GEA Pioneers Sustainable Food Transformation at IFFA 2025

GEA Pioneers Sustainable Food Transformation at IFFA 2025

(IN BRIEF) At IFFA 2025, GEA has showcased its comprehensive suite of innovative solutions aimed at transforming food processing and packaging. The company’s presentation emphasized state-of-the-art technologies that drive efficiency, sustainability, and safety in food production. GEA’s solutions, which incorporate advanced process control, energy optimization, and waste reduction techniques, are designed to help food producers meet both global regulatory standards and rising consumer expectations. By addressing key challenges such as operational resilience and environmental impact, GEA is positioning itself as a vital partner in shaping a more sustainable and secure food supply chain. The event highlighted GEA’s commitment to innovation and its strategic role in modernizing the food industry.

(PRESS RELEASE) DÜSSELDORF, 17-Mar-2025 — /EuropaWire/ — At IFFA 2025 in Frankfurt, Germany, from May 3 to 8, GEA—one of the world’s leading technology groups—will unveil a host of breakthrough innovations in food processing and packaging. Set to exhibit in Hall 8 at Booth G10, GEA will highlight its latest advancements in meat, alternative protein, and cheese production. The company’s new technologies are specifically engineered to boost operational efficiency and reduce energy consumption, empowering food processors to adapt to an increasingly dynamic and cost-conscious market.

As global food demand and variety continue to expand amid rising living costs and inflationary pressures, food producers face mounting challenges to optimize production without compromising efficiency. In this context, GEA’s customer-centric approach is dedicated to offering integrated solutions that not only address these market pressures but also enhance sustainability. Peter Lauwers, CEO of GEA Food & Healthcare Technologies, stated, “We are committed to supporting our customers in today’s challenging market by delivering innovative technology solutions that improve production efficiency and sustainability. Our systems help maximize raw material utilization, reduce packaging volume, and promote the use of recyclable mono materials, all in accordance with the EU’s Packaging and Packaging Waste Regulation. By optimizing energy consumption and reducing greenhouse gas emissions, our state-of-the-art automation and digital tools provide comprehensive Overall Equipment Effectiveness (OEE) improvements and increased production yields.”

At IFFA 2025, GEA will showcase several key innovations:

CookStar First – New Spiral Oven:
Expanding its successful CookStar family, GEA introduces CookStar First—a spiral oven tailored for medium-capacity markets, especially those producing coated and plant-based products, with a throughput of up to 1,700 kg/hr. This oven offers up to a 3% higher yield and 10–12% energy savings compared to standard models, earning it GEA’s TÜV-validated “Add Better” ecolabel. For instance, a 1% improvement in yield during a two-shift operation at 1,500 kg/hr could save up to 55 tons of product annually, resulting in financial benefits of up to 200,000 EUR, depending on the substrate and coating. CookStar First is equipped with advanced process enhancements for improved control and insights, and it comes with a cloud-connected Starter Package Plus for preventive maintenance, along with the Insight Partner module that provides a detailed energy usage dashboard to help optimize SKU settings.

MaxiFormer II Concept:
The next evolution in drum forming technology, MaxiFormer II, sets new industry benchmarks for efficiency, consistency, and sustainability. Building on the legacy of its predecessor, this next-generation machine offers the lowest total cost of ownership on the market, with a drum capable of running continuously for up to 60 hours at speeds up to 10 tons/hr without cleaning interruptions. It delivers consistent product quality with over 1.7% lower giveaway and uniform weight distribution, even when processing a diverse range of products—from poultry, fish, and vegetarian items to pork, potato masses, and cheese-based mixes. Featuring the advanced SmartControl HMI and automated weight reporting, MaxiFormer II provides real-time data insights that enhance decision-making. Its integrated MaxiClean system, an intelligent automated cleaning solution, minimizes downtime by reducing annual water usage by up to 80% and hot water consumption by 91%, which significantly cuts operating costs and environmental impact. This innovative system also boasts the TÜV “Add Better” ecolabel, reflecting GEA’s commitment to sustainable production.

OptiScanner 5000 and OptiSlicer 7000 – Precision Slicing Redefined:
GEA is also debuting a state-of-the-art slicing, loading, and packaging line that features the innovative combination of the OptiScanner 5000 and OptiSlicer 7000. The OptiSlicer 7000, available with either a mono drive or dual independent drives, facilitates high-capacity slicing of natural products with individual weight control per lane. When paired with the new GEA Slicing Blade R505, which offers an extended cutting edge, it achieves superior portion quality and accommodates wider products. In synergy with the OptiScanner 5000—an advanced optical scanning solution—the system minimizes product giveaway and maximizes throughput. In one application, reducing the portion weight by just 2 grams in a 200-gram package could save up to 400,000 EUR annually in a two-shift operation. Moreover, all machines are IoT-ready and seamlessly integrated with the GEA Cloud for real-time performance optimization.

GEA NEXUS – A Holistic Approach to Energy Efficiency:
Recognizing that large-scale food production is a significant energy consumer, GEA introduces GEA NEXUS, a holistic engineering solution designed to optimize energy usage and minimize carbon emissions in the food industry. By integrating food processing with heating and cooling solutions, GEA NEXUS can reduce energy consumption and operating costs by up to 30%, cut CO₂ and NOₓ emissions by up to 100%, and lower water consumption, thereby paving the way for closed-loop, carbon-free production. A critical element of this solution is the intelligent application of GEA heat pump technology.

At IFFA 2025, visitors will have the opportunity to interact with GEA experts and explore these innovative solutions, gaining firsthand insight into how GEA is driving a better food future through sustainable production processes. Join GEA in Hall 8 at Booth G10 to experience these groundbreaking technologies.

Media Contact:

Nicole Hoffmann
Trade Press for Dairy Processing and Food
Phone: +49 (0)211 9136-1503

SOURCE: GEA