BLOWING MOLDS

ELECTRICAL P.

COMPRESSED AIR

Product pasteurizer UNITHERM 18 – Tubular heat exchanger UHT plant

Max Capacity               18.000 l/h

Technology                  Tubular Heat Exchanger

Each tubular module is 6m in length

Design: multitube

The product coming from the preparation tanks is collected in a Balance Tank.

From the Balance Tank by a centrifugal pump the product will be sent to Tubular Heat Exchangers that includes 3 main sections:

–      Recovery section in order to heat the product from 20°C up to roughly 70°C by thermal exchange with hot water (closed circuit: the water is heating by thermal exchange with the hot product)

–      Heating section in order to heat the product from 70°C up to max 95°C by hot water

–      Cooling section in order to cool the product down to filling temperature by cold water

At the pasteurization temperature, the product makes a tubular holding of around 30”.

It’s included also a pressurized water balance tank for plant sterilization and to manage water recirculation loop.

In case of a problem with the filling machine, the product will recirculate into the Balance Tank. In case of long stop, after a preset recirculation time (decided by the customer) the plant puts in water that pushes all the product into the balance tank and it starts the water recirculation loop on the water balance tank in order to maintain the production thermal profile.

When the problem stops the product comes again into the system and pushes the water out; the production restarts.

Scope of supply:

–      Product balance tank device

–      Product centrifugal pump

–      Magnetic Flow Meter

–      Tubular Heat Exchangers in order to achieve the thermal profile specified above

–      Water recirculation system for recovery heating system

–      Hot Water System including

·     Heat exchanger

·     Recirculation water pump

·     Expansion vessel

·     Steam modulating valve

·     Stop steam valve

·     Steam filter

·     Steam trap

–      Pressurized Water Balance Tank

–      Pneumatic valves for product and utilities

–      Double holding tube with multiway plate and proximities switches

–      Instruments

–      Electric panel including PLC (Allen Bradley/Siemens) with operator interface

Deaerating System – used bottle filling machine for sale

The system is composed by:

–      Deaeration vessel

–      Condenser for aroma recovery

–      Product pump

–      Vacuum pump

–      Level probe

–      Vacuum probe

–      Set of valves

Homogenizer 18.000 l/h, 250 bar

Pasteurizer independent CIP unit

–      Set of pneumatic valves

–      Conductivity meter

–      Pump for feeding the detergents from tanks located close to the plant (tanks excluded from our supply)

STERITANK 1-10

Used in conjunction with UHT processing, in conjunction with steam-N2-air filtering unit UNIFLUX AS, suitable for wide range of liquid products. The scope of the unit is to maintain the upstream units at the nominal production conditions also in the event of output fluctuation of the bottling line.

Technical data:

10.000 l  aseptic tank made of AISI 316L pressurized with sterile Nitrogen and covered with water cooling jacket

Equipped with an aseptic magnetic stirrer, in case of pulpy products

Sterile CO₂ injector – UNIFLUX AS – Utility filtration unit

Skid-mounted, factory tested, filtration unit in conjunction with STERITANK

Technical data:

Steam filtration:           1mm absolute

Compressed air pre-filtration: 0,6 mm absolute

Compressed air and Nitrogen final filtration: 0,01 mm absolute

Cumulative steam sterilisation (142°C) time limit regarding the filtrations at 0,01 mm absolute: 165 hrs

–      The final double series of filters on the nitrogen and compressed air lines safeguard the user against accidental damage to the filter cartridges

–      The system performs the filter sterilisation and cooling down cycles entirely in automatic mode.

–      Capacity:  steam 500 Kg/h at 2barg, Nitrogen 200 Nm3/h, air 500 Nm3/h

CO2 dosing performed via a stainless steel injector

UNICLEAN for the syrup room

N° 1 CIP station complete of two stainless steel AISI 304 tanks (insulated only for soda and water) of capacity 3.000 l/each and:

–     N° 1 tubular heat exchanger for the recirculation heating of cleaning solutions complete of modulating steam valve, filter, pressure reducer, manometer and steam trap

–     N° 1 centrifugal pump for dosing lye from plastic container to the tank complete of min level probe; capacity 250 l/h

–     N° 1 centrifugal pump for dosing disinfectant from plastic container complete of min level probe; capacity 100 l/h

AISI 304 piping for the connection of the above items inside the AREA 3

Electrical and pneumatic material for the connection of the above unit

UNICLEAN  3A CC for the aseptic line

UNICLEAN carries out the washing of the machines present on the bottling line.

