HOT FILLING MACHINES MirageIndustries.com 322 Breesport San Antonio, TX 78216
Bottle & Cap02+ ITEM 500ML Capacity 5,000 BPH Shape Cylindrical Base Flat Preform Type PET Bottle Weight Non-Light Weight Neck Type Short Neck Neck Size 29/25 Capping System Screw Cap Cap Material HDPE Product Tea Label ITEM Label Type Label Material Glue Type 500ML Sleeve PVC Hot Steam Pack 200ML Type of Packing Film Shrink Wrap
Energy Requirement for FGH4 //CGF16/16/5 Blowing, Washing, Filling & Capping Machine BOTTLE SPECIFICATIONS Bottle Capacity liter 0.5 Number of mold(s) mold 4 Capacity Bph 5000 Reference bottle height mm TBD g TBD Preform Weight POWER SUPPLY Estimated Consumption kwh 250kw NB: the power consumption is indicated for information only, and may not bee considered as contractual. Power Ratings kwh Approx 14.7 Total Power Rating Minimum * * This power takes into account the minimum configuration installed on the machine. This means: Standard oven, heating configuration + Auxiliary outputs in series.
For Auxiliary Equipmentt Conveying System Power Consumption Kw 0.75 kw/motor Weight kg About 35kg/m Labeling Machine Bottle Capacity liter 0.5 Label Machine Capacity Bph 9,000 Power Consumption Kw 18 Installed Power Kw Approx 25 Shrink Wrap Around Packing Machine Bottle Capacity liter Pack Format Machine Capacity 0.5 3x4 CPM 10-12 Power Consumption Kw 25 Installed Power Kw Approx. 32
For 5,000 BPH For 500ml Tea Filling Line FGH4&CGF16/16/32/8- BLOWING, WASHING, FILLING & CAPPING MACHINE This Blow, Wash, Fill, Cap machine is a high-speed machine developed by applying the world s most advanced bottle making technology. Based on an optimized structure integrating the preform oven, the stretch blow molding section and bottle filling & capping section. The machine features automatic and intelligent workflow, stable and reliable performance, high production efficiency, and is low cost, without pollution, it is widely used for foods, beverage, cosmetic, medicine etc
PREFORM INFEED Preforms are conveyed from the storage hopper to the automatic unscrambler. From the unscrambler they travel under gravity down support rails fed into the rotary heating zone. HEATING ZONE Individually controlled infrared lamps positioned along the perform path provide longitudinal differential heating and uniform heat penetration optimizing the temperature profile throughout perform. All the parameters adjusted automatically by temperature curve. BLOWING STATION In the stretch blowing station, performs undergo two stages. First stretching and pre blowing, secondly final blowing by compressed air. At this point performs are transformed into bottles. FINAL STAGE From the stretch blowing station the bottles are picked up by special grippers and conveyed to the air conveyor before filling. During this stage faulty bottles if any, get rejected.
Main Points Reduced initial investment and low maintenance costs thanks to the special design and the state of the art technology. High Precision production processes granted by drive motors controlled by intelligent CPU system and mechanisms. Easy and flexible control thanks to the highly proven control system developed by the research & development department. Easy operation parameters adjustment from the Mitsubishi operator panel system thanks to its user friendly graphic Man/Machine Interface. The superior quality of the finished product is thanks to the molds perfect closure system. Innovative technology that allows monitoring of the temperature Profile throughout the whole Preform providing constant product quality. The instant feedback from each process stage, permits independent control and parameter setting of each stretch blowing station. Very low machine noise due to the use of deadening panels and very few mechanical transmissions. The entire closed blowing space provides a maximum level of hygiene. Great visibility of the whole production process and easy access to every part of the machine through its wide see through shockproof doors. Multi-language system (English & Chinese); the selection of the language can be carried out while the machine is working. Tele-assistance for immediate diagnostics and fast updating of the machine software. Real time production data transfer to the production line control system through TCP / protocol via ethernet LAN (optional) Production of lightweight bottles thanks to the very precise control of the entire blowing process. Lower production costs due to the reduction of the compressed air volume necessary for the blowing, thanks to the innovative optimizing of air flow and process stages. Quick and simple mold change over because of the lightweight molds with easy locating and fixing system.
