No. 12 02/2007 Our International Wire&Mesh Magazine for Existing and Prospective Customers

Our Customers – The Winners!

Dear Reader!

What can be better for a supplier than to know that their customers are being suc- cessful with the products that they sup- ply? That is why, for example, we were very pleased to hear that one of our cus- tomers has just won the German environ- mental prize. Or when the Ariane 5 safely PACO and Chocolate Production: launches another two satellites at a time into orbit. Or when somewhere in the world, a piece of chocolate slowly melts in Extracting Excellence! somebody’s mouth and this was made possible by our sieving and filtering tech- Numerous processing stages influ- Houten recognised that the cocoa bean nology (see our article for more in- ence the way that the cocoa bean is had got everything that was needed to formation). Whenever our customers are transformed into a piece of mouth- be a success in the mass market. But watering chocolate. Some of these first of all a solution had to be found to successful, we automatically share their require demanding sieving and fil- take the fat out of the cocoa bean. success. tering procedures. That is why it is Otherwise, the high fat content would Our contribution is a quality that helps no surprise that you will find PACO interfere with the intended solubility in sorting things out here. More than water or milk. all of our customers to succeed: an under- that: we have been supplying sieves standing of what they need, wish and want and filters to the manufacturers The principle of the cocoa press – to achieve – at the highest level. Invalu- and users of chocolate filter press- nowadays a high-tech product es around the world for a number of To take the fat out of the cocoa bean, C. able for this is our extensive experience of years. The fascinating thing about van Houten invented the cocoa press in a wide range of industries, a variety of working with cocoa and chocolate 1828. Regardless of whether whole processes and numerous technologies. producers is not just the technical beans, de-shelled cocoa nibs or fine nib challenge. It is also about being as- dust is pressed, the resulting products All of this provides a synergy potential sociated with a craft that has a long are the same: yellowish-white cocoa but- from which all of our customers can tradition which began with the Ma- ter and brown cocoa press cake. Today’s benefit. As far as we are concerned, the yas and Aztecs and has continued cocoa presses, which have been perfect- with names like C. van Houten or ed through modern technology such as best success is when our customers are Rudolf Lindt – with no foreseeable hydraulic operation, electronic control the winners in their markets, among their end in sight. and a high pressing forces in excess of customers and with the juries that judge 500 bar, enable the fat content in cocoa The cocoa bean has a problem: to be dropped to only 9 %. This compares their products. it is rather fat to a figure of 20 % in the days of Van The Aztecs took their cocoa beans as Houten’s original press. Best Regards they found them – after all, they consid- The cocoa butter that is extracted ered them to be a present from Quetzal- using this method is not only used in the Peter Ruppel coatl – the god responsible for their fer- production of chocolate. It is also an in- Managing Director tility. When the Spanish conquistador gredient in cosmetics (e.g. creams and lip­- Hernando Cortez arrived to conquer stick) and medicines (e.g. suppositories). Mexico in 1519, the Aztecs offered him The press cake is turned into cocoa ”chocolatl“. The extremely bitter taste of powder which is either sold pure or fur- the drink made of fermented and crushed ther processed to produce a range of cocoa beans was, however, one that he other products. didn’t quite readily acquire. After the Spaniards had brought co- From bean to cocoa powder: coa back to Europe, it found its way into only the best is good enough the homes of the royal families – togeth- The quality of the cocoa powder and co- er with sugar – as a delicacy that was coa butter will, of course depend on the completely beyond the reach of normal quality of the beans. The best come from mortals. This wasn’t to change until the equatorial regions of South America and Dutch industrial pioneer Conrad van Continued on page 2 Cocoa Beans Cocoa Beans

