GEA is supporting hands-on training at Geisenheim University with process technology specifically designed for research and teaching. For the newly opened Beverage Technology Center (GTZ), the engineering group supplied a multipurpose plant that replicates industrial beverage processes on a small scale – flexible in use, broadly applicable, and designed to support both teaching and applied research.

GEA technology makes processes visible and understandable

GEA’s pilot-scale solution combines industrial process standards with didactic accessibility. It consists of a flash pasteurizer, a cleaning-in-place (CIP) and sterilisation-in-place (SIP) system, a carbonator, an automated interconnection matrix, and a separator suitable for fruit juice, beer, and wine applications. All components are skid-mounted, with an integrated maintenance walkway for optimal access – a setup specifically adapted to the demands of university-based operations.

“Students should learn how processes work – and how to design them,” says Astrid Heller, project manager at GEA and expert for non-alcoholic beverage processing. “With this setup, they can modify process sequences, understand control points, and at the same time gain insights into the hygiene and efficiency standards of industrial production.”

The automated interconnection matrix allows specific process steps to be switched on or off, enabling students and faculty to construct, modify, and analyze entire process chains. This flexibility enables a learning experience that goes far beyond conventional training models.

“Our students not only experience real industrial automation here, but also develop a deep understanding of the logic and structure of modern beverage production – from pasteurisation to filling,” explains Michael Ludwig, head of the GTZ at Geisenheim University. “We aim to train the people who will move the industry forward – in production, innovation, and product development.”

Transfer platform for academia, research, and industry

The GTZ is designed as an open center for technology and knowledge transfer. In addition to university students, the infrastructure is also used by collaborating research institutes, industrial partners, and – via Germany’s federal vocational class for fruit juice technology – even vocational school programs. Continuing education courses, technical workshops, and joint pilot projects help ensure that knowledge transfer is active and ongoing. With this approach, the GTZ strengthens Geisenheim’s position as one of Germany’s leading centers for beverage education and applied development – both alcoholic and non-alcoholic.

GEA was involved early in the project’s system planning. Even before construction began, requirements related to utilities, automation, and process integration were jointly defined – a model for successful collaboration between academia and industry.

Pilot-scale systems: a growing strategic area

For GEA, the Geisenheim project exemplifies a growing application field: scaled-down process lines for research, education, and product development. The combination of industrial-grade automation, didactic accessibility, and flexible multipurpose design makes these systems increasingly relevant – not only at universities, but also in pilot labs and innovation hubs across the beverage industry.

Döhler, a global producer, marketer and provider of technology-driven natural ingredients, ingredient systems and integrated solutions, has announced a strategic partnership with Nukoko, the innovative company behind the world’s first cocoa-free ‘bean-to-bar’ chocolate. Together, Döhler and Nukoko will scale up the production of Nukoko’s patent-pending chocolate alternative, made from fava beans, in response to the growing challenges facing the global cocoa supply chain. With this partnership, Nukoko aims to revolutionise the chocolate industry with a sustainable, low-emission alternative.

This partnership will enable both companies to scale Nukoko’s innovative fermentation process to an industrial level by 2025. Nukoko’s unique process transforms fava beans into a sustainable chocolate alternative, addressing critical issues in the chocolate industry, including rising cocoa prices, environmental impact and socio-economic concerns surrounding cocoa production.

The collaboration between Döhler and Nukoko marks a major milestone in the evolution of chocolate manufacturing. Nukoko’s cocoa-free chocolate is made possible through its patent-pending fermentation technology, which mimics traditional cocoa fermentation to create chocolate’s characteristic flavours from fava beans. This breakthrough offers a sustainable alternative to conventional chocolate, reducing carbon emissions by up to 90 % compared to traditional cocoa-based products.

As the global cocoa industry faces unprecedented challenges—cocoa prices surged by 89 % in 2023 alone, driven by climate change and declining yields—Nukoko’s cocoa-free solution offers a viable and eco-friendly alternative. Cocoa production has long been associated with deforestation, child labour and high carbon emissions, ranking among the top five food sources contributing to CO2 emissions. Nukoko’s fava bean-based chocolate eliminates these issues by using a domestically grown, nitrogen-fixing crop that promotes soil health and reduces the need for fertilisers.

In addition to its environmental benefits, Nukoko’s chocolate alternative boasts 40 % less sugar and higher levels of protein, fiber, and antioxidants, offering a healthier choice for consumers without compromising on taste.

With the support of Döhler’s expertise in fermentation scale-up and ingredient systems, Nukoko will transition from pilot-scale production to full industrial-scale batches by 2025. This process will involve producing in 10,000-litre fermentation batches, significantly increasing output while maintaining high efficiency.

Döhler’s deep knowledge in regulatory processes and food safety will also be instrumental as Nukoko approaches its market launch.