CAPTURING
NEW OCEANS
Seafood production redefined

GEA.com2Capturing new oceans - Seafood production redefined

PARTNERS IN
PROGRESS
Seafood producers, facing the imperative forhigher efficiencies and new value creation,
are adapting to evolving consumer trends
and assuming responsibility in a world ofresource scarcity. As GEA we recognize
the challenges shaping your industry.
These challenges demand for ingenuity,
collaboration, and inventive solutions.
We are pleased to present our robust
portfolio of solutions that not only address
challenges like labour shortages, supply/
demand imbalances and sustainability but
also harness the potential for new value
creation.

This brochure explores the domain ofinnovation, presenting new strategies toenhance efficiency and maximize value
throughout the entire processing chain. Our
objective is not simply to showcase products
but to inspire you, encouraging you toenvision the future of seafood processing.
Let GEA be your partner in progress as we
aspire to move the market forward together.

GEA’s broad portfolio supports youin the following process steps:
Preparation

Forming

Marination

Heat treatment
Coating

Chilling & Freezing
LoadingPackaging

3Capturing new oceans - Seafood production redefined

CRAFTING CULINARY
EXCELLENCE

Today’s consumers wish for culinary
experiences that blend health, convenience,and innovation. This necessitates refining
your offerings and leveraging newtechnologies to meet these expectations.
Yet, amidst these challenges lies theopportunity for significant value creationand the discovery of new propositions.
In order to assist you in adapting to shifting
consumer trends and preferences, GEA
offers a comprehensive range of equipment
designed to elevate seafood processing

to new levels. Our extensive line-upof marination, cooking, and packaging
equipment serves as a versatile toolbox
to unlock these opportunities, whether it’sdelivering pre-marinated and seasoned
options or ensuring precise portioning andhigh quality packaging.

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Capturing new oceans - Seafood production redefined

Solutions Highlights:

GEA OptiDipper:
Our advanced batter machine delivers superior
pre-marinated fish fillets, enticing consumers
with innovative flavors. Featuring a one-piece
conveyor design, it minimizes product transfersand ensures quality. With guaranteed total
product
coverage,
reducedwaste, and easy maintenanceand cleaning, the OptiDipper setsa new standard in efficiency andtaste.

GEA PowerPak PLUS:
Choosing the appropriate packaging type isessential to influence consumers’ perceptionof freshness, quality, and sustainability. That’s
why our high-performance thermoformer
packaging line offers versatility to seafood
producers, allowing them to select from a wide
variety of packaging options, including modified
atmosphere packs, skin solutions, vacuum packs
and shrink packs.

Equipped with motorized bottom film unwinding
and tensioning systems for enhanced package
quality and control, as well as top film unwinding
and tensioning systems to improve package
sealing and minimize wrinkles.
Additionally, it’s capable ofeffortlessly running sensitive 10k
films, thanks to a superior film
unwind and tracking system.

5Capturing new oceans - Seafood production redefined

PRECISION WITH A GENTLE TOUCH

Ensuring the gentle handling of fish portions
throughout the production process is crucial
for minimizing waste, optimizing yield andenhancing the overall appearance andquality of the final product for consumers.
These factors are paramount for maintaining
competitiveness in the market. GEA’smachines are purposefully designed withthis critical element in mind, spanning frominjectors and freezers to robot loaders andpackaging lines.

6Capturing new oceans - Seafood production redefined

Solutions Highlights:

GEA MixMaster and MultiJector:
Homogeneous brines are a critical factor in themarination process. GEA MixMaster delivers
perfect mixing, from light brines and pickles up
to higher viscose marinades.
Injecting fish products with brine is a delicate
process to improve moisture retention during
the production process and enhance the naturalflavours of seafood. Featuring theinnovative 2 mm OptiFlex needlesystem, it ensures precise brine
distribution in delicate fish fillets
while leaving minimal marks.