No. 12 02/2007 Cleaning Cleaning PACONews Pre-Drying Pre-Drying Deshelling Deshelling Alcalisizing PACO and Roasting Roasting Cocoa Mass Roasting Chocolate Grinding Grinding remelting Grinding Production Cocoa Liquor Cocoa Liquor Alcalized Liquor Continued from page 1 Hydraulic West Africa. Famous varieties Pressing are, for instance, Criollo or Fo- rastero. Nevertheless, no mat- Production Flowsheet Cocoa ter how good the beans are, they Cocoa & Chocolate Presscake will not provide satisfactory products when their quality is not matched by that of the manufacturing and processing Cakes procedures. To begin with, the cocoa beans are cleaned to remove all extrane- Filtration Schmelzen Milling Deodorization Kakaobutter Stabilizing Cocoa Butter Cocoa Powder

Dark White Chocolate Milk Chocolate Chocolate

Dosing: Dosing: Dosing: Liquor/Butter/ Liquor/Butter/ Liquor/Butter/ Sugar Sugar Sugar ous material – to all intents and purpos- es, the first sieving process. In most cases, the beans are then roasted to in- Pre-Grinding Pre-Grinding Pre-Grinding tensify their aroma and bring out the Fine-Grinding Fine-Grinding Fine-Grinding typical cocoa colour. Following this, the Conching Conching Conching roasted beans are broken open and sieved again to separate the so-called late“ – because of the high number of nibs from the shell remainders. The co- metal wire cloths, sieves and filter solu- coa nibs are then milled to form a liquor tions that are needed in its making. In Liquid Storage and heated to 70 °C or more. Due to the common with other sieving processes, high fat content, heating will cause the the efficiency with which the bulk mate- liquor to become thinner so that it can rial is separated is of the utmost impor- Tempering be efficiently pumped into the cocoa tance – from whole beans, through Depositing press. And this is where both product nibs and shells to ultra-fine Cooling and processing technology are tested to cocoa powder. PACO filter their extremes: the cocoa butter is liter- elements put in a tremendous ally pressed out of the cocoa liquor. performance in the cocoa press. To en- Depending on the desired residual sure that they can withstand the enor- Solid Chocolate fat content, a pressure of up to mous pressure placed on them, they are 1000 bar will be exerted on the inserted in layers. The basis is formed by wire to break, any metal fragments can alike. And what would a cappuccino be press cake. This not only places PACOPERF perforated supported discs, easily be removed from the cocoa with without a topping of cocoa powder? an intense load on the mechan- PACOMESH woven support and backup corresponding magnetized tools. The highest form of artistry and craft ics of the cocoa press, but also screens and PACOSCREEN woven filter of the chocolatier are, of course, prod- on the filter media that separates cloths. They are mounted onto filter The final step: welcome to paradise! ucts such as pralinés, petit fours, confec- the cocoa butter from the press cake. plates that are individually designed for One of the secrets of the success of co- tionery products and a number of des- Finally, further sieving and filtering each specific type of press. The most coa is that it harmonises so well with serts. It is, therefore, no surprise that the operations are needed to produce the commonly used filter cloths are PACO other aromas. Apart from its long-stand- leading manufacturers of cocoa presses cocoa powder and further process the SIMPLEX, PACO DUPLEX and PACO TRI- ing companion sugar, these include cin- come from the countries that are re- cocoa butter. PLEX (for specifications, please refer to namon, cloves, cardamom, coffee or va- nowned for their cocoa and chocolate www.paco-online.com). The 1.4016 (T 430) nilla. The Aztecs also combined their products: for instance, Italy, the Nether- PACO solutions for cocoa and material that is used these days for the “chocolatl“ with extremely hot chillies, a lands and Germany. At PACO, we are fa- chocolate processing from A - Z metal cloth is magnetic. This means that taste that has come back into fashion miliar with the manufactures of cocoa When you take a closer look at a bar of should the combination of high pressing among chocolate gourmets. Cocoa drinks presses – and also the sweets and can- chocolate, you could also call it “PACO- force and material fatigue cause a metal remain popular among young and old dies that their machines help to produce.

