Aseptic filling from krones Protects your customers and is gentle to the product

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Andra Jackson
5 years ago
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1 Aseptic filling from krones Protects your customers and is gentle to the product

Krones filling technology Equipped for every task They can be sparkling or still, some are technically sophisticated while others are less complicated, some look great in PET containers, others in

2 Krones filling technology Equipped for every task They can be sparkling or still, some are technically sophisticated while others are less complicated, some look great in PET containers, others in glass bottles or cans: there is a huge amount of variety in beverage types and it s almost infinite when the various types of container are considered as well. Krones filling technology is a match for every one of these possibilities. That s because it comprises a large selection of filling processes, performance spectrums and hygiene levels. You just need to choose the system that meets your requirements. Can Glass PET HDPE PE Hotfill

krones aseptic lines Three systems, two media, countless products krones aseptics Container sterilisation Preform sterilisation PET-Asept L2 PET-Asept D Contiform AseptBloc System PAA H 2 H 2 144

3 krones aseptic lines Three systems, two media, countless products krones aseptics Container sterilisation Preform sterilisation PET-Asept L2 PET-Asept D Contiform AseptBloc System PAA H 2 H hours of continuous production time Filling systems: Modulfill Asept VFJ (flow meter), Modulfill Asept NWJ (load cells), Modulfill Asept VFJ-D (flow meter, particle dosage) Non-carbonated products Products Juices, tea and coffee, milk and mixed milk beverages, beverages containing particles

krones aseptic lines Sterile, compact, all-in-one Filling sensitive beverages is something of a balancing act. On the one hand, absolute safety for the consumer must be guaranteed.

Aseptic filling can bring both sides into balance but only if the right degree of microbiological know-how and tried-and-tested technology is applied. The Krones aseptic lines meet both requirements.

4 krones aseptic lines Sterile, compact, all-in-one Filling sensitive beverages is something of a balancing act. On the one hand, absolute safety for the consumer must be guaranteed. On the other, many thirst quenchers react extremely sensitively when given preserving media or exposed to thermal stress. Aseptic filling can bring both sides into balance but only if the right degree of microbiological know-how and tried-and-tested technology is applied. The Krones aseptic lines meet both requirements. They can handle wet or dry sterilisation according to need, have a filler with load cells or flow meter and function in the high or low performance range. Their enormous flexibility and reliability is why they are used by bottlers the whole world over delivering first-class results under a huge variety of general conditions. Features Enclosure in clean room housing principle with hermetic separation of the sterile area Mechanical components in the clean room housing reduced to a minimum Simply designed, easily cleanable surfaces Low clean room housing volumes Energy-efficient servo motors used throughout Functions Sterilisation of packaging (preforms or PET containers, depending on the system) Aseptic filling Aseptic sealing Processing range Products Mixed milk beverages UHT milk Juice Ice tea Tea Energy drinks Beverages containing particles Containers Round, square and rectangular With different neck diameters Standard and lightweight Caps Sports caps Flat cap

PET-Asept L2 The experienced professional for difficult tasks General features Can be installed as a user-friendly blow moulder filler block Monitors and records all relevant processes with a line

5 PET-Asept L2 The experienced professional for difficult tasks General features Can be installed as a user-friendly blow moulder filler block Monitors and records all relevant processes with a line documentation system Requires fewer filter fan units than comparable systems, saving on maintenance and energy costs Liquid barriers separate moving from rotating parts Output Up to 56,000 containers per hour Container steriliser Sterilises quickly and reliably with a peracetic acid-steam mixture Treats the containers from inside and outside at the same time Compact, manageable structure Adjusts the media input optimally to the container Dispenses entirely with the use of tensides Rinser Removes peracetic acid residues from the containers Uses efficient single-channel nozzles Consumes only sterile water, not air Adjusts the media input optimally to the container Filler Guarantees microbiological safety through hygienic design and contactless filling Comes with its own CIP module Determines the product amount exactly by flow sensors or load cells The Modulfill Asept VFJ-D variant also fills particles up to 8 x 8 x 8 mm gently Cap disinfection system Leads the caps through a peracetic acid bath Removes peracetic acid residues before forwarding to the capper Can also be configured as an H 2 sterilisation system if necessary Can also be equipped with a cap disinfection system if necessary 4 Capper Handles different cap types Monitors every single capping process Drives each capping head with a separate servo motor Clean room housing contains no electronic components or drives 3 1 Container sterilisation 2 Rinser 3 Filler 4 Capper 2 L2 = Liquid, Generation 2 1

That s because the steam transports the peracetic acid into every corner of the bottle within a matter of seconds.