The system carries out the dilution of concentrated basic or acid solutions with water to obtain the sanitizing solution at the required concentration and temperature.

Easy maintenance

–     The mounting of the machine on a single skid makes every component easy to access for inspection and maintenance work.

Safety

–     The key point of the design is its perfect integration with the system downstream.

–     All the automatically performed operations are controlled through pressure, temperature, and flow rate feedback or actuation checks on the pneumatic valves.

Automation

The UNICLEAN 3 A CC is equipped with the most technologically advanced automation in terms of both software and hardware, to guarantee:

–     a simple and immediate machine-operator interface

–     a rapid and effective diagnosis of problems

–     the total automation of all the production phases (from start-up to sanitation) in the most complete version.

Structural characteristics

–     A unit for preparing and recovering the basic washing solution with a 2000-litre recovery tank, conductive type of level probe and a pneumatic dosing pump for loading

–     A unit for preparing and recovering the acid washing solution with a recovery tank of 2000 litres, conductive level probe and pneumatic dosing pump for loading

–     Shell-and-tube heat exchange unit in the steam line

–     Temperature regulation loop obtained through a modulating valve and PT100 probe

–     Centrifugal boost pump for sending a sanitizing agent to downstream supplies, placed under inverter for managing different washing flow rates

–     Automatic control of the percentage dilution of the acid and basic washing solutions carried out through a conductivity meter

–     Full automation of the sanitation operations with automatic valves

–     Single main frame made of stainless steel

–     Stainless steel electric cabinet is located onboard the machine with an incorporated graphic control panel.

Piping UIPIPE

Technical data:

–     Distribution and sterile return lines are realized in AISI 316L

–     The remainder of the lines are realized in stainless steel AISI 304

–     The welding is executed manually with method T.I.G. under inert gas protection

–     Pipe cutting by means of orbital cutters without ferrous material contamination

–     Use of lubrication products containing no chlorine or lead

–     The bends are executed with pipe bending machines with no contrast core tool, for diameters up to 18mm, with welded fittings for diameters over 18 mm.

–     Suitable piping supports in order to permit free expansion of the actual piping.

Steam generator to supply the required steam to filling line and syrup room machines (pasteurizer, C.I.P., UNIFLUX.

Steam capacity: 2.000 kg/h

Propellant: natural gas

Air compressor to supply the required compressed air to filling lines and syrup room machines.

Air pressure: 8 bar

Product

0,5 l

1,0 l

Still fruit juices and nectars

18.000 bph

18.000 bph

Carbonated drinks with juice content

17.000 bph

14.000 bph

CO₂ content: up to 5 g/l

The caps which are sent to the sterilisation system by means of an elevator and belt conveyor pressurised with sterile air, are sterilised with an oxidising agent and then rinsed with sterile water before being sent to the UNIBLOC via a caps chute, the latter is also pressurised with sterile air.

The UNIBLOC is equipped with a microbiological isolator made of rigid transparent PVC in order to separate the internal environment, which is pressurised with sterile air, from the outside environment. There are pressurised tunnels both on the bloc bottle entrance and the bloc bottle outlet to ensure a total separation of the external environment from the internal environment. The aim of using a microbiological isolator is to control all the environments which make up the CC UNIBLOC HA system.

Rotary system for sterilizing containers PROCOMAC

The sterilization of the inside and outside surfaces of empty containers with an oxidizing agent solution is carried out by a rotary system, which also rinses them with sterile water and feeds them to the filler.

This system is ideal for use on bottling systems for acid pH products.