Description and Operation Preform infeed An elevator lifts the preforms onto the top of the infeed rails held by their support ring, they are then fed by gravity to the infeed system. The preforms continuously pass in front of the oven modules each of which is equipped with nine 2.5-KW infrared lamps and one lamp 3.0 KW downside. Oven lamps are ventilated separately from the air-cooling through which the perform pass, to obtain optimum heat Penetration of the preform wall. Preform Transfer At the outfeed from heat conditioning, the Preforms are transferred onto the fixed blowing Positions by means of robot arms fitted clip gripper, this gripper movement is driven by servo motor. Stretch Blowing of Bottles The blowing station is fitted with pin lock molds with cam-actuated opening and closing systems. Each mold is placed in an easy mold holding unit with integral mechanical locking. This configuration enables quick mold changing within 30 minutes. The blowing nozzle is inserted into the perform neck and guides the stretching rod which controls axial stretching. The blowing process which controls the longitudinal stretching operation takes place in two stages: Medium Pressure Pre-blowing and High Pressure blowing, which ensure optimized distribution of the material thickness in the bottle wall. The blow nozzle design guarantees a perfect seal no matter what the blow pressure is. The blowing pressure regulation is built into the machine.
Technical Specification 1. Unscrambler 1. Stepless transmission 2. Simple structure, wide probational range 2. Perform oven 1. Longitudinal and Radial Heating. 2. Infrared lamps individually controlled. 3. Guiding wind device can overcome the convection of the air, be propitious of leveling of the heating environment, improving the heating efficiency. 4. Cooling device can avoid secondly heating of the neck. 3. Stretch Blowing station 1. mold holding units made from special mechanical stress Resistant Aluminum Alloy. 2. molds made from special wear resistant Aluminum Alloy. 4. Change over- mold replacement 1. Reduced time for change over thanks to the simple operations required transmission to the central production line control system: Change over time for each mold: 30min
BOTTLE WASHING SYSTEM Rotary type bottle washing machine, mainly used to wash bottles for drinking water and other beverage. New bottles go into the machine through air conveyor. Bottles are held by grips and turned over onto washing heads. After washing and drain water, bottles go into filling parts by star wheel. Main structure, protect shell and contact water part of washing part are all stainless steel304. BOTTLE FILLING SYSTEM The entire filling system is Low Vacuum Gravity (LVG) System. The filling level of the bottles is accurate, which leads to less wastage. Also there is an inbuilt electric probe in the product tank to control the water level. No filling takes place if the bottle is not present. The product contacts are made of AISI304 stainless steel or food grade plastic material. FILLING VALVE The filling valves are fully made of stainless steel AISI304 with food grade, sterilization resisting plastic gaskets. The valves are secured to the bowl and allow easy assembling and dismantling. Each valve is internally polished (mirror finish). If the bottle is not present than valve will not deliver any product. CAPPING HEAD The capper consists of a steel structure externally clad with a stainless steel AISI304 casing. The main element of this structure is rotating and is supported by a large diameter ball bearing. This rotating member of the capper is fitted with the capping heads, the relevant guides and the bottle holder plates. The fixed part consists of the cap hopper, the cap feeder with relevant motor and the cam actuating the capping heads. The hopper and all the parts in contact with the caps are made of stainless steel AISI304, polished finish. The feeder guides the caps onto a chute fitted with a device to deliver them to the pick-off point with the open end down.
CAPPING HEAD The capper consists of a steel structure externally clad with a stainless steel AISI304 casing. The main element of this structure is rotating and is supported by a large diameter ball bearing. This rotating member of the capper is fitted with the capping heads, the relevant guides and the bottle holder plates. The fixed part consists of the cap hopper, the cap feeder with relevant motor and the cam actuating the capping heads. The hopper and all the parts in contact with the caps are made of stainless steel AISI304, polished finish. The feeder guides the caps onto a chute fitted with a device to deliver them to the pickoff point with the open end down. MAIN ACCESSORIES Magnetic Valve Item Servo System Cylinder Frequency Inverter Blowing Valve Touch Screen One-WayValve Reducing Valve Throttle Valve Brand Origin Germany Japan Japan USA Germany Germany
Tea Preparation System CIP SYSTEM HOT WATER TANK, MIXING TANK & PLATE STERILIZER Sugar melting system is one of the main ingredient of fruit juice beverage. The process of sugar cane dissolved in water is called sugar dissolving operation. Sugar dissolving system generally contains sugar powder conveying, sugar powder dissolving, syrup sterilizing, syrup filtration& cooling and syrup storage unit, etc. In some circumstances, de-aeration treatment to syrup is required. The typical hot dissolving process is using 85 water and hold 10 minutes, then to cool hot syrup to required temperature (less than 40 ) step by step.
