Smart Integration with Serac Fillers OPTIMIZED» CONVENIENT» EFFICIENT» MODULAR

Transcription

1 COMBOX Smart Integration with Serac Fillers FROM PREFORM TO filled BOTTLE OPTIMIZED CONVENIENT EFFICIENT MODULAR 13 14

2 SMART INTEGRATION WITH OUR FILLERS For several years now, the gap between packaging manufacturing and filling has been diminishing. With 40 years experience in designing and manufacturing filling machines, we ought to provide you with the capability to integrate the SBL blower with our range of fillers-cappers. The COMBOX series (blow-fill-cap) is ideally suited for high value added products and low/medium size batches: no over-sizing, no over-investment. COMBOX: The only monobloc combining the advantages of a linear blower with a rotary weight filler! HIGH RELIABILITY AND EFFICIENCY WORKING PRINCIPLE Benefit FROM integrated systems Cost reduction, higher quality, increased uptime Production start-up Since blowing machines only run at a constant production rate, a special filling mode is used on the filler-capper to ensure it adjusts quickly to the blower output. A unique and patented transfer system converts the sequential motion of the linear blower into a continuous motion adapted to our rotary fillers. During production Bottles enter the filling carousel, are filled, controlled, monitored, validated, capped. The machine continuously measures the final weight of each bottle, compares with the target weight, automatically adjusting the force fill factor to guarantee a constant performance over time. End of production Integrated systems incorporating blowing, filling and capping are growing in popularity as they offer valuable benefits: Lower investment than in classic bottles packaging (no silos, unscramble, air conveyor ). Maintenance costs savings with less equipment and less spare parts. Labor cost savings with only 1 operator for 2 machines. Material cost savings: Bottles weight can be reduced as bottles transportation is not required. Improved hygiene: Less risks of dust present in the bottles, hygienic level of the bottle is naturally insured by PET perform heating and direct transfer to the filler. Higher flexibility: Fewer parts to change and set-up to be modified with optimized format change-over. When the order is given to stop producing after a certain amount of bottles, both machines communicate with each other to ensure all remaining preforms in the blower are used and properly filled and capped

3 Why are PET bottles so popular? Light weight, Durable, Distinctive PET plastic containers are a popular choice for fillers due to the numerous benefits they provide both to manufacturers and consumers, in terms of design, costs reduction and convenience. Milk drinks Edible oil Fruit drinks Sauces Home and Personal care SBL Serac Blow Linear of PET bottles Lightweight: Cost-effective to produce and require less energy to transport. Cost effective: Reduction in the price point of PET versus other material such as high density polyethylene. Safe: Do not shatter and cause a hazard if broken or damaged. Convenient: Because they are safe, lightweight, squeezable, they are also convenient for on-the-go consumption. FROM PET PREFORM TO BOTTLE Re-sealable: Suitable for multi-serve packs. Recyclable: Can be recycled so that the PET can be used over and over again. Sustainable: Increasing numbers of PET plastic bottles are made from recycled PET. Distinctive: Can be molded into different shapes, colors, or clear packaging to display the product enabling brands to use them to build identity. Flexible: Manufacturers can switch from one bottle shape or size to another, meaning a high level of efficiency and freedom of material choice. OPTIMIZED CONVENIENT EFFICIENT MODULAR 1 2

4 SMART SIZING TO THE RIGHT OUTPUT The Serac Blow Linear (SBL) series of PET blow molding machines are the obvious solution for medium-size bottle fillers who want to keep control of their transporting and storing costs, while optimizing the quality of their bottles. A wide range of formats up to 12,000 PET bottles per hour (300ML) No over-size, maximum flexibility SBL Series Max. volume (l) Max. output ( bph) 8 0,3 12, ,6 10,800 Serac blow molding machines are designed to produce formats ranging from very large, such as 8 liters edible oil containers, to as small as 50 ml for samples or premium products. The output rate ranges from 2,400 to 12,000 bottles per hour, which brings new opportunities to manufacturers of high added value liquid products or medium size batches. 5 1,5 9, ,5 7, , ,400 Up to 1,800 bottles per hour per cavity. 3 4