Characteristics

The system is made up of:

–     GRIPSTAR ACE PET2 GX 90

Rotary sterilizer with bottle gripping on the neck and electronic control of treatment times

–     GRIPSTAR ACE PET2 GX 65

Rotary rinser with bottle gripping on the neck and electronic control of treatment times

System of bottle transfer by means of starwheels fitted with grippers with positive grip in the area of the ring under the lip of the bottle.

Structural characteristics

–     Sterilization system suitable for use on bottling systems for acid pH products

–     Fixed height GRIPSTAR ACE GX rotary sterilizer with electronic control and adjustment of treatment times from the operator panel

–     External stainless steel tank for recovery of the sterilizing solution and for its return to the UNIDOX production and replenishment system

–     Fixed height GRIPSTAR ACE GX rotary rinser with electronic control and adjustment of treatment times from the operator panel

–     Bottle gripper with irreversible symmetric movement

–     Bottle transfer system by means of starwheels having grippers with positive grip in the area of the ring under the bottle lip

–     Sterile water distribution manifold with thermal steam barrier

–     Bottle-pitch scroll at the sterilizer infeed

–     Full automation of machine sterilizing operations with automatic valves

–     Components suitable for the automatic control of all critical process parameters

–     Centralized lubrication in a single easy-to-reach point

–     Mainframe made of AISI 304 stainless steel

–     Parts in contact with the treatment fluid made of AISI 316 stainless steel

Mechanical equipment

–     ASEPTIC PROCOMAC seals and hose fittings without crevices

–     Equipment for processing two bottle size

–     Mobile bottle neck guide safety device on the bottle infeed

–     Torque limiter with limit switch on the transfer starwheels to stop the machine in the event of obstacles so avoiding possible damage

–     Drive transmission from the filler geared motor with safety torque limiter

Electrical equipment

–     Machine management with PC

–     Bottle flow control with a system of photocells

–     Wiring with “Fieldbus” type data communication network

–     Wiring between the machines with “Ethernet” type data communication network

–     Stainless steel electric board in a remote position

Rotary electronic steriliser model GRIPSTAR 90.113

Number of grippers:       90

Machine Pitch:               113 mm

–     The automation continuously monitors the critical process parameters, in other words, the flow rates, the temperatures and the pressure of the fluids.

–     Machine is equipped with an electronic control sensor that monitors the spraying performances of every single nozzle. A further sensor verifies that the penetrating nozzle fully treats the inside of the bottle.

–     Treatment times are electronically handled and thereby do not depend upon the speed of the machine.

Rotary electronic rinser model GRIPSTAR 65.113

Number of grippers:       65

Machine Pitch:               113 mm

–     The automation continuously monitors the critical process parameters, in other words, the flow rates, the temperatures and the pressure of the process fluids.

–     Machine is equipped with an electronic control sensor that monitors the spraying performances of every single nozzle. A further sensor verifies that the penetrating nozzle fully treats the inside of the bottle.

–     Treatment times are electronically handled and thereby do not depend upon the speed of the machine.

–     The manifold which distributes the sterile water, from the fixed part to the rotary part of the machine, is fitted with a steam barrier in order to avoid contamination in case of leakage. The temperature of the steam barrier is monitored continuously.

Filler-Capper PROCOMAC model FILLSTAR CX 70.10.113 with AROL capper

The FILLSTAR CX is an electronic volumetric isobaric rotary filler suitable for filling flat and carbonated beverages in plastic bottles.

UNIBLOC 2 (Neck handling) version

Said bottle neck handling system (with positive grip gripper) is able to handle any type of plastic bottle (neck diameter being equal) without the use of the body counter-guide.

The use of positive grip transfer star-wheels drastically reduces format changeover downtime, and moreover reduces the possibility of any jamming.

Outlet tunnel – used bottle filling machine for sale

By means of the outlet tunnel, the filled and capped bottles are transferred from the isolator to the outside without the two environments ever coming into contact with one another.

Pressurised mechanical caps elevator

Hopper capacity: ~ 1 m³

–      The hopper and the capper conveyor are pressurised by means of independent pressurisation modules.

