Industry: Mineral water
Problem: Strict legislation in Germany sets high requirements for the purity and quality of mineral water. Haaner Felsenquelle constantly faces the task of protecting the integrity of processes.
Solution: To preserve the natural qualities and purity of the water during bottling, and to respond flexibly to the growing demands of the beverage market, the company must use the latest technologies. To Donaldson's filtration technologies, especially the new LifeTec™ depth and membrane filter elements, an important role is assigned at this plant.
The Bergische Waldquelle mineral water received the rating "Excellent" from ÖKO-Test magazine
In November 2017, the German magazine ÖKO-Test tested the products of 21 mineral-water producers suitable for preparing baby food. The Bergische Waldquelle mineral water in a glass bottle received the rating "Excellent".
This means that it not only has a pleasant taste but also meets the highest quality requirements. This became possible largely thanks to Donaldson's filtration technologies.
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The range of products manufactured by Haaner Felsenquelle includes more than 80 beverages: from mineral water to isotonic soft drinks. Haaner Felsenquelle has been bottling mineral water in the city of Haan, Germany, since 1909 (fig. 1). Currently, the company obtains water with a balanced mineralization level from seven wells 140 to 345 meters deep.
In Germany, a strictly limited number of processes are permitted in water treatment, for example the addition and removal of carbon dioxide or the removal of iron and manganese. These processes must be carried out using gentle aeration and/or filtration. Mineral water such as Haaner Felsenquelle is officially recognized as "natural mineral water" because it meets the legal requirements for applying such a label. This official certification is unique to Germany; no other food product in the country is subject to such a check.
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"Along with checks by authorized bodies and independent laboratories, we carry out a large number of our own tests to ensure that the products comply with strict technical specifications. This constantly poses for us the task of ensuring the integrity of the processes at the plant. And the decisive contribution to this task is made by filtration technology," — said Lukas Schellenberg, chief technologist at Haaner Felsenquelle. He also noted: "I can only roughly name the number of individual filters, but there are clearly more than a hundred of them." (Fig. 2)
Solution
The use of highly purified compressed air and special quality control
Although the process air at a pressure of 8 bar is produced by two oil-free screw compressors, it must be cleaned with compressed-air filters and passed through an activated-carbon adsorber after moisture removal. After such cleaning, the compressed-air quality is guaranteed to exceed that specified for class 1 air under the DIN ISO 8573-1: 2010 standard, according to which the required residual oil content must be less than 0.01 mg/m³ and the particle concentration less than 0.1 mg/m³. The PET-bottle water-filling machine can fill up to 13,000 bottles per hour. To supply compressed air at a pressure of 30 bar to this machine, a piston compressor is used which, like the screw compressors, is oil-free. To ensure a high level of air purity, special high-pressure filters and a P-SRF sterile filter are used. They remove bacteria and contaminant particles from the air used to blow out the bottles.
Lukas Schellenberg explains: "We carefully control the entire compressed-air treatment process. The primary task is to meet the requirements for particle retention and sterility, as well as to control the energy consumption of the two 30 kW compressors. Their energy consumption largely depends on the differential pressure of the filters."
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Preserving natural qualities and purity
"The specifics of the Bergisches Land region play a significant role in the quality of our mineral waters. They are characterized by natural purity. Our task as a producer of mineral waters is to preserve these natural qualities and purity during bottling and treatment."
This principle formed the basis of all production processes at Haaner Felsenquelle. The filtration requirements in each specific case are determined in close cooperation with Donaldson's filtration specialists. Our practical experience and constant testing in our own laboratory allow us to effectively use the latest filtration technologies applied in the LifeTec depth and membrane filter elements. (Fig. 3)
The LifeTec filters (fig. 4) differ from the previous-generation filters by a significantly more durable polypropylene sleeve. Its diamond-shaped structure not only improves the static properties but also creates favorable conditions for the flow.
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The success of this series of liquid filters, approved for direct contact with food products in accordance with EU Regulation 1935/2004 and Title 21 of the US Code of Federal Regulations, is based on a modern cleanroom production concept at Donaldson's plant in Haan, Germany. The fast automated manufacturing process according to the customer's specifications supports the production of both large and single-unit batches and makes it possible to shorten delivery times.
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Sterile-filtration filters: a new level of efficiency and an extended service life
For Haaner Felsenquelle, the service life of the compressed-air filters used in the especially critical sections of mineral-water bottling (for example, in the processing of PET bottles) is also very important.
P-SRF C and SRF V depth filters can also be used as venting filters to equalize pressure in tanks for water, concentrate and sugar. These pleated filters in stainless-steel housings are characterized by especially high material durability and a long service life. The P-SRF V series includes filters from 5 to 30 inches in size with different types of connections.
The retention efficiency for bacteria 0.2 microns in size and bacteriophages/viruses 0.02 microns in size reaches 99.999999995 %. For nano-sized contaminants (0.003 microns), this figure reaches 99.9999999991 %. P-SRF V filters are resistant to ozone and hydrogen peroxide in the vapor phase, withstand exposure to cleaning-in-place chemicals in aerosol form, and can be used at temperatures up to 200 °C (392 °F).
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Quality service and fast delivery times
Donaldson also offers a wide range of services. We measure the differential pressure of the customer's filter elements, check the integrity of depth filters (dioctyl phthalate (DOP) test), and carry out a quantitative and qualitative analysis of particles (0.8–120 microns) in liquids. We also offer the regeneration of filter elements in a stainless-steel housing with the measurement of differential pressure before and after cleaning.
Lukas Schellenberg appreciated the advantage of fast filter delivery: "Despite the long service life of the filters, which we monitor by measuring differential pressure, it is important to us that the filter elements are delivered quickly." This opinion is shared by senior manager Helmut Römer, who emphasizes: "Working with a company engaged in filtration technologies and offering products for all the needs of a mineral-water production company has proved to be extremely advantageous."
Contact us for more information about Donaldson process-filtration solutions.
The cooperation between Danone and Donaldson clearly illustrates how even minor changes can lead to a tangible economic effect. This is fully in line with the goals and objectives of Donaldson: safety, sustainability, innovation.
Important note