GEA OptiRobot:
When seafood producers seek to automate
without compromising quality, our new robot
picker is the answer. Engineered for gentle
handling, it ensures precise loading of salmon
chunks into packaging machines. Capable ofloading a broad range of portion shapes, including
shingled, stacked, turned, and overlapped, itoffers an optional state-of-the-art vision system
to ensure only high-quality portions are loaded
and % of give-away gets reduced.
Seamlessly integrating with other
GEA line solutions, it provides
comprehensive automation.

GEA CookStar SuperHeatSmoke:
Revolutionizing smoking in a spiral oven,this innovative and patented in-line process,developed in collaboration with Kerry Red
Arrow, empowers seafood processors toproduce fully cooked smoked seafood products
on an industrial scale. By introducing freshlygenerated, purified natural smoke into theairflow, it delivers a distinctive and customizableflavor, attractive color, consistentquality, and extended shelflife. Say goodbye to traditionalsmoking methods and hello toefficiency and flavor.

7Capturing new oceans - Seafood production redefined

RIDING THE WAVES OF AUTOMATION
AND DIGITIZATIONIn the dynamic seafood landscape, where
labour shortages are increasingly pressing,digitization and automation have become
essential tools unlocking new opportunities
to enhance production yield and quality.
At GEA, we recognize the critical importanceof these aspects and are committed toproviding intelligent software solutions
tailored to the needs of seafood producers.
From intuitive Human-Machine Interfaces(HMI) for seamless process control andoptimization to data-driven analytical tools,
our solutions empower seafood processors
to elevate overall efficiencies and thrive inan ever-evolving industry.

8Capturing new oceans - Seafood production redefinedSolutions Highlights:

GEA Smart Sealing System:
Introducing our Smart Sealing System, agroundbreaking feature on our GEA SmartPacker
CX400’s vertical packaging line, marking a newera of productivity. Experience an impressive
increase of up to 20%, with the capability toseal up to 1 million bags without changing.
Its ‘click and go’ sealing strip replacement featureensures minimal downtime andmaximum output, revolutionizing
your packaging efficiency.

GEA SmartControl HMI:
Our newly developed user interface places theoperator at the heart of the production process,facilitating collaboration between operatorsand machines. With a role-based permission
system, operators can adapt better to individual
needs, while performance and event-related
insights drive improved team performance.
Advanced recipe management
ensures process efficiencies
and traceability, empowering
operators to optimize production
at every step.

9Capturing new oceans - Seafood production redefined

THE EYE FOR DETAIL MATTERS

In seafood production success depends on
keen attention to detail. Even minor changes
can yield significant impacts on the bottomline. From reducing waste and giveaways tooptimizing line speed, every improvement
matters.
For example, a mere 5% reduction in tempura
battering or a 1% decrease in giveaway cangreatly enhance profits and overall success.
At GEA, we take pride in our keen eye forthese critical details, driving progress andefficiency for our seafood customers.

10Capturing new oceans - Seafood production redefined

Solutions Highlights:

GEA CrumbMaster Gen2:
Representing over 60 years of expertise incoating machine development, our latest
innovation in dedicated crumb coaters sets newstandards. With the lowest crumb breakdown
and a closed machine design that eliminates
up to 90% of dust, operations, cleaning,and maintenance are simplified. Featuring
integrated blow-off control andcrumb recirculation, it enhances
product quality consistency
while minimizing waste.

GEA ProFry:
Drawing upon over 50 years of expertise infrying technology, our advanced industrial fryer,
the GEA ProFry, delivers a 30% enhancement inoil flow, real-time inline oil quality measurement(patent pending) and a 15% increase in capacity
within a smaller footprint.
Optimize your frying process
and elevate the quality andprofitability of your flash fried
and deep fried products.

11Capturing new oceans - Seafood production redefined

THRIVING THROUGH
VALORISATION

The winners in the market are those who
understand how to extract the maximum
value from raw materials, aligning withconsumer demands for health andsustainability.
This strategic approach, known asvalorisation, is paramount. GEA has alongstanding commitment to this industry,

supporting seafood producers for years
in harvesting as much value from raw
materials as possible. With our expertiseand dedication, we empower producers tothrive in a landscape where sustainability
and value creation go hand in hand.