–      The air filtration is performed by means of  HEPA 99,999% filters.

Caps sterilisation system PROCOMAC model STERILCAP 3W

Number of treatment tracks:    3

–     The machine is fit to handle just one type of cap.

UNIDOX SPIN peracetic acid dilution and dosing system

UNIDOX SPIN performs volumetric dilution of the concentrated solution using the batch technique in order to produce the sterilization solution for containers and caps to the concentration and temperature parameters required. UNIDOX SPIN automatically adjusts the concentration of the sterilizing solution with minimum operator intervention thanks to its timed-release system that replenishes the concentrated solution.

UNIFLUX – FOAM spin fluid filtering and foaming system

UNIFLUX – FOAM SPIN performs:

–     sterilization by filtering those points of use (steam, process air, controls air, nitrogen or other liquid) required by the bottling line, and their subsequent, totally automatic supply to the bottling line during both sanitation-sterilization and production. The system automatically performs a sterilization cycle of the various filters before starting up production. A built-in dosing system of the sterilizing solution also makes it possible to sterilize the sterile fluid distribution piping and rapid sterilization of the filling environment;

–     the production of washing foam composed of foaming detergent agents added to sterile water which, properly distributed by a system equipped with highly-mechanized nozzles positioned to reach even the most difficult points, guarantees automatic cleaning of the external surfaces of the filling area.
The system also rinses the surfaces using sterile water and sterilizes them using a disinfectant.

UNITHERM sterile water production – water bottling machine for sale

UNITHERM H is a water sterilizer that guarantees the production of sterile water for supplying the container and cap rinsing system and for supplying the system downstream.

UNITHERM H was designed to ensure low electricity consumption, thanks to the adoption of a three-section heat exchanger and an operating logic that includes the recovery of heat from the sterilized water to carry out the pre-heating of the water to be treated.

The operating logic of UNITHERM H is completely integrated with the system downstream in order to guarantee the correct supply of sterile water in every phase of its operation.

Microbiological Isolator – bottle washing machine

1^st Sterile air pre-filtration:          EU3 85% gravimetric

2^nd Sterile air pre-filtration:         EU9 95% parametric

1^st Sterile air final filtration:         EU13 99,97 DOP

2^nd Sterile air final filtration:        EU14 99,97 DOP

Sterile environment class at rest: M 3.5  FS 209E

Peroxide extinction efficiency on vapour exhaust:

Scrubber emission-concentrations

Acetic Acid (ppm)

Peroxides (ppm)

At the inlet

20

1,8

At the outlet

<  2

<  0,5

The aim of the microbiological isolator is to control all the environments which make up the CC UNIBLOC HA, be it either environments where a process phase is performed (sterilisation-rinsing-filling-capping) or areas where the bottles or caps are transported.

The bottling room represents the environment inside of which the monobloc sterilisation-rinsing-filling- capping system is installed.

It is composed of the following:

WALLS

1.     Moving partition walls realised with self-standing modular sandwich panels, thickness 45 mm.

Main characteristics:

–     External surfaces in laminated phenolic resin, 4 mm, thickness, lined with melamine, ivory colour.

–     internal frame in anodized aluminium profiles

–     Internal insulation made with polystyrene class 1, fireproof.

–     Ceiling, wall and angle type junction made in anodized aluminium profiles, natural colour, sealed with silicon.

–     Joints between modular panels realized with internal rabbet and silicon sealed.

2.     Flat aluminium profile, for the junction between walls and floor, outside the clean area.

3.     Aluminium Profile, round corner, for the junction between walls and floor, inside the clean area

4.     Holes for electrical cables

5.     Holes for return grilles in phenolic resin walls.

6.     Holes for machines

7.     Removable panels  with aluminium profile

8.     AISI 304 support structure for Caps sterilizer room

9.     PVC covering for walls

DRYSTAR carries out the drying of containers exiting from the filling block by means of air blown onto the container itself from specially designed nozzles that guarantee maximum drying efficiency in relation to the flow of air used.

The air is supplied to the nozzles by blowers with very low noise levels.