PET aseptic cold filling production line technical description
Based on the advanced technology of similar foreign products, our company has independently developed a PET aseptic cold filling production line. The aseptic cold filling production line adopts aseptic isolation technology to ensure the sterilization of filling materials, packaging environment and packaging containers. Sterilize the bottle and cap by soaking in disinfectant to ensure the sterility of the packaging container. The internal and external surfaces of the equipment are cleaned and sterilized by the SOP method, and the filling environment is kept at positive pressure by using sterile air to achieve a 100-level clean environment. The material pipeline is cleaned and sterilized by CIP and SIP, which ensures that the material after UHT sterilization is not contaminated, and ensures that the final product meets the commercial sterility requirements. The PROFINET bus control technology is used to realize the communication between single machines and the control of the whole line, online display of the running status of the whole line and fault alarm, which greatly improves the level of automatic control and reduces the possibility of human misoperation.
- Adopting modular design, the empty bottle sterilizer, empty bottle washing machine, filling machine and capping machine are combined into a five-in-one unit, and the part above the table is sealed with an isolation cover.
- Empty bottle sterilizer uses empty bottles to be sprayed and sterilized by two sterilizers on the same platform in turn.
- The rinser is designed with sterile water for internal flushing, external washing and draining.
- The filling valve adopts non-contact type, which can effectively prevent secondary pollution.
- Electromagnetic flowmeter is used to measure the filling volume, with high measurement accuracy and easy adjustment of product varieties.
- Equipped with an automatic fake bottle mechanism, which automatically fills fake bottles during CIP cleaning and SIP sterilization.
- Using the Italian AROL upper turret system to ensure the qualification rate and stability of the screw cap.
- Set up centralized automatic lubrication system.
- The interior of pipes and valves in contact with materials are all sanitary standards.
Whole line parameter
| Rated capacity (500ml) |
15000-36000BPH |
| Single machine efficiency |
≥96% |
| Filling accuracy |
±1.5% |
| Bottle damage |
≤0.1% |
| Cap loss |
≤0.1% |
| Qualified rate of screw cap |
≥99.95% |
| Cover opening torque |
1.5-2.8N m (the national standard value is 0.6-2.8) |
| Contamination rate of finished products |
≤0.1‰ |
| In continuous production, the interval between shutdown and cleaning |
neutral products - 72 hours |
Aseptic blowing, filling and rotating system, the empty bottle blown by the bottle blowing machine is sent to the aseptic filling combination machine through the dial and bottle clamp system, and the PET bottle is sprayed and sterilized by two disinfectant washing machines and then sent to the aseptic filling machine. Enter the bottle rinser, rinse the disinfectant remaining on the inner and outer surfaces of the bottle with sterile water, drain and enter the filling machine part for filling, after the filling is completed, rinse with multiple channels of sterile water before entering the capping machine The residual material on the thread of the bottle mouth is dropped; the product with the cap screwed on is sent out by the conveyor belt, and sent to the finished product warehouse after automatic labeling, coding, automatic packing and palletizing.
The caps are sent to the capping machine after passing through the cap conveyor, capping machine, sterilizing machine, rinsing with sterile water, and drying with sterile air.
Sterile water system, sterile air filtration device, disinfectant preparation system, steam filtration device and CIP/SIP system are all necessary peripheral equipment for aseptic filling.
The key to aseptic filling of PET bottles is how to realize the aseptic treatment of filling materials, production environment (filling equipment, filling environment), packaging materials (empty bottles, bottle caps), etc. in the filling process to ensure that the final product is commercially sterile.
Aseptic cold filling combined machine unit
1.The unit consists of a disinfectant rinser, which consists of two disinfectant rinsers, a sterile water rinser, a filling machine, and a capping machine.
(1)The bottle blown out by the bottle blowing machine is transferred into the disinfectant rinser 1 through the star wheel. In the disinfectant rinser, the bottle is first turned 180°, and then the peracetic acid disinfectant is sprayed on the inner and outer walls of the bottle for a certain period of time. After rinsing and sterilizing, after a certain period of drip drying, the bottle is reversed by 180° and sent to the disinfectant rinser 2 by the star wheel.
The bottle enters the disinfectant rinser 2, repeats the process in the disinfectant rinser 1, and then is sent to the sterile water rinser by the star wheel.
(2)The structure principle of the sterile water rinser is similar to that of the disinfectant rinser, except that sterile water is used instead of peracetic acid as the flushing medium.
(3)After the bottle is washed and dried as a whole, it is sent to the filling machine through the star wheel. The filling machines all use non-contact filling valves to prevent cross-contamination through the filling valves. The aseptic filling valve adopts the volume measurement method of the electromagnetic flowmeter. Each filling valve is equipped with an automatic fake cup. During internal cleaning and disinfection, the feed pipe and the return pipe form a cleaning and disinfection circuit through the fake cup and the filling valve. In order to ensure reliable sterility, steam barriers are provided on both sides of the dynamic seal of the material channel in the center tube of the filling machine to prevent bacteria from entering the material pipeline. There is a disinfectant water sealing groove between the rotating parts of the filling machine and the outer cover to prevent the external atmosphere from entering the isolation room. A bottle detection device is installed next to the bottle feeding star wheel of the filling machine to realize the action of no bottle filling. After filling, it is rinsed through the bottle mouth and sent to the capping machine by the star wheel.
(4)Only the capping head part of the capping machine is in the clean room, and the rest of the transmission parts are arranged outside the clean room. There is a water sealing groove between the rotating part of the capping machine and the isolation cover to prevent the external atmosphere from entering the isolation room. The cap-screwing machine is equipped with a cap-stopping cylinder, and no cap is provided without a bottle; it is equipped with a cap-missing detection sensor, which automatically stops when the cap is missing. The screwed product is sent by the star wheel to the conveyor belt.
The bottle transfer star wheel of the combination machine adopts the bottle clamp and bottle neck conveying form. When changing the bottle type, if the neck size is the same, all the star wheel bottle clamps do not need to be replaced.
Technical parameter
| Model |
1300908A |
| Capacity |
15000BPH(based on 500ml) |
| Module |
Sterilization 80;rinsing 55;filling 35;capping 10 |
| Dimensions |
L-W-H 11650*9250*4500mm |
| Weight |
26500kg |
| Applicable cap |
Plastic pilfer proof cap φ26~45mm |
| Applicable bottle |
Φ: 50~95mm;height: 140~320mm;volume: 260~2000ml |
| Filling temperature |
≤15-25ºC,Special products excepted |
| Applicable beverage |
tea,juice,water,milk drinks,yogurt, etc.(neutral,acid products) |
| Sterilization ability |
≥6D |
| Residual disinfectant in the bottle |
≤0.5mg/L |
| Sterile cycle |
72H(It depends on the product.) |
| Filling accuracy |
±1.5% |
| Capping qualification rate |
≥99.99% |
| Power |
21.6kw |
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