6 PET-Asept L2 Your benefits 6 days without a break Other systems can only stand and stare: PET-Asept L2 runs continuously for 6 whole days. The line only has to be cleaned after 144 hours of production. Steam bath, not shower Sterilisation by means of a peracetic acid-steam mixture is a unique and extremely efficient method. That s because the steam transports the peracetic acid into every corner of the bottle within a matter of seconds. And that in turn allows shorter treatment times and lower media usage than systems with liquid treatment. Cost-efficient components Despite its output, the line is decidedly modest when it comes to energy consumption. That s because it works only with efficient servo motors, using much fewer filter fan units than other systems. Everything under control A line documentation system continuously monitors and records all relevant processes and machine statuses. That protects you and your production from serious quality defects. From the last to the first bottle in 2.5 hours With the PET-Asept L2, the sterilisation of the product route and cleanroom takes place in parallel. This means that the system is up and ready for the next round just two and a half hours after the last bottle. When is the PET-Asept L2 the right choice? If you are looking for an aseptic system that has proven its worth with beverages producers throughout the world. delivers absolutely reliable results under difficult ambient conditions. sterilises bottles perfectly in a short time whatever their shape. boasts a maximum availability of 144 hours of continuous operation. is sparing in its consumption of energy and sterilisation agent. is easy to operate and resistant to faults. L2 = Liquid, Generation 2

PET-Asept PET-Asept D and PET-Asept D Compact The dry zero-risk solution General features Executes all sterilisation processes without water Can be installed in a block with a stretch blow moulder,

7 PET-Asept PET-Asept D and PET-Asept D Compact The dry zero-risk solution General features Executes all sterilisation processes without water Can be installed in a block with a stretch blow moulder, allowing optimal room utilisation, efficiency and hygiene Driven continuously by energyefficient servo motors Ventilated by means of a central system with HEPA filter Comes with a central distribution system for H 2 and process air Liquid barriers separate moving from rotating parts Container steriliser Sterilises quickly and reliably with gaseous H 2 (hydrogen peroxide) Operates in a continuous process with a central monitoring unit Treats the containers from inside and outside at the same time Removes the H 2 mixture from the container after sterilisation, ensuring minimal residues Filler Guarantees microbiological safety through contactless filling and hygienic design Determines the product amount exactly by flow sensors or load cells Comes with its own CIP module The Modulfill Asept VFJ-D variant also fills particles up to 8 x 8 x 8 mm gently Cap disinfection system Sterilises caps quickly and reliably with gaseous H 2 Integrated cap disinfection system ensures the rejection of faulty caps Capper Handles different cap types Monitors every single capping process Drives each capping head with a separate servo motor Clean room housing contains no electronic components or drives Output PET-Asept D Compact: up to 12,000 containers per hour PET-Asept D: 12,000 to 48,000 containers per hour D = Dry

PET-Asept D Your benefits No water, high microbiological safety While production is in progress the entire system does not consume a single drop of liquid.

8 PET-Asept D Your benefits No water, high microbiological safety While production is in progress the entire system does not consume a single drop of liquid. This lowers overall water consumption while simultaneously enhancing microbiological safety. Gentle treatment for containers Other H 2 systems heat the containers in order to activate the sterilisation agent which exposes them to even greater stress. PET-Asept D, on the other hand, brings the medium into the already warm container in gaseous form. This prevents the medium from condensing, reduces contact time and minimises the formation of residues. Reduced to the essentials The line dispenses with additional peripheral equipment such as chemical treatment and sterile water generation systems and uses a single controller for all the aseptic processes. This makes the system easy to maintain and operate. Twofold precision landing From the amount of product still to be filled, the system calculates the precise number of PET containers and caps it will need and so sterilises exactly the quantity of both materials that it actually needs. Always in motion The PET-Asept D does not work on the stop-and-go principle, but instead runs continuously, making it more stable than linear systems. 6 days without a break Other systems can only stand and stare: PET-Asept D runs continuously for 6 whole days. The line only has to be cleaned after 144 hours of production. When is the PET-Asept D the right choice? If you are looking for an aseptic system that sterilises quickly and effectively. treats PET containers particularly gently. is sparing in its consumption of energy and media. is easy to operate. boasts a maximum availability of 144 hours of continuous operation. D = Dry