PACO Factory Herolz: Expanding Capabilities with an Additional Area of 1800 m2! At the end of January 2007 a further phase of the factory extension at used to expand our manufacturing op- the PACO site in Herolz (between Frankfurt/Main and Fulda) was commis- erations. Before the end of 2007, eight sioned. This consists of additional storage area that increases capacity to high-performance looms built by our 1800 m2 and a new office building with 200 m2 space for the accounting own engineering group will be installed and human resources departments. and put into operation. In this way our weaving and processing capabilities will Increased flexibility and speed so that we can react faster and more be substantially increased. And the staff The increase in the storage area at our flexibly to the needs of the market. At in our accounting and human resources Herolz factory is primarily intended to the same time, the space that has been departments are also looking forward to allow more metal wires to be stocked freed up after moving our stores can be having more space to work in.

To keep up with the needs and wishes of our customers, PACO has substantially increased the metal wire storage area. At the same time, production capacity at the Herolz site has also been expanded. PACO with Damavand at the EXPOKISH 2006:

Kish Island – Visit us online! the Dubai of Iran www.paco-online.com Iran is not a destination that is started a campaign to economically de- ture partner Damavand. They showed ramping-up of production in Iran – has readily associated with mass tour- velop Kish Island as a rival to Dubai. Part a range of products that are of specific had a very positive effect. PACO/Dama- ism, despite its beaches, sun and of this plan is the establishment of an oil interest to the energy industry, which vand are already very well known and rich history. However, for the oil bourse trading in petroeuros. included metal wire meshes, sieving have a large market share. Further to industry and its suppliers, trade Tourism is very important for the frames and filter elements for the petro- this, PACO’s high standard of quality is shows in Iran are among the most approx. 16,500 inhabitants of Kish. Even chemical industry. widely recognised and valued. This me- important in the world. That is the shah of Iran spent his vacation there. ant that the joint exhibition stand was why PACO was represented with a There is no shortage of luxury hotels. Al- Known and respected as a force very busy – and elsewhere around the stand at the EXPOKISH 2006. though everything is very westernised, The reaction at the exhibition showed ENEX there were plenty of opportunities the strict ban on alcohol remains very that the attention that PACO has paid to to come into conversation. A number in- Jewel in the Persian Golf much in force. And women still bathe on the Iranian market for a number of years teresting options on orders were negoti- Kish Island is situated in the Persian Golf the beaches behind high corrugated iron is definitely reaping rewards. Particular- ated that should come to fruition during approx. 