5 Operator friendly HMI Clear, powerful, intuitive The Human Machine Interface is the central point for production management, monitoring and reporting. SMART DESIGN FOR MORE USER FRIENDLINESS The SBL series immediately distinguishes itself with its innovative design, which makes it operator safe and user friendly, increasing production uptime. Operator friendly machine High visibility, easy access The Human Machine Interface records production indicators for heating, stretching, and blowing operations. The user interface is easy to use with clear graphical illustrations. The extensive use of brushless technology allows most operations to be handled from the operator control panel. Helps maximize efficiency. Reduces operator training time. Speeds up product changeover. 2 3 Operator safe environment Reduced risks, reduced noise 1 4 The operator can visually check each step of the process: feeding, heating, stretching & blowing, all performed at eye level. 1 The electrical cabinet is embedded on the machine. Direct access to the electrical cabinet with no rewiring during installation. Self contained and compact solution. 2 3 Tool-free lamp replacement. Simple and safe replacement of lamps. The Human machine interface uses a touch screen B&R PLC centrally located at hand-level on the machine. Operator interface within the operator s immediate reach. Solid structure in electro-welded steel. Reduces vibrations and noise levels. 4 Mold change-over sliding rack is located at the front of the machine. Simple and effortless replacement of molds. Access to internal parts of the machine is simplified with wide sliding doors. Operators circulate freely around the machine. The machines comply with the strictest security standards, such as safety switches on all gates. Guarantees a safe production environment. 5 6

6 SMART CONCEPTION FOR TOP EFFICIENCY The SBL machines are equipped with state of the art technologies and integrate proven, long-lasting materials. They offer above-grade production quality with low maintenance needs. RELIABLE AND SAFE TRANSFERS No jam, no bottle drop, no scratches Our patented transfer system ensures accurate pitch adjustements and excellent repeatability From infeed to exit, only few transfer points are necessary. Ensures smooth and precise movements with no fall-out. Spindle nozzles are designed to ensure preforms are firmly held by the inside of the neck. High quality finished packages with no body manipulation. A reliable high speed 4 axis brushless motion system carries the preforms out of the oven in batches and removes them from the mold. Maximizes the blowing time. Preforms and bottles are always positively transferred. No risk of body damage. 1 Preforms infeed rail with gravity chute. 2 Preforms infeed star wheel for pitch adjustment and dedusting module (option). 3 Preforms are gripped with spindle nozzles for transfer to the oven. 4 Preforms are transferred to the molds and contained inside the pressing unit. 5 Finished bottles are transferred out of the blow molding unit (interface with Serac filler, interface to air-conveyor, table-top conveyor or bulk discharge). 7 8

7 Total control of the heating process No over-heating, no neck deformation, uniform bottle thickness Rigidity Log Modulus (dyn/cm2) GLASSY 10 Tg Tc Tm 8 6 RUBBERY RUBBERY LIQUID To give you total control of the heating process, the SBL series is equipped with new Generation of NS-IRS heating boxes from Olicorp. 4 INCREASING POLYMER MOLECULAR AR WEIGHT Temperature The energy supplied to the radiation lamps is constantly monitored and each lamp can be adjusted individually. Extremely precise heat distribution. 85 C / 185 F 130 C / 270 F 250 C / 480 F The preforms circulate around both sides of the IR oven in a continuous motion. Consistent heat penetration. Tg (+/-85 c): temperature transition to rubber The rotations of performs in front of lamps provide perfect homogeneity of circumferential temperature. Homogeneous heat penetration. Tc (+/-130 c): temperature transition to crystal Tm (+/-250 c): temperature transition to melt Powerful fans and heat-reflecting polished panels distribute the heat evenly inside the perform material. Uniform bottle thickness. Heated to a temperature above its glass transition temperature (about 105 c), PET softens and can be molded to its desired shape. As the heat of the PET increases, its structure goes from a glass or amorphous state, with unorganized molecules, to a semi crystalline/rubbery state, and finally to a liquid state. The system cools down the preform necks to ensure they stay in shape. Each batch of preform is temperature tested when exiting the oven and rejected if not compliant. No neck deformation. Guaranteed conformity of heating process. 9 10