Contiform AseptBloc Winner products are sterile from start to finish General features Sterilises preforms instead of bottles Ventilated by means of a central system with HEPA filter Comes with a

9 Contiform AseptBloc Winner products are sterile from start to finish General features Sterilises preforms instead of bottles Ventilated by means of a central system with HEPA filter Comes with a central distribution system for H 2 and process air Executes all sterilisation processes without water Driven continuously by energyefficient servo motors Automatically calculates the cap and preform requirement from the amount of product Preform sterilisation Processes preforms with gaseous H 2 Preforms do not need to be heated again after the oven Sterilises the preforms simultaneously on the inside, on the outside and at the neck finish Achieves short process times thanks to gaseous medium Coordinates the number of treated preforms precisely with the product quantity Aseptic blowing module Produces PET containers in sterile moulds Uses clean room housings to ensure the sterility of the stretching rod Can also be equipped with an air wizard recycling system for blow air if necessary Filler Guarantees microbiological safety through hygienic design and contactless filling Comes with its own CIP module Determines the product amount exactly by flow sensors or load cells The Modulfill Asept VFJ-D variant also fills particles up to 8 x 8 x 8 mm gently Cap disinfection system Sterilises preforms with gaseous H 2 Shortens the treatment time by sterilising at high temperature Integrated cap disinfection system ensures the rejection of faulty caps Capper Handles different cap types Monitors every single capping process Drives each capping head with a separate servo motor Clean room housing contains no electronic components or drives

Contiform AseptBloc Your benefits Sterilising bottles? No need! Instead of sterilising bottles, the Contiform AseptBloc performs the sterilisation even before the blowing process takes place.

10 Contiform AseptBloc Your benefits Sterilising bottles? No need! Instead of sterilising bottles, the Contiform AseptBloc performs the sterilisation even before the blowing process takes place. This route is extremely effective. Fact is: preforms are more even than bottles and smaller by a multiple. For the Contiform AseptBloc system this means less work and for you lower costs. Twofold precision landing From the amount of product still to be filled, the system calculates the precise number of PET containers and caps it will need and so sterilises exactly the quantity of both materials that it actually needs. No water, no risk The Contiform AseptBloc does not consume a single drop of liquid during production. This lowers overall water consumption while simultaneously enhancing microbiological safety, in strict compliance with the principle No water, no life. From the last to the first bottle in 2.5 hours In the Contiform AseptBlow, the sterilisation of the product route and cleanroom takes place in parallel. This means that the system is up and ready for the next round just two and a half hours after the last bottle. 6 days without a break Other systems can only stand and stare: The block runs continuously for 6 whole days. The line only has to be cleaned after 144 hours of production. Seamless sterile process chain The Contiform AseptBloc looks after sensitive products from start to finish: As soon as the preforms leave the oven they enter a hermetically sealed sterile zone and leave it again as finish-blown, aseptically filled and capped bottles. Reduced to the essentials The Contiform AseptBloc dispenses with additional peripheral equipment such as a hygiene centre or sterile water UHT system and uses a single controller for all the aseptic processes. This makes the system easy to service and immune to malfunctions. When is the Contiform AseptBloc the right choice? If you are looking for an aseptic system that scores with particularly low media consumption. sterilises quickly and effectively. treats PET containers particularly gently. is sparing in its consumption of energy and packaging. is easy to operate and resistant to faults. can be easily used for lightweight containers. boasts a maximum availability of 144 hours of continuous operation. reduces media residues to a minimum. is based on the FDA-approved method for sterilisation with hydrogen peroxide.

