Aseptic Filling System for Dairy Products
In recent years, more and more enterprises choose PET bottle filling products. Even though the controversy caused by plastic waste has never been cut off, it will not affect the wide use of plastic products. In the aseptic filling process of dairy products, the PET bottle is an ideal container, which can be used for filling temperature-sensitive products.Cocoa, organic milk and whey drinks-dairy factories have developed various novel products to meet the diverse tastes of consumers. In addition to a healthy diet, a packaging style is also a place where consumers pay more attention. Packaging must be sustainable, which can protect products, and be easy to use. Previously, PET bottles were mostly used for filling water. With the advantage of aseptic filling, PET bottles have now occupied the low-acid dairy industry.
At present, various aseptic filling solutions are prevalent in the market. The emphasis is on safe and efficient sterilization. It is becoming more and more important to quickly change specifications and modularized systems. Dairy products must adapt to the changing market faster. Safe sterilization strategy is an effective method to sterilize with a slightly hot peracetic acid solution. But it also means that a lot of water needs to be consumed. With the enhancement of environmental awareness, some enterprises have developed new methods, such as dry sterilization.
Aurora Organic Dairy Company has used this aseptic filling system in its dairy factory in Colombia-Combi Predis of Sidel. Excellent performance and multi-party quality certification are the main reasons why dairy factories choose Combi Predis. The manufacturer emphasizes that Combi Predis has been installed in 180 units worldwide, and it is also the first aseptic filling machine for PET bottles to sterilize bottle blanks in a dry mode. Since 2017, Combi Predis had been certified by the US Food and Drug Administration (FDA).
The working principle of Combpredis is based on dry sterilization of bottle blanks, and hydrogen peroxide (H2O2) is injected into the bottle blanks before they are put into the furnace. In this process, the key parameters will be continuously monitored to ensure the sterility, purity and food safety of the whole process. The ultraviolet lamp is responsible for disinfecting the outer surface of the bottle embryo. Dry sterilization is designed and manufactured according to the requirements of the European Health Engineering Design Organization (EHEDG), which can meet the requirements of the 3-A standard of liquid dairy products at the same time.
Aseptic filling system
The easier aseptic filling process is the latest development achievement of KHS: InnoPET, an aseptic linear filling machine. BloFill ABF is an integration of InnoPET Blomax V series of rotary stretch blow molding machines and Innosept Asbofill ABF712 of sterile linear filling machines. It not only occupies less space than a single machine system but also does not need a pneumatic conveying system, further reducing energy consumption. It also has the advantage of reducing the personnel cost-only one operator is needed. Thomas Redeker, Marketing Director of KHS European Dairy Products Market, said, "We are not just satisfied with the integration of equipment. Accordingly, we also added the Konti-Takt module. In this way, the possibility of pollution in the filling process can be minimized. This has a positive impact on health and system availability."
The new aseptic filling system solves the problem of sterilization efficiency. Sensitive product filling machines can provide two specifications, which meet the standard of long shelf life (ESL) and sterility standard respectively. During the use of the KHS filling machine, sterilization is divided into several steps. First, the neck and interior of the bottle will be disinfected: H2O2 aerosol will be sprayed into the container twice, with a spraying speed of 80 km/h. Thomas Redeker explained, "In this way, H2O2 aerosol will touch every part of the bottle. Even with personalized design and irregular containers, it can be completely disinfected." Then there will be two steps of aerosol reaction and four steps of sterile drying with hot air.
Flexibility to quickly change specifications and height
On the one hand, the diversity of products shortens the life cycle of products. On the other hand, it also reduces the batch size in food production. Under this background, the concept of modularity came out at the historic moment, which required that the system configuration time designed by equipment manufacturers was shorter. The quantity and specifications of products could be easily changed. KHS's "aseptic filling machine" is the solution to meet this market demand. Under the aseptic condition, it can change the specifications within 10 minutes at the soonest, without extra cleaning and sterilization. Fast switching makes it possible to fill a large number of different products in a short time. The linear aseptic filling machine is suitable for filling milk, mixed milk drinks, fruit juice, smoothies and iced tea in PET bottles with a capacity of 250 ml to 2 L.
Thanks to the modular design, the filling system can be expanded at any time. Users can use small capacity filling machines or additional filling & sealing units to refit machines.
Thomas Redeker explained, "Modular design represents higher flexibility. In this way, users don't need to consider the limitations of filling products when purchasing machines. "
Meet the hygienic design requirements of the highest standard.
On Contipure Asept Bloc DN, Krones took a similar approach. Modular aseptic filling machines are specially developed for low acid products. The system includes drum sorters of bottle blanks, infrared ovens, disinfection modules of bottle blanks, aseptic bottle blowing modules, aseptic filling machines, bottle cap disinfection modules and aseptic sealing machines. Its disinfection solution is to uses gaseous H2O2 to disinfect bottle blanks.
Contipure Asept Bloc DN has a very smooth surface. Through certified Evoguard valves, filters and mirrors, the machine can minimize the risk of re-contamination of the final products. In this regard, at the beginning of 2020, it obtained the 3-A Sanitary standard certification of independent organization 3-sanitary, which is the best proof of its performance. All filling equipment entering the North American market must pass the 3-A certification issued by this institution before filling dairy products in the cold chain.
Summary
At present, equipment manufacturers can fully meet the requirements of food and beverage manufacturers for hygienic and flexible production systems and filling systems, and provide them with modular systems for each process step. According to different application scenarios, they can also expand the functions of the equipment-by means of single module re-integration—so as to improve the security and efficiency of the system.