20 kilometres away from the fences. ly the joint venture with the local partner the course of this year. Iranian mainland. It takes about 45 min- Damavand – together with a continuous www.expokish.com utes to fly there from Dubai. Teheran is ENEX 2006 – 3rd International about two hours flight away. Kish Island Exhibition of Energy has the status of a free trade zone with For the third time, the ENEX invited an special tax concessions. That is why the international audience of energy pro- one and a half million visitors that it at- fessionals to Kish Island. Between the American Textile tracts each year view it as a shopping 14th and 17th November, the island’s paradise. The Iranian government has exhibition halls provided the state-of- Machinery Exhibition: the-art backdrop to show off the latest technologies, services and equipment for the oil, gas and petrochemical indus- PACO at the tries. PACO was also represented on a stand together with its Iranian joint-ven- ATME-I® 2006 in Atlanta, Welcome to the exhibition stand: PACO export manager Klaus Ruppel (right), Mr. Radjabi (CEO Georgia (USA) Damavand (left) and Ms. Khodayari from Damavand The ATME-I 2006 presented itself fibres and yarn as well as for at the EXPOKISH 2006. once again as the largest event weaving and knitting etc. PACO of its kind in the Americas. It is was there together with their considered to be the number one partner Petree & Stoudt to show exhibition for textile machines, solutions for the filtration of equipment, accessories and ser- liquefied polymers that are used International vices for manufacturing textile to produce synthetic fibres. Phosphate Conference: PACO Subsidiary CANAL Shows Their Experience in Morocco The imperial city of Marrakech was the venue for “The Second International Conference on the Valorization of Phosphates and Phosphorous Compounds”. Once again the event was organised by RECHERPHOS (Researcher’s Network on Phosphates). The Belgian PACO subsidiary CANAL Engineers, a company that has had considerable At the ATME-I approximately experience with phosphates, fertilisers and the African market, was represented with a stand of their own at the 1000 exhibitors presented conference. their production lines, machines and products for textile fibre manufacturing. PACO together Top-class stage The main subjects discussed during the ucts. Around 300 delegates from 24 with its partner Petree & Stoudt, It is no coincidence that the COVA- event were, for example, the geology of countries were in attendance. Approxi- devoted itself to the subject PHOS II was staged in Morocco. After all, phosphate, the theoretical and practical mately two thirds were scientists and of filtration. this North Af rican country is home to usage of phosphates, phosphoric acids the other third were from industry. The more than half of the world’s presumed in the chemistry of fertilisers, applica- quality of the event can be judged by the . reserves of the raw material phosphate. tion of fertilisers, phosphorous and bio- fact that all of CANAL Engineers’ impor- The problem that the country has had logical materials and protection of the tant customers from North Africa and t until now, however, was that the major- environment. the Middle East participated. The exhibi- ity of the phosphate that was mined left tion stand was very busy, with visitors Morocco unprocessed. As this meant an Numerous delegates expressing a particular interest in Dutch unsatisfactory level of returns, the con- CANAL Engineers used the conference weaves for sulphur filtration, perforated ference looked at new strategies which as an opportunity to present their prod- sheet segments and elements for filter- would be more lucrative for the domes- ing phosphoric acids as well as fine dust The CANAL stand was very busy. tic industry. Once again, the organisers This pleased managing director separators. The numerous conversa- Repo r succeeded in bringing together scien- André Brassine (middle) as well tions served not only to intensify exist- .