Filling systems: Modulfill Asept VFJ The aseptic professional with flow meter Method of operation The filling process begins as soon as the PET container is centred underneath the valve.

11 Filling systems: Modulfill Asept VFJ The aseptic professional with flow meter Method of operation The filling process begins as soon as the PET container is centred underneath the valve. Two different speeds ensure optimum flow characteristics. The amount of liquid flowing in is controlled by an inductive flow meter. The valve closes once the exact filling volume has been reached. Features Precise determination of the fill quantity by inductive flow meter High microbiological safety through contactless filling Safe and low-loss product feeding from above with steamlocked sliding ring manifolds Rapid, energy-saving sterilisation of the valves by means of steam Short stoppage times thanks to parallel cleaning of the product route and clean room housing Perfect flow characteristics through two filling speeds Turbulence-free switching between speeds thanks to diaphragm valve technology Cleaning with open SIP can in the clean room housing, no CIP return channel and no lower manifold required Product route steam sterilised with closed SIP can, steam outlet monitored by stationary pressure sensors Hygienic design Electropneumatically controlled filling valve functions Everything good comes from above To reduce product losses at the end of production to a minimum, the product is led into the machine from above. A sliding ring manifold handles the feeding process and creates perfect hygiene conditions by means of a steamlock. Faster and more cost-efficient with steam Because the product route is sterilised with steam rather than hot water, the system can be connected directly to the steam supply. That removes the intermediate step of a sterile water UHT system entirely just as it does the associated time and cost. When is the Modulfill Asept VFJ the right choice? If you are looking for an aseptic filling system that ensures precise fill quantities. offers high microbiological safety. is gentle on the product. requires little time and energy for cleaning. VFJ = Volumetric filling, Flow meter, Full Jet

Filling systems: Modulfill Asept NWJ Exact fill weight for every product Method of operation The PET container is centred under the valve and weighed by the load cell.

12 Filling systems: Modulfill Asept NWJ Exact fill weight for every product Method of operation The PET container is centred under the valve and weighed by the load cell. Once the tare weight of the container has been determined, the valve opens and the filling process begins. Two different speeds ensure optimum flow characteristics. During filling the load cell controls the amount of liquid that flows in. The valve closes once the specified weight has been reached. After a short settling phase, the weight is verified again and the filled product leaves the machine. Features High-precision determination of the fill quantity by load cells High microbiological safety through contactless filling Safe and low-loss product feeding from above with steamlocked sliding ring manifolds Rapid, energy-saving sterilisation of the valves by means of steam Short stoppage times thanks to parallel cleaning of the product route and clean room housing Perfect flow characteristics through two filling speeds Turbulence-free switching between speeds thanks to diaphragm valve technology Cleaning in the closed system by automatic CIP cups Hygienic design Electropneumatically controlled filling valve functions Everything good comes from above To reduce product losses at the end of production to a minimum, the product is led into the machine from above. A sliding ring manifold handles the feeding process and creates perfect hygiene conditions by means of a steamlock. Faster and more cost-efficient with steam Because the product route is sterilised with steam rather than hot water, the system can be connected directly to the steam supply. That removes the intermediate step of a sterile water UHT system entirely just as it does the associated time and cost. When is the Modulfill Asept NWJ the right choice? If you are looking for an aseptic filling system that guarantees absolutely precise fill quantities for products with a wide variety of characteristics. offers high microbiological safety. is gentle on the product. requires little time and energy for cleaning. Up onto the scales The valves of the Modulfill Asept NWJ are equipped with load cells. This enables the system to achieve precise fill quantities for every product, whatever its characteristics. NWJ = Net weight filling, Weighing cell, Full Jet

