Pasteurized & extended shelf-life filling in plastic bottles. Sensofill FMm

Transcription

1 Pasteurized & extended shelf-life filling in plastic bottles Sensofill FMm

2 LIQUID DA I R Y A N D S E N S I T I V E P R O D U C T S T O D AY A R E P L AY I N G A N I M P O RTA N T R O L E IN T H E D A I LY LIFE O F C O N S U M E R S. TH E VA R I E T Y O F N E W P R O D U C T S A N D R E C I P E S B E I N G L A U N C H E D IS H U G E A N D E A C H O N E IS U N I Q U E. The hygienic solution for pasteurized and ESL products Sidel has dedicated the Sensofi ll FMm (Flow Meter milk) platform to fi ll milk, LDP and sensitive, non-carbonated products, for pasteurized and ESL applications. The fl exible concept of the Sensofi ll FMm platform offers signifi cant advantages in terms of hygienic safety, fl exibility and fi lling/closing. 2 _ Sensofi ll FMm

3 HY G I E N I C SA F E T Y FL E X I B I L I T Y FI L L I N G The confi guration of the fi lling machine is mainly determined by the product to be fi lled, the processing parameters applied and the shelf-life to be achieved. The machine has been designed to meet the stringent requirements of an ESL application as well as the minimum requirements for pasteurized products. Key elements of the hygienic design are the self-drainable surfaces, the fully automated cleaning system and the automatic CIP cups closing the fi lling valves during cleaning of the internal system. In terms of hygienic process the fl ow rates of the cleaning detergents have been adapted and sanitization temperatures vary according to the shelf-life requirements. The output of the Sensofi ll FMm ranges from 6,000 to 50,000 bph for 100 to 2,000 ml containers. PET, PP and HDPE are transferred by their neck guaranteeing quick format changes and fl exible production. Bottom handling can be offered in addition to secure safe transport of bottles with an unusual neck fi nish. Thanks to the modular concept of the Sensofi ll FMm Platform various types of rinsers can be joined to the fi lling unit if chemical bottle treatment is required. It is also possible to combine the Sensofi ll FMm fi ller directly with a Sidel stretch blow molding machine for most cost effective production. (Please read more in the chapter Combi ). The fi lling system used in the Sensofi ll FMm is based on fl owmeter technology. The fl owmeter in combination with the special design of the fi lling valve and the dual fi lling speed allows to fi ll with highest accuracy resulting in a minimum fi lling deviation. Due to a simple product recovery system, no product is wasted at production start-up and termination. CL O S I N G Safe closing of the bottle is the key to ensuring perfect sealing integrity. As different applications demand different closing solutions, the system can be equipped with either screw caps or foil seal. In terms of screw caps customers can choose between a variety of cappers in order to meet specifi c hygienic requirements. The heat sealing technology, developed by Sidel, allows to adjust sealing parameters individually and is mainly recommended for extruded bottles. The innovation of a product is mainly determinated by the shape of the bottle 3

4 Pasteurized SE N S O F I L L FMM CL A S S I C SE N S O F I L L FMM SE L E C T The classic Sensofi ll FMm fi lling machine is a stand alone integratable system combining fi ller and closing functions in one unit. In its classic confi guration the housing of the unit consists of a closed cabinet only. In a typical production environment this confi guration would be used for pasteurized products being distributed in the cool chain. In its select confi guration the housing of the unit consists of a closed cabinet with HEPA air fi lter protection (fi nal fi lter ISO5, class 100). The Sensofi ll FMm select does not require a chemical treatment of the bottle and closure. However it is recommended to dedust and de-ionize the screw caps before application to the bottle. In case of a foil seal as closure, it is recommended to protect the foil by UV light during transport. This allows to increase by a few days the shelfl ife of a pasteurized product distributed in the cool chain. The modular concept of the Sensofill FMm platform provides various machine configurations (classic, select, ultra) and permits the integration of numerous options. Hygiene represents a key factor in the machine. The fi ller is accessible through transparent safety glass doors providing an open view into the hygienic chamber which is hermetically sealed during production and sanitization. This makes maintenance, inspection and monitoring easier. The table is selfdrainable and there are no moving parts above the fi lling section. 4 _ Sensofi ll FMm

5 Extended shelf-life SE N S O F I L L FMM ULT R A 1 SE N S O F I L L FMM ULT R A 2 The Sensofi ll FMm Ultra 1 is a stand alone system combining bottle sterilizer, rinser, fi ller and closing units in one housing. The chamber is additionally equipped with an exhaust system, as chemical vapours need to be removed during production and machine sanitization. The Sensofi ll FMm Ultra 2 confi guration contains the highest hygienic level of the entire platform and basically has the same machine functions as the Ultra 1. The system is additionally equipped with a steam condensate barrier around the rotary union and the temperatures during sanitization (SIP) are increased. This is the ideal solution for Extended Shelf-Life applications of up to 90 days, distributed in the cool chain. Introduced into the fi ller, the bottles are immediately taken by their neck. The machine base supports the direct bottle inlet starwheel, the bottle transfer starwheels, and the fi lling carrousel. The number of body guides has been minimized, so that friction on the bottle body can be avoided and fewer transfer problems occur. Bottles may exit the fi ller on a height adjustable fl at chain conveyor equipped with a digital counter for repeatability. 5