tists, industry and technology suppliers as the visitors. ing customer relationships but also to t interested in phosphates and phospho- promote CANAL Engineers and PACO as rous compounds around a single confer- qualified partners for the phosphate and ence table. fertiliser industries. xpo r PACO. E No. 12 02/2007 PACOMosaic

Add the numbers from 1 to 100 – as quickly as possible, please! PACOSLOT wedge wire screens One plus two is three, plus three is six, are valued by brewers because of their quality, reliability and plus four is ten, plus five is... – it’ll take product safety. Their qualities are a long time before we’ve added all hun- also appreciated in a wide range dred integers together – won’t it? of other applications such as That’s what a primary school teacher coolant filtration, resin traps and thought in 1784 as he wanted to keep nozzle filters. his pupils busy for an hour or two. But PACOSLOT Wedge Wire Screens: he hadn’t taken one of his pupils into account – the seven year old Carl Frie- derich Gauss. He put up his hand af- Reliable Tools ter just a few minutes and said what the correct answer was: 5050. As his teacher enquired how he had worked for the Finest Beers out the answer so quickly, the little Germans take pride in their beer. That is why the centuries old Reinheits- Gauss replied: “it’s quite easy: gebot (purity law) only allows the purest ingredients. But these alone are 1 + 100 = 101 no guarantee for the finest beers – the manufacturing process also has to 2 + 99 = 101 ensure utmost purity. PACOSLOT wedge wire screens stand for ultra-pure processing technologies and filtering results – not only for breweries. 3 + 98 = 101 4 + 97 = 101 The joins are the key All clear for beer purification etc. etc. until PACOSLOT wedge wire screens have a The PACOSLOT wedge wire screens used 50 + 51 = 101. spirally running surface structure with in the production of beer have an outer in total, 50 equations can be formed axially arranged supporting sections at diameter in the range of 27 to 37 mm that always equal 101. And 50 x 101 the cross-over points. These joints are with lengths between 800 and 2400 mm is 5050.“ welded without the use of any addi- and slot widths between 40 and 80 μ tional materials and are, consequently, Filtration occurs with the help of Would you have been able to work out the answer so quickly? Somehow, extremely pure! The lengthy experience an additional filtering layer of sediment when it comes to solving a problem, that has been gained using optimised that collects on the PACOLSLOT element we always seem to take the more labo- processing parameters ensures that the with the PACOSLOT initially acting as rious and long way round. But looking material structure of the shaped wires the carrier material. The precision of the at a challenge or problem from a com- will remain unchanged. PACO’s joining PACOSLOT wedge wire screens enable pletely different point of view can often expertise in combination with leading- the fast and effective bridging of the save a lot of time and effort. And to do edge production equipment has been sediment. The beer filtration itself oc- that you don’t need to be another Carl perfected to such a fine art that wedge curs through a separation of the liquids Friedrich Gauss who, even during his wire screens with a slot width as small and solids, whereby the fluid to be fil- lifetime, was titled the “Prince of Math- as 25 μ can be produced with extremely tered flows through a porous body cre- ematics“. The creative capability of fine manufacturing tolerances. The spe- ated by the additional filtering layer. This changing the order of things to reach cific design concept of a wedge wire traps the turbidity – which with beer is innovative solutions is something that filter depends on the selected material, primarily the yeast cells and protein-tan- can be very helpful to us in our every- the required filtering direction (from out- nic acid complex as well as precipitations day working lives. side to inside or inside to outside) and such as oxalate crystals and hop resins. Carl Friedrich Gauss, 1777 – 1855, mathematician, particularly the hydraulic qualities and The filtering sediment is removed by physicist and astronomer. In all three disciplines his work paved the way for developments that we associated mechanical requirements. reversing the flow. know today.

Steinau an der Straße: The Donkey’s Way – You Can Also Walk to Steinau! More than two thousand years ago, tracks and roads were already provid- ing the infrastructure for cultural exchange and the flow of trade. One such old-established transport link is the Eselsweg (Donkey’s Way). This runs val caravans that used the backs of don- tude of between 400 and 500 metres, for 111 km from Schlüchtern, in the Main- district of , through keys to transport salt from the saltworks without valleys (in other words, easy to Steinau an der Straße and the beautiful forest to Großheubach at nearby . walk along) and to each side charming in the Bavarian district of . Today the Donkey’s Way is a popular towns and villages full of picturesque hiking route. This is particularly because architecture and rich on history. Today a very popular hiking route their entourages, knights, craftsmen of the romantic path that it takes: 111 In times past, celtic warriors, roman and peasant journeyed along the way. km running almost exclusively through www.walk-in-europe.com/germany/ merchants, bishops and counts with Incidently, the name refers to the medie- old beech and oak woods at an alti- donkey-way

Imprint PACOs Publisher: PACO PAUL GmbH & Co. Short Guide to Manufacturing Metallgewebe und Filterfabrik Industriegebiet West 36396 Steinau a.d. Straße Work at PACO is characterised by a variety of different production techniques. We Germany present the most important of these in a series that appears periodically in the next few Telephone: +49 66 63 - 97 80 issues of PACO WORLD: Editor, copywriter: [email protected] 4. Welding and other joining techniques Layout: [email protected] As every day as the joining technique called welding appears to be, it nowadays takes on a number of Printer: different forms. At PACO “the non-detachable joining of two components through the application of Druckerei Chmielorz, heat and pressure“ is interpreted in a variety of ways. In each case, high process reliability and welding Wiesbaden-Nordenstadt quality is combined with innovative welding process control and quality assurance. The welding tech- Photos: pp. 1 top and pp. 2 left – Fotolia / niques used by PACO include: plasma welding, tungsten plasma welding, electron beam welding and pp. 4 centre – Business and Tourist Office wolfram inert gas welding. Other joining techniques include soldering, sintering and gluing. Steinau / all other pictures PACO