13 Filling systems: Modulfill Asept VFJ-D The specialist for beverages containing particles Product tank 2 Inductive flow meter 3 Switching valve fast/slow 4 Product discharge valve 5 Valve stem control cylinder 6 Valve stem 7 Dosing stem control cylinder Method of operation The system first doses the particles into the filling valve and then fills both the particle phase and the juice phase together. The liquid product first gets to the valve stem along the product pipe. The particles are then added by means of a separate pipe. An inductive flow meter measures the volume of the product displaced in the filling valve, thus allowing the dosed quantity of particles to be precisely calculated. When the filling valve opens, particles and juice flow into the PET container centred underneath. The valve closes once the exact total filling quantity has been reached. Features Short filling times and maximum protection for the particles because both components are filled at the same time High microbiological safety through contactless filling Precise determination of the fill and dosage quantity by inductive flow meter Safe and low-loss product feeding from above with steamlocked sliding ring manifolds Rapid, energy-saving sterilisation of the product routes by means of steam Short stoppage times thanks to parallel cleaning of the product route and clean room housing Perfect flow characteristics through two filling speeds Turbulence-free switching between speeds thanks to diaphragm valve technology Cleaning in the closed system by automatic CIP cups Hygienic design Electropneumatically controlled filling valve functions One valve, two flows, three benefits Juice and particles reach the filler by two separate pipes. Only in the valve do the two flows meet. They are then filled together. This refined method means that the Modulfill Asept VFJ-D has a threefold advantage over other systems. That s because it guarantees short filling times exact fill quantities without expensive overdosing of the particles gentle treatment of the sensitive pieces of fruit Safe and sound right from the start Beverages containing fruit particles need to be not only filled gently, but also prepared gently. That s why Krones developed the dual-flow process a complete line that handles all the steps, from production to filling. The clever thing about this: the line processes juice and particles separately. That means each component receives precisely the treatment it needs. Good to know Modulfill Asept VFJ-D is also suitable for dosing aromatic components and can be operated even with the particle doser switched off. When is the Modulfill Asept VFJ-D the right choice? If you are looking for an aseptic filling system that doses juice with pieces of fruit up to 8 mm long precisely and without losses. is particularly gentle on the product. offers high microbiological safety. requires little time and energy for cleaning. VFJ-D = Volumetric filling, Flow meter, Full Jet, Double filling valve

14 UltraClean A protective shield for ESL and EHF products Mastering every level of hygiene: the Krones filling process Conventional filling UltraClean ESL and EHF Hotfill Aseptic filling A filling line is not a casino: uncertainties and leaving things to chance are never an option. This applies in particular to microbiological safety. With the Krones UltraClean you are always on the safe side throughout the entire process. That s because the hygienic processes guarantee a protective atmosphere that protects the product and thus also the consumer from risks caused by germs. Lemonades Spritzers Water Liquid food Juice Beer Wine, sparkling wine Spirits Spritzers Beverages containing particles Flavoured water Beverages containing juice Mixed drinks containing beer Energy drinks Liquid food Milk Mixed milk beverages Yoghurt drinks Smoothies Juice Ice tea Tea Liquid food Water Mixed milk beverages Beverages containing particles Mixed milk beverages UHT milk Juice Ice tea Tea Energy drinks Beverages containing particles Flavoured water The UltraClean creates safe filling conditions for sensitive refreshment drinks which do not contain preserving media. beverages which must be distributed in a cold chain.

15 We do more. Subject to technical changes The illustrations can contain optional auxiliary equipment PDF_en 10/14 krones ag Böhmerwaldstraße Neutraubling Germany Phone Fax info@kic-krones.com Internet kosme s.r.l. unipersonale Via dell Artigianato, Roverbella (Mantova) Italy Phone Fax kosme@kosme.it Internet evoguard gmbh Dr.-Hermann-Kronseder-Straße Nittenau Germany Phone Fax info@evoguard.com Internet kic krones Internationale Cooperationsgesellschaft mbh Böhmerwaldstraße Neutraubling Germany Phone Fax kic@kic-krones.com Internet konplan s.r.o. Poděbradova 2842/ Plzeň Czech Republic Phone Fax pilsen@konplan.cz Internet hst maschinenbau gmbh Gewerbestraße Dassow Germany Phone Fax info@hst-gmbh.com Internet syskron gmbh Oskar-von-Miller-Straße 6b Wackersdorf Germany Phone Fax info@syskron.com Internet

krones Sleevematic The labeller for sleeves

krones Sleevematic The labeller for sleeves The labeller for sleeves Sleevematic AF The rotary machine for stretch and shrink sleeves Shrinking or stretching? The multitalented machine can do both. The labels are pulled over the empty or full containers