6 Bottle decontamination (ESL) BO T T L E D E C O N T A M I N A T I O N ON A MULTIWHEEL SYSTEM A multiwheel concept for bottle decontamination is used to sterilize and rinse the bottles with a standard neck fi nish. It allows to keep the size of the sterilizer and rinser wheels small and makes installation in existing plants easier. Filler configurations with screw capper Type pitch max. bottle ø. max bph 100 ml 1000 ml # steril. wheels # rins. wheels max bph max bph max bph FMm 24 60pi , , FMm 36 40pi , , FMm 40 45pi , , FMm 50 36pi , , FMm 54 40pi , , FMm 60 36pi , , TH E B O T T L E S T E R I L I Z AT I O N IS A F O U R S T E P P R O C E S S 1. Chemical (PAA) spraying at high pressure inside the bottle 2. activation time (the ideal combination of temperature and time) 3. rinsing with sterile water pulses (more effi cient than continuous spraying) 4. dripping (to reduce the water residuals in the bottle). 6 _ Sensofi ll FMm

7 BO T T L E D E C O N T A M I N A T I O N O N A R I N S E R The 2-channel rinser has an increased diameter, as bottles have to be turned, decontaminated and rinsed on one wheel. This system is recommended for bottles requiring additional bottom support for perfect transport. Filler configurations with foil sealing Type pitch max. bottle ø. max bph rinser ø. 100 ml 1000 ml # rinser grippers max bph rinser ø. # rinser grippers FMm 24 60pi , , FMm 36 40pi , , FMm 40 45pi , , FMm 50 36pi , , FMm 54 40pi , ,000 n.a. n.a FMm 60 36pi , , HI G H L I G H T S O F B O T T L E D E C O N T A M I N A T I O N - Sterilization performance: up to 4 log reduction - secure production with a mechanical washing effect on bottles - no shrinkage effect on packaging allowing bottle weight reduction - reduced chemicals and fl uids consumptions with recovery of approx. 70% rinsing water (optional) - continuous monitoring and traceability on PAA and sterile water parameters: temperature, fl ow, pressure - bottom support handling for non standard neck fi nish. 7

8 Filling with electromagnetic fl owmeters located before each fi lling nozzle Supplied from the processing the product fl ows into the product tank by low pressure. The product level is controlled by the modulating valve connected to an analogical probe allowing a constant and regular flow of liquid through each valve. In order to achieve the best fi lling results the valve has two fl ow rates. Due to the electro-pneumatic control of the fi lling cycle it is possible to fi ll hygienically, with no bottle contact. To perform internal cleaning and sanitization cycles of the product circuit, each fi lling valve is equipped with fully automated CIP cups connecting the fi lling valve to the closed loop of the CIP platform. During the CIP and SIP cycles, the fl ow rate is monitored on all fi lling valves. Air Product Cleaning cups in open position Cleaning cups in closed position during CIP 8 _ Sensofi ll FMm

9 Cleaning and sanitization is effected by a set of nozzles placed inside the tank. The fl owrate of the detergents is monitored and controlled during CIP. The sanitization of the fi lling system is with hot water. HIGHLIGHTS OF FILLING - High fi lling accuracy - easy fl avor changeover due to recipe control from the panel - pulp fi lling up to 60g/l - no contact between the fi lling valve and the bottle - closed loop CIP with automatic cleaning cups. The fi ller is equipped with a product recovery system allowing to return remaining product back to the processing unit. After production the product can be drained from the tank into a tray through the fi lling nozzles. 9

10 Closing Safe and secure capping of the bottle is a must to ensure product integrity SC R E W C A P P E R Sidel always offers cappers with proven quality, manufactured from top class suppliers. The capper is mounted on the fi lling machine and is delivered as one unit. Supporting the ultra clean design of the entire capper, all hygienically critical parts, such as the upper box, the plate, the head carrier and the collars and mechanical turret covers, are made out of stainless steel. CA P F E E D E R The Sidel cap feeder features three functions in one machine: cap storage, elevation and orientation. The cap feeder operates very effi ciently with minimum space requirements. Ringless caps and upside down caps are detected and automatically rejected. On ESL applications cap decontamination has the same process steps as the bottles: hot PAA spraying at high pressure, chemical activation, sterile water rinsing and dripping. HIGHLIGHTS OF CAPPER - Individual control and adjustment of head tightening torque - detection and rejection of wrongly capped bottles - different cap shapes and diameters can be handled - cleanable design: no gears and driving parts inside sterile zone - easy access for maintenance - no required steam barriers - centralized manual lubrication with progressive distribution. 10 _ Sensofi ll FMm