Blending system includes the following auxiliary equipment: feeding pump, filter, pipes & valves, converting plates, etc. According to juice beverage type, there are hot blending and cold blending two process methods for option. For hot blending, the blending tank should have heat preservation. The volume of the preparation tanks is decided by the capacity and production batch. Usually there are three tanks. Tank 1 feeds product to the filling machine. Tank 2 prepares and inspects product. Tank 3 is for CIP. The 3 tanks switch for operation in turn. If tank s volume is enlarged, 2 tanks are enough. Sterilization is the most common technics. And according to the product s characteristics, the matched filling technics and the shelf life, UHT and HTST are also available. UHT usually holds over 130 for several seconds, while HTST usually holds 95 for 30 seconds. Both technics have similar structure, working principle, and function of temperature holding. The heat exchanger has plate type, tubular type, sylphon bellows type, etc. For the product with pulp and high viscosity product, the tubular type exchanger must be used to avoid congestion. Also the tubular heat exchanger has stronger resistance to pressure, but the cost is higher than plate heat exchanger. For the turbid juice and milkbased beverage, we recommend tubular UHT; for the clear juice beverage, we recommend plate type UHT. CIP system function is to do automatic cleaning to surface contacting with product. The cleaning area includes inside surface of the tank, pipe, liquid carousel and other liquid channels. CIP system is composed of cleaning agent storage tank, acid and caustic dosing device, heating device, feed pump, recycle pump, pipes, and steam valves, etc. The critical technical parameters of CIP system: cleaning media, concentration, temperature and flowrate. The caustic usually adopts NaOH, acid usually adopts nitric acid or phosphoric acid. The concentration is 1-3%.
HIGH PRESSURE AIR COMPRESSOR Our air compressor system will make sure there will be sufficient and clean air supplied to the blowing machine system, as the blowing machine is driven by the electrical servo motor, so no need the low pressure air compressor. Besides we improved the air supplying structure which makes better use of the high pressure air, this 7200BPH blowing machine only needs 4m3/min; 30bar. This increases the use efficiency by 30%.
This air compressor design is from America famous Ingersoll brand, and already take place of the Ingersoll market in China when speak of the piston high pressure air compressor, with the mature technical and high precision, it always supplies the sufficient air capacity and pressure, machine key part which needs to be moved frequently, adopts the King Herbiger high pressure valve and SKF well-know bearing to make it have same performance even after 5 or 6 years. Considering the safety and automation, this air compressor equips safety valve and automatic pressure and sewage exhaust valve, so even unskilled engineer can handle it after basic training. Moreover, there will be air filters&dryers equipped to make sure the outlet air will be up to sanitary grade, without dust, water, oil and bad smell, there will be no second pollution on the preforms. The 3 set air filters, oil separator and dryer will be connected already in a mounted unit, quite convenient for the transportation and site installation. We equip one square meters volume air storage tank, this tank has the function of buffer mainly, on one hand the air compressor can use this tank to rest, no need to work all the time, on the other hand, the pressure supplied to the blowing machine will be stable not flexible. Technical Parameters Main Parameter Air Capacity 6.0m3 Air Pressure 30bar Outlet HP air temperature Outlet HP air filter precision Air compressor power Air compressor motor speed Air compressor dimension 10-30degC Up to 0.001ppm 66kw 670r.p.m. L 2150 x W 1200 x H 11600mm Air compressor weight 1200kg Air tank volume 1.0m3 Air tank max pressure 30Bar Height 2800mm Diameter 1000mm
LOW PRESSURE AIR COMPRESSOR Features Air end is imported form ROTORCOM OR GHH-RAND company in Germany PLC Control Discharge capacity: 1~42m3/min Discharge Pressure: 0.7 Mpa ~ 1.4Mpa Wind driven tool start, Air compressor station and Power station
Technical Parameters Low Pressure Air supply Flow Chart Low Pressure Air Compressor Water Chiller Air Oil Separator Gas Storage Tank Technical Specification of low pressure compressor Item Model Character 1 Air compressor Flux: _m3/min, Pressure: 10 bar 2 Water chiller Flux: _m3/min, Pressure: 10bar Refrigerant: Water 0.8T/H 3 Air-oil separator Flux: _m3/min, Pressure: 10bar 4 Gas storage tank Flux: _m3/min, Pressure: 10bar
OIL TEMPERATURE AC-SERIES Oil Temperature controller Easy to operate, the temperature can be kept at the set point with variation of +2degC Original American and Japanese brand compressors, featuring built-in safety protection, low noise and durability. Original SCHNEIDER brand electric components Complete protection measures, intelligent fault indicator and alarm. High automation and no need of personal for operating.