8 Perfect shaping of light weight bottles No partling lines, no distortion Longitudinal stretching Longitudinal + circumferential stretching Circumferential stretching The stretching rods are driven by servo-motors. Accurately stretches your light weight bottles up to their limit without distorting them. Solenoid pre-blowing and blowing valves are based on the Seitz technology. Guarantees high blowing precision and repeatability for perfect inflating into the cavity shape. The pressing unit sustains up to 50 tons of force for a perfect closing of the mold. Ensures limited partling lines appear on your bottles. The mold opens and closes in 0.6 seconds. Allows for more heating time. The final bottle shape results from the combined actions of the longitudinal and circumferential stretches within the mold

9 H2F APPLICATIONS customized to your chilled drinks The Highly Hygienic Filler, H2F has been designed from our latest aseptic filler and developed for the specific requirements of fresh dairy products such as pasteurized milks, flavored or supplemented milks, drinking yogurts, milk-shakes but also of chilled juices, smoothies, milk-juice blends Drinking yogurts Supplemented milks Because hygiene plays a key role in the design of your filling systems, the H2F design may be adapted from one liquid product to another depending on the characteristics of the liquid food to be packed (microbiological sensitivity, shelf life, quality of cold chain ) and the type of packaging (HDPE, PET ). Chilled juices Smoothies Specifically designed for small/medium bottle format and neck transfer technology The market of small bottles is growing as a result of the increased consumption of on the go drinks. The H2F has been designed to meet this market but also to handle bottle sizes currently present in the retail market. Consequently, the whole H2F range can cover bottles from around 60 ml to 2 liters. Thanks to neck transfer technology, this solution is even more flexible than bottom transfer technology with the added benefit of a reduction of tooling changeover time which considerably improves productivity. Industrial buyers will also notice a reduction in their tool purchasing costs. Flavoured milks Pasteurized milks 1 Milkshakes Milk juice blends 2

10 MODULAR AND EASY TO UPGRADE HYGIENIC DESIGN The H2F is compact and modular which allows for rapid installation. Depending on your needs, the H2F machine is also available as a stand alone or as the COMBOX H2F version when there is a need for a bottle production on site. Inspired by aseptic filling Additional modules such as bottle decontamination, heatsealing, neck-trimming can be added over time. H2F up to 24,500 bottles/hour (1l) The design of the machine is directly inspired by the new generation of aseptic SAS4 Serac fillers by adapting its features into a more streamlined version suited for liquid food products. Ultra-hygienic filler designed to cope with the hygienic constraints for filling chilled sensitive products. COMBOX H2F up to 12,000 bottles/ Hour (300ml) The solution provides a blow-fill-cap bloc including the new Serac SBL linear blow-molder and the H2F for small and medium output lines. Besides Serac can also provide bloc solutions for higher output thanks to partnership with a rotary blow-molder manufacturer. Uncluttered volume ans surfaces in the filling area. H2F with a slopped casing. Hygienic machine design: slopped casing, net weigh filler with CIP/SIP facilities, on board electronics and mechanical parts located under machine frame clearing the bottle transfer area. Improvement of the cleanability of the filler. Optimization of the cleaning and sanitation cycles. Mechanical elements such as screw-capping head actuators and driving system are outside the filling area. Eliminates the risk of contamination due to the screw-capping mechanism. 3 4

