Name: Falling Film Evaporator
Brand: Gausin International Engineers Pvt. Ltd.
Availability: InStock

Product Overview

The Gausin Falling Film Evaporator is a vertically oriented heat exchanger where the liquid feed is distributed uniformly over the top tube sheet and flows downward as a thin film on the inner tube surfaces. Steam or hot water condensing on the shell side supplies the heat required for evaporation.

This design allows evaporation at relatively low temperatures (through vacuum operation), making it ideal for heat-sensitive products like milk, fruit juices, pharmaceutical solutions, and chemical liquids. The short residence time and low temperature difference across the tubes ensure minimal product degradation.

Gausin's FFE systems are engineered using CHEMCAD process simulation and HTRI thermal design software, ensuring precise heat transfer calculations, optimal tube dimensions, and guaranteed performance from day one.

Thin Film Evaporation

Liquid forms a thin, uniform film on tube inner surfaces for maximum heat transfer efficiency.

Low Temperature Operation

Vacuum operation allows evaporation at 40 - 75 deg C - protecting heat-sensitive products.

Multi-Effect Design

Up to 7-effect configurations with vapor reuse between effects for exceptional steam economy.

TVR / MVR Ready

Thermal Vapour Recompression (TVR) / Mechanical Vapour Recompression (MVR) upgrade available for minimum steam consumption.

CIP Compatible

Designed for clean-in-place (CIP) cleaning without dismantling - fully hygienic design.

PLC/SCADA Automation

Full PLC automation with SCADA HMI for precise process control, alarm management, and data logging.

Technical Specifications

Process Parameters

Evaporation Capacity	500 to 50,000 L/hr
Number of Effects	Single / Double / Triple / Up to 7
Operating Temperature	40 - 90 deg C (Vacuum)
Operating Pressure	Full Vacuum to 1.5 bar (g)
Steam Consumption	0.14 - 0.45 kg steam/kg water (MEE)
Steam Economy	2.2 to 6.5 (2 to 7 Effect)
Outlet Concentration	Up to 65 - 70% Total Solids
Residence Time	Very Short (Seconds per Pass)

Construction Details

Material of Construction	SS 304 / SS 316L / Duplex SS
Internal Surface Finish	Ra <= 0.8 um (Electropolished)
Tube Diameter	38 - 51 mm (Standard)
Tube Length	4 m / 6 m / 8 m / 10 m / 12 m
Tube-to-Tubesheet Joint	Expanded + Welded (Seal Weld)
Heating Medium	Steam / Hot Water / Vapor
Design Pressure	As per ASME Sec. VIII Div.1
Inspection Standard	ASME / IBR / Third-Party

Instrumentation & Controls

Control System	PLC / SCADA with HMI Touchscreen
Temperature Sensors	PT-100 RTD / Thermocouple (per effect)
Pressure Gauges	Diaphragm Type, SS Wetted Parts
Level Control	Magnetic Level Gauge + Level Transmitter
Flow Measurement	Electromagnetic / Coriolis Flow Meters
Density / Brix Control	Inline Refractometer / Density Meter
Vacuum System	Steam Ejector / Liquid Ring Vacuum Pump
CIP Connection	Full CIP Circuit with Spray Balls

Applications

Dairy Industry

Whole milk, Skim milk, Whey, Lactose, Casein, Sweet and Condensed milk, cream concentration

Fruit Juice

Apple, orange, mango juice concentration while preserving flavor

Pharmaceutical

API solutions and Effluent treatment plant

Chemical

Caustic soda, Dye & Pigments, Effluent, Organic chemicals, polymer solutions

Coffee & Tea

Liquid coffee/tea extract concentration before spray drying

Starch & Sugars

Corn syrup, glucose, starch hydrolysate concentration

Pulp & Paper

Black liquor concentration, pulp mill effluent, and recovery evaporator applications

Distillery

Molasses, spent wash, and ethanol stillage concentration for distillery plants

Nutraceutical

Herbal extracts, botanical concentrates, and functional ingredient processing

Key Advantages

Exceptional Energy Efficiency

Multi-effect design achieves steam economy of 2.2 - 6.5, reducing steam consumption by up to 85% versus single-effect systems. TVR option reduces steam consumption, MVR option virtually eliminates steam requirement.

Gentle Product Treatment

Short residence time (seconds) and low evaporation temperatures protect heat-sensitive components - vitamins, proteins, flavors and colors remain intact.

Wide Capacity Range

Modular design allows capacity from 500 L/hr to 50,000 L/hr in a single unit, with further scale-up through parallel trains.

Continuous Operation

Designed for 24/7 continuous operation with minimal maintenance. Automated CIP cycles keep downtime to a minimum.

Standards Compliance

Manufactured to ASME Section VIII, 3-A sanitary standards (dairy), GMP guidelines (pharma), and all relevant BIS/IS Indian standards.

Low Maintenance

Simple mechanical design with no moving parts in the evaporator body. Predictive maintenance enabled through online monitoring instruments.

How It Works

Feed Distribution

The liquid feed is preheated and fed to the top distribution tray of the evaporator. A patented distribution system ensures uniform, even distribution of liquid to all tubes - preventing dry spots and ensuring consistent film formation.

Film Formation & Evaporation

The liquid flows downward under gravity as a thin film on the inner tube wall. Steam condensing on the shell side transfers heat through the tube wall to the falling liquid film, causing rapid evaporation of water at the film surface.

Vapor-Liquid Separation

At the bottom of the tubes, concentrated liquid and generated vapors exit together and enter the vapor-liquid separator. The separator efficiently separates the vapor (secondary steam) from the concentrated product liquid.

Multi-Effect Vapor Reuse

In multi-effect systems, the secondary steam generated in Effect 1 is used as the heating medium for Effect 2 (operating at lower temperature/pressure), and so on. This cascading of vapor energy dramatically reduces total steam consumption.

Condensate & Product Discharge

Vapor from the final effect is condensed in a barometric or surface condenser. Steam condensate is recovered and reused. The concentrated product at target Total Solids content is discharged via a density/Brix-controlled outlet pump.

Thermo Vapour Recompressor (TVR)

A Thermo Vapour Recompressor (TVR) uses high-pressure motive steam in a steam jet ejector to compress low-pressure vapor from an effect, raising its pressure and temperature so it can be reused as heating steam in the same or preceding effect. This boosts steam economy beyond standard multi-effect operation while keeping investment lower than full MVR systems.

Mechanical Vapour Recompressor (MVR)

A Mechanical Vapour Recompressor (MVR) system uses a centrifugal or roots-type compressor driven by an electric motor to compress evaporator vapor, increasing its saturation temperature so the same vapor can serve as the sole heating medium. MVR plants can operate with minimal or zero live steam, delivering the highest energy efficiency for large-capacity falling film evaporators.