ANGES Oil temperature controller AC series Model Item Quantity AC-10 (D) AC-12 2 1 Normal Cooling Capacity Keal/h 50HZ / 60HZ 22446 26935 25585 30702 KW 50HZ / 60HZ 26.1 31.3 29.79 35.7 Total input power KW 10.47 11.82 Power Refrigerant 3 P H ~` 380V 50HZ (200V / 220V 415V 50HZ / 60HZ) Type R22 (R134a / 407c) Control method (Capillary) Expansion valve Type Hermetic scroll type (piston type) Compressor Power (KW) Type Condenser Cooling air flow (m3/h) Type Evaporator 10000 12000 Water tank with coil (shell and tube) 5.12 6.15 Tank volume(l) 200 200 Inlet and outlet Pipe caliber 1-1/2 2 Power(kw) 0..75 1.1 Lift(m) 20 20 Length (mm) Finned copper tube+low noise outer rotor fan 4.47 5.37 Safety Protection Weight 9.82 Chilled water flow (m3/h) Water Pump Dimension 4.41x 2 Compressor over temperature, over current,high and low pressure, over temperature, flow switch, phase sequence, 1530 1530 Width (mm) 780 780 Height (mm) 1430 1430 Kg 450 530
BOTTLE CONVEYOR Bottle Conveyor System Full bottle conveyors are composed of several sections. According to application and plant layout, it can convey different kinds of containers, such as, glass bottle, PET bottle, can, and so on. Working processes (e.g., container conveying, distribution, lane change, etc) are controlled by electric system automatically. The manual control mode can separately control devices on full bottle conveying system (e.g., bottle stopper, bottle ejector, etc). Schematic Diagram of Full Bottle Conveyor CONVEYOR FULL BOTTLES Bottle Conveying, single and multi-lane: Structure for MCC chains width 82,5 mm, 1.8mm Thick - pitch 38,1 mm in 304 Stainless, included in the supply Side Plates in cold profiled stainless steel sheet AISI 304 Spacers with rolled section in stainless steel AISI 304 Sprockets and idler wheels to match table top Chain and with 23T Sprockets, with 30mm 304 Shaft material for Motor Connection Wear Strips for chain sliding in molecular high-density polyethylene Clamps to support bottles side guides in reinforced polyamide, width adjustable on single lane conveyor, fixed with Stainless Steel Rods. Guide Rails in covered Polyethylene Sheet (As per the Specifications Supplied) Rollers for chain return in polyamide with anti-seizure calibrated hole Dripping Trays in stainless steel SEW Gear-Box and Motor with manual Speed Adjustment. Hollow mounted Gear-Box and mounting Brackets
Chain Plate Position chain in different models on floor at first, and then connect them one by one. After that, install the chain plate onto housing. This can avoid chain plate from twisting and ease connection work. Special attention should be paid that installation of chains has specific direction: direction of arrow on back must be the same with running direction. If there is bypass sections, (in standard design) the conveyer speeds up from multilane to single lane. Or, the conveyer slows down from single lane to multilane. Guardrail Guardrail is used to guide containers on the conveyer and prevent them from falling down or dropping. During installation, keep the guardrail straight, and keep the connection part smooth. Usually, connection part is located at clamp on guardrail. Drip Tray There is central outlet between adjacent drip trays. Therefore, properly incline the drip tray to the outlet. The waste water will flow into the outlet, and then drains out to ditch or for recycle. After installation, the drip tray can also function to prevent water from contacting return side of chain plate.