11 EXPERT IN WEIGH FILLING FOR LIQUID FOOD A pioneer in weigh filling for milk on rotary machines since 1969, Serac continues the trend with unique solutions and patented filling technologies for our H2F machine. Multiflow: smart aseptic type filling valve New weigh filler with Upfill concept Weigh filler with Upfill concept. Easy access without going into the machine. New EHEDG designed load cell in the Upfill turret. Patented technology (neck transfer + weigh filling technologies). Weigh filling technologies. Neck transfer. The scales are on the upper part directly connected to the grippers. The electronic controls are under the table. Unique solution by Serac. Accurate and hygienic solution. Filling traceability is available thanks to weigh filling. Flexible solution with various bottle formats. Quick change-over and reduced number of change parts (compared to bottom transfer). Easier access below the machine for a fast and secure maintenance outside the filling area. New EHEDG designed load cell with hygienic design. No retention zone, easy to clean. Patented filling system. Originally designed for aseptic application. The filling valve is actuated by an electro-magnet that allows to monitor the fill flow according to each product characteristics (foaming, viscous, with pulp ). Metal to metal seal (no screen meshes). Magnetic valves. Tank with reduced capacity fitted with rotary joint and remote valves. Unique solution by Serac. High hygienic standard. Simple selection of the SKU to be filled by the operator from control panel. Automatic and preadjustment of the nozzles. Handles foamy and viscous products with no valve/nozzle change. Straight forward product circuit. No retention parts. Cleaning in Place. No pneumatics, no membrane on filling valves. Closed tank with comparable features with aseptic filler tank. 5 6

12 HYGIENIC CAPPING In order to prevent particles ingress coming from mechanical parts inside the filling sensitive area, we design and assemble mechanical cappers with a simple operation and with capping heads driving system removed from filler zone. new TCS 4 screw capping with centralized monitoring of tightening torque chemical-free cap decontamination by pulsed light The mechanical elements of the screw capper are outside the filler. Eliminates the risk of contamination. Easy access for fast and secure maintenance. Flexible and simple torque adjustments for each cap centralized on FCS HMI thanks to an electrical instead of pneumatical control. Pneumatic torque control with torque adjustment on screen. The cap is taken and the cap gripper is opened only when stopped. Flexible solution with several type of caps possible. No manual adjustment by the operator for a new cap. No marks after screw capping, the cap remains intact. H2F is also available with a heat-sealing station for aluminium foil caps fed from a reel and made on a capping press. Once sorted and orientated in the cap chute, the caps are transferred to a tunnel equipped with a pulsed light system. Combining a photochemical effect and a photothermic effect, the obtained microbiological reduction is 3 Log on Aspergillus Niger moulds. In-line decontamination just before capping. Chemical and water free treatment. No chemical residue. No effect on cap tightening. 7 8

13 Airflow management and CIP connection with H2F uni-directional air generator CIP manifold system with closed loop The H2F filler-capper is protected by a stainless-steel cabin with security glass doors. Moreover, the filling of chilled sensitive products requires to prevent from having airborne contamination coming from the ambient air. The H2F filler can be supplied either with a turbulent sterile air flow or with a uni-directional air flow depending on the application. There are a variety of CIP programs but a CIP with a closed loop has many benefits for the end users. H2F filler with Multiflow nozzle and a cleaning collector. HEPA filtration. ISO 5 uni-directional air flow. Air overpressure and high rate of air recycling. Sterile filtration. Controlled air velocity. Filler maintained under ultra-clean environmental conditions. A collector ensures the circulation of the cleaning solutions in a closed loop configuration. Filler circuit sanitation facilities with hot water Filler linked with plant CIP or integrated CIP module delivered by Serac. Optimization of cleaning cycles. No open cleaning process. Convenient and fumeless cleaning. Filler under ultra-clean conditions prior to production start. Flexibility for cleaning solutions supply mode. 9 10