12Capturing new oceans - Seafood production redefined

Solutions Highlights:

GEA MaxiFormers:
The production of fish burgers and innovative
hybrid foods offers seafood producers avaluable opportunity for value creation. Byutilizing fish by-products such as trimmings,off-cuts, and less common species, theseproducts help reduce waste and diversifyofferings. Additionally, they
appeal to a broader audience,
including those hesitant about
consuming whole fish or fillets.
Our patented drum forming

GEA Separation:
GEA’s separators and decanters have beenused for the processing of fish by-products
since 1929. Our separation expertise stands
for top quality fish meal, fish oil and protein.
Not only do we offer individual machines but
we engineer complete productionprocesses that extract more value
from raw materials, ranging fromfish and animal feed to omega-3
production.

technology, GEA’s MaxiFormer, surpasses
competitor equipment in both quality
consistency and total cost of ownership.
Its distinctive drum design, unique patented
filling process and streamlined softwarecommunication deliver immediate savings in
product usage, water consumption, waste
disposal, and power usage. Offering ourcustomers the lowest total cost of ownershipover the operational life of the equipment.

13Capturing new oceans - Seafood production redefined

NEW FOODFRONTIERSWith 85% of fisheries already at or beyond
their limits and constraints on fish farming,
traditional seafood supplies struggle to meetdemand. To address this challenge, seafood
producers are turning to alternative proteins.
Cultivated, fermentation-based, and plantbased products emerge as promisingalternatives due to their similarities andmarket readiness.
Leveraging our extensive experience as anindustry supplier in the New Food world,

GEA is well-prepared to serve the market
for alternative proteins, particularly thosefrom plant-, cell-, and microorganismbased sources. Many of these innovativefoods require liquid processing—a domain
where GEA excels. But that is not all, ourtechnologies support the complete value
chain, from raw materials to packaged
products.

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Capturing new oceans - Seafood production redefined

New Food Highlights:

GEA New Food Application and Technology
Center of Excellence (ATC):
Investments in the new food sphere require adifferent kind of approach. It requires technology
partners that are willing to invest time inexperimentation and handle uncertainties.
For seafood producers, the primary hurdle lies intransitioning from laboratory prototypes to fullfledged commercial production. Our New Food
Application and Technology Center of Excellence(ATC) has been established as a central hub
to support innovation in the emerging field of
cellular agriculture, providing
invaluable support to corporate
startups as they strive to scale
their innovative initiatives.

Helping the world eat less meat:
In a partnership spanning two decades,
GEA has been an integral part of Vivera’s
journey towards excellence in vegan andvegetarian food production. More thanjust suppliers, we’re collaborators, working
closely to refine processes and pioneer

new products. From our service centers toour Technology Center inBakel (NL), we’re supporting
Vivera’s mission to redefine
the food industry. Read more
about our partnership here.

15Capturing new oceans - Seafood production redefined

CAPTURING NEW OCEANS TOGETHER

We believe that, in order to set new industry
standards and redefine seafood production,
we need to design specialist solutions at
every stage of a line rather than employing
a blanket, one-size-fits-all approach.
That means, in some cases, starting
small, building modularly, and supportinga growing customer as they progress.
For others, it means optimizing existingprocesses. Building complete lines that are

fully integrated and work in perfect harmony.
It is the combination of creativity, businesssense, and working closely together thatwill bring us there.
We work closely with our customers toassess their processes, build compellingbusiness cases, and craft optimal solutions
that align perfectly with the requirements ofthe seafood industry.

Whether you want to learn more about specificsolutions and single process steps or talk about
a full-line solution.
Reach out to our experts directly or visit ourwebsite to learn more.

GEA.com

GEA Food Solutions Germany GmbH
Branch Wallau
Im Ruttert
35216 Biedenkopf-Wallau
GermanyTel +49 6461 801 0

gea.com/en/food/seafood/

GEA Seafood_EN_042024. Published on 10/04/2024   © GEA Food Processing and Packaging. All rights reserved.   Subject to modifications.