11 TH E F O I L P R E S S M A N U F A C T U R I N G T H E SEALING LIDS The foil press is an independent unit, punching foil seals from a pre-sterilized foil reel. If required the press can be kept under laminar air fl ow and UV light can protect the single lids during the transport to the sealing turret. Downtime for the foil splice is reduced to a minimum thanks to the second tandem wheel which can already be prepared before the actual splicing starts. AD D I T I O N A L P R O D U C T S A F E T Y C A N B E A C H I E V E D B Y C L O S I N G T H E B O T T L E WITH A PEALABLE LID Heat sealing technology is used to apply the lids on the bottles. The sealing turret is mounted on the fi ller table and mechanically synchronized with the fi lling carrousel. All parameters of the sealing heads are individually adjustable. As the sealing head is moveable, imperfections on the surface in the neck area can easily be compensated. HI G H L I G H T S O F H E A T S E A L I N G - No greasing of the punching tool required - light protection during transport of the lids - individual adjustable parameters of sealing heads (temperature, time) - compensation of neck tolerances. 11

12 Auxiliaries The Sidel valve unit is the interface between the processing and the filler DE D I C A T E D T O: - inlet of the product into the fi ller - level regulation inside the product tank - production and distribution of compressed air and nitrogen. The PAA and sterile water platform is a Sidel manufactured processing unit DE D I C A T E D T O: - PAA preparation, distribution and recirculation - full control of all bottle and cap desinfection parameters - desinfection of the external surfaces of the isolator (SOP cycle) - sterile water preparation & distribution - full control of the sterility of the rinsing water. 12 _ Sensofi ll FMm

13 Options GA S E O U S N I T R O G E N F L U S H I N G The Sidel patented nitrogen technology helps to reduce the residual oxygen to a minimum. This feature helps to improve signifi cantly the shelf-life of oxygen sensitive products. WA T E R R E C I R C U L A T I O N This technology is able to recover approx 70% of the rinsing water. AIR C O N D I T I O N I N G F O R EL E C T R I C A L C A B I N E T S AU T O M AT I C L U B R I C A T I O N U N I T MO D E M F O R O N L I N E R E M O T E S U P P O R T Modem with integrated router for online remote access for diagnostic/ intervention through internet or phone line (through VPN), password protected. EF F I C I E N C Y IM P R O V E M E N T TO O L (EIT) To record and visualize line performance data. COP UN I T (CL E A N I N G OU T OF PL A C E ) Foam preparation unit for external surface cleaning. BOTTLE INK JET CODER The bottle coder is dedicated to product and production traceability. It is located at the outfeed and codes the following information in two lines: date & time, batch number, team number, product code, fi lling valve number, capping head number, alarm codes. FU L L B O T T L E I N S P E C T I O N With a control system, each container undergoes a quality check directly and the results of the fi ller and capper are analysed. The wide range of inspection possibilities ensures that top quality is produced at the heart of the fi lling line. UV L A M P O N C A P C H U T E IN C A S E O F F O I L S E A L (S T A N D A R D F O R U LT R A ) DO U B L E B E LT C A P F E E D E R I N C L. C O N T A I N E R D I S C H A R G E S Y S T E M, E X T E R N A L H O P P E R (1200 L I T R E S), A N T I S T A T I C B E LT ICS I N T E G R A T E D C L E A N I N G S Y S T E M (CIP & SIP) The automated product circuit cleaning and sanitization is integrated in the valve unit. The ICS unit is based on a concept using the fi ller tank as a CIP tank, able to clean and sanitize the machine very effi ciently. The design optimizes the chemical consumption, effl uent, energy and time. BO T T L E R E J E C T O R If a control system is installed, the rejector receives a combination of information for sanitary, sampling and quality reasons from the system. 13

14 Combi Solution a single integrated system combining the following functions fi lling positive bottle transfer blowing bottle outfeed capping cap feeding 14 _ Sensofi ll FMm

15 thermal conditioning preform feeding preform infeed TH E S Y S T E M C A N B E A D A P T E D T O A N Y S I D E L F I L L I N G M A C H I N E A N D P R O V I D E S T H E F O L L O W I N G A D V A N T A G E S RE D U C T I O N IN... - initial bacteriological load of the bottle before fi lling - investment and production costs - fl oor space - operating personnel (with a more ergonomic workplace) - bottle costs through lighter bottles - maintenance and spare parts costs. IN C R E A S E S IN L I N E E F F I C I E N C Y In pasteurized and ESL applications, the Combi can provide ideal microbiological conditions, making the use of additional bottle decontamination and rinsing unnecessary. Sidel has optimized this technology in the past few years and has a number of references all over the world. For more details about the Combi Solution, please refer to the Combi Catalogue or to the Sales Team in your respective country. 15

16 In a world of constantly changing needs, today s bottle is tomorrow s old news. But by having approximately 5,000 skilled employees all over the world, we are able to listen to our customers, offering them reliable production-systems that are easily adaptable to new developments without causing expensive downtime. The Sidel Group, headquartered in Switzerland, has production sites in 13 countries and 30,000 machines installed in 190 nations worldwide. Leading in packaging solutions, our value-added service secures both our customers & us with a sustainable business in the global environment. No doubts, no compromises, just A Better Match. February No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, without the previous written approval of Sidel. All intellectual property rights, including copyright, are reserved by Sidel.