Wrapper Conveying Generally, the common composition of case conveyor is as follows: Roller Conveyor Chain/Net Chain Conveyor Conveying Belt Roller Conveying Belt Special Bypass Conveyor 1. Lateral panels, conveyor base and feet of stainless steel 2. Slat-band chain of stainless steel or plastic material 3. Rollers of galvanized steel or plastic, diameter 50mm 4. Drives not adjustable 5. Height-adjustable plastic cup feet 6. Pneumatic components according to Japanese famous company s standard 7. Electrical components acc. To European famous company s standard 8. All design features correspond to the applicable European regulations on machine and operator safety 9. Accumulation for film only packer will be designed 10. Soft handling devices for film only packer will be equipped. Housing The case conveyor is composed of several sections with different quantity of standard housings and lanes. Before installation, read plant layout as carefully as possible at first, and position each housing as indicated in the layout. Keep the housing level and straight, and the connection part smooth. The deviation should not overpass 0.3mm.
Fasten each screw to avoid re-installation. Make sure that each screw is fastened and will not loosen. Make sure standard height of each housing follows requirements in layout. Plastic Guide Usually, the guide is made of HMWPE. During installation, keep the guide in line. If possible, use one strip only. In consideration of influence from heat, only one end of the guide is fixed up by one (or two) screw, while the other end is flexible. Chain Plate Position chain in different models on floor at first, and then connect them one by one. After that, install the chain plate onto housing. This can avoid chain plate from twisting and ease connection work. Special attention should be paid that installation of chains has specific direction: direction of arrow on back must be the same with running direction. If there is bypass sections, (in standard design) the conveyor speeds up from multi-lane to single lane. Or, the conveyor slows down from single lane to multi-lane. Guardrail Guardrail is used to guide cases on the conveyor and prevent them from falling down or dropping. During installation, keep the guardrail straight, and keep the connection part smooth. Usually, connection part is located at clamp on guardrail.
Sleeve Labeling Machine 1. Main Structure 10. Shelf 1. Label shelf 11. Brush structure 2. Label supply structure 12. Belt adjustment structure 3. Label brush off structure 13. Belt structure 4. Label conveyor structure 14. Bottle inspect structure 5. Label inspect structure 15. Bottle divide structure 6. Main machine lift structure 7. Label cut off structure 8. Control box 9. Conveyor structure
2. Function of every parts 1. Label cut off structure: Inner knife, deflection steel structure, used too cut off label. 2. Label conveyor structure: servo-actuator control make label conveyor obey to rated size. 3. Center column device: put label on the column and open, make the label could be conveyed and cut 4. Label inspect structure: Signal transmits by optical fiber switch to the control system ensure label cutting into right size. The position of sensor is adjustable that could make knife in the right position. 5. Main machine lift structure: The whole machine adopts high quality, resistant stainless steel that makes the machine steady. 6. Label supply structure: It s used to fix the label, control the force of label. Label driven by motor. 7. Bottle divide structure: It makes bottles in order then conveyor into machine. 8. Conveyor structure: Adjust the speed of conveyor by frequency converter. 9. Label brush off structure: Adopt in-phase adjustment structure; conveyor wheel connects with wheel under center column a little. Put the label rapidly when the label passing. 10. Bottle inspect structure: It could adjust left or right and up or down, used to inspect bottles for right labeling. 11. Belt adjust structure: Adjust belt structure 12. Brush structure: Use soft rubber to brush off label and make it in the right position. 13. Belt structure: Adopt two sides in-phase driving, adjust the height and position by adjustment structure. It s used to make bottle conveyor steady and position label height. 14. Control box: It s the key part of this machine. There are manual, automatic, inspect and so on function with several buttons for operation. 15. Thermal shrinker: Use steam to make label shrink