 3 µm • Mist 100µm What are these micron ratings? A filter micron rating is not the physical pore size. Micron ratings are defined by the size of the particles that you are removing. FACT: A 0.45 µm membrane removes particles that are 0.45 µm. Why a .2 micron membrane? 0.2 µm 0.2 µm Permeate : Filtrate (dissolved compounds) more plugging with .45 micron membrane! 0.45 µm Permeate : Filtrate (dissolved compounds) 0.45 µm Doesn’t Cross flow beat up the wine? Comportment of Polyphenols Polyphenols P Deformation of the polyphenols through the pores Re-stabilization in time Applications • Filtration of juice prior to fermentation • Arrest or prevent alcoholic or ML fermentation • Pre-bottling wine preparation • Taking high solids wine (500 NTU or higher) and end up with wine at 1.0 NTU or lower What Makes Bucher System unique? •Process •Volumetric Feeding Pump P1 @ variable speed: • maximum pressure is 1.2 bar- will not beat up the wine • pressure and flow rate are optimized for each type of wine- easy, standard, or difficult • low pressure = less heating of wine •Centrifugal Circulating Pump P2: • maintains a constant speed, and therefore good membrane cleaning •Integrated Membranes Protection: • continuous measurement of retentate concentration • stops the filtration and empties the filter when the safety pressure level is reached • avoids capillary blocking • decreases the intermediate water rinsing number and to simplify the cleaning •Process •Back-Flush Process: Only a surface clogging (and not in-depth clogging) The FX filter periodically carries out a short inversion (one second) of the direction of filtration of the wine through the membranes. - Allows to put back into suspension the membrane surface deposits. - keeps pores open during the entire filtration Wine to be filtered 0.2 µm •Very frequent - Very short - Very efficient. •Process of FX range with back flush tube •P1: Feeding Pump (Volumetric) •P2: Circulating Pump (Centrifugal) •1: Wine Inlet •2: Lees Outlet •3: Cleaning Water Outlet •4: Permeate (Filtrate Wine) Outlet •5: Back-Flush outlet to ext. Ret. tank •6: Back-Flush Tube •7: Retentate loop •8: Back-Flush system •9: Option : Turbidity meter •10: Flow meter •Process •Self-test diagnosis : the •DISCLOGGING PROCESSES Control of the clogging •Retentate renewal •Intermediate water rinsing •Back flushes •Retentate renewal •Retentate renewal PLC measures the efficiency of each disclogging process. Membrane Asymmetric Structure Retentate : Wine to filter (dissolved compounds, in suspension, microorganisms,…) 0.2 µm 0.2 µm Permeate : Filtrate (dissolved compounds) Asymmetrical membrane (BV Filter) - Better efficiency of back flushes. - Reduction of in-depth clogging. Symmetrical membrane •Process • The operator choose the type of wine to filter : Type of Wine Non clogging wine Standard Wine Difficult wine • - Automatic adjustment of the TMP and of the maximum flow rate per membrane. •Better control of the clogging, •Reduction of the number of water rinses, •Reduction of the water consumption, •Increasing of the average flow rate, • The operator set up of the volume to filter and press the start button Cleaning • • • • • Key to Cross Flow is the back flush Water or wine rinse helps Chemical cleaning every 20 hours Caustic & H2O2 most common Water must be clean! Hard water can plug filter • Chemical Cleaning dictates module life •Chemical product dosing pumps (Recommended option) •Liquid Citric Acid •Hydrogen Peroxide •Alkaline product Juice lees filtration • Why should we filter juice lees ? – Economics- why throw this away? – Filtered juice has high amount of Fatty acids and flavor precursors – The Bucher Vaslin Process will allow a 90% must recovery of the 10% lees volume (i.e. 99% of the initial tank) The process Alcoholic fermentation Enzymes 100 hl 90 hl + 9 hl 90 hl Permeate 9 hl (<1 NTU) 10 hl Homogenization Cold settling @ 8°C for 12/24 h + Juice lees filtration Retentate 1 hl (1% of the total volume) For a 20% vol/vol suspended solids initial product Page 28 The Juice lees filter Upper motorized manifold D3 Automatic rotary pre-filter LWL modules Flavy FX1/2/3 filtration unit Page 29 Adaptations on the Flavy filter •Motorized manifold and anti blocking system •3mm capillaries (LWL) and 1.5mm capillaries (standard) Benefits of juice lees filtration – No oxidation -fresher and clearer must – Easy to use – Allow a batch by batch process – No diatomaceous earth (D.E.) – Economic Benefit- saving good juice! Filtration Results Original juice lees •January 2012 Filtered juice Final retentate Page 32 Bucher Cross Flow Advantages… Low pressure protects wine Frequent, short back flush maintains flow rates Most popular cross-flow filter for high end wineries Fully automated- very easy to use Juice lees filtering offers significant savings Cons to Cross Flow… Initial Expense Bentonite can permanently plug- need to rack off bentonite lees Small lots difficult- higher losses Locked into micron rating Filter elements can break/plug (but there are ways to repair) Bucher Sizing and Cost FX2 200 - 600 gph $ 85,000 FX3 300 - 1,000 gph $ 95,000 FX6 600 - 2,000 gph $ 155,000 Larger systems available… Summary • Filter micron rating is the size of the particle you are removing, not the physical pore size! • Cross flow is a great option especially if looking to get away from D.E. • Talk to other winemakers! • If possible, do a demonstration that compares to your current filter Why Filter? • Visual Clarity • Fix microbial problem • Sleep better at night Questions? Thank You!
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