se-success-story-dcp-netherlands

Continuous production of food grade products

Production of animal proteins at DCP INGREDIENTS, Netherlands

DCP Ingredients is an international producer and marketer of highly functional collagen proteins for the food industry. In the production of animal proteins, the last process step consists of drying viscous material. Hence, the customer was looking for a solution that could turn a very pasty product into dried powder.

The challenge: 

Turn animal by-products into high-quality food ingredients

DCP carried out R&D on their product as well as pilot plant tests at ANDRITZ Gouda to find a stable and reliable solution. They found out that a so-called thin-film contact drum dryer was the answer to their quest. Test work has proven this dryer to be the appropriate choice of technology. A very thin layer of the product to be dried is applied to the outside of a rotating cylinder (drum). This drum is heated on the inside by steam. When in contact with the heated surface, the liquid evaporates very quickly from the thin product layer. After almost one complete rotation of the drum, the remaining dried product is scraped off the drum surface with a sharp knife, forming flakes that are then ground into protein powder.

Our solution: 

Highly efficient and well-controlled drying process

ANDRITZ Gouda has a widespread reputation in the food industry and offers a full range of processing machinery for the production of high-value products. In particular, the drying process must be carried out
as gently as possible without strong mechanical or thermal impact. We have designed an innovative solution that is especially suitable for processing edible raw materials into protein products for human consumption for pet food. 

Viscous raw material is best dried using a contact drum dryer. The heated steam on the inside of the drum body condenses and the moisture is removed continuously from the drum. As such, the largest possible surface area remains available for condensation of the steam. Steam heating provides uniform temperature distribution over the drum surface, which results in a consistent product quality. The system is a closed loop. As the drum rotates and is heated on the inside, the product dries on the outside of the drum surface. 

Because of the continuous, indirect drying method and the short retention time of the product at high temperature, virtually no heat damage will occur. Also taste, smell, and texture quality of the product are guaranteed.

Results: 

Strong growth thanks to high-quality end product from Gouda dryer

DCP had been looking for a reliable process for drying animal proteins since 2005. Their specific objective was to obtain a consistently high-quality product and gain a significant share of the market. In 2006, the first pilot plant tests took place in collaboration with ANDRITZ Gouda. DCP ordered a first contact drum dryer in June 2010 that was installed successfully in November 2011.

In 2012, DCP began operations with its new production facility in the Netherlands, including ANDRITZ Gouda’s advanced drum drying technology. The new facility is FSSC 22000 approved and is able to produce collagen proteins using the most upto-date production techniques. By the end of 2013, the market had picked up for DCP! They then decided to expand and ordered a second drum dryer, commissioned in October 2015. Business is going very well.

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