Used Bottling Lines
Complete Line
Ref: LC292
  • Used Aseptic PET Filling Bottling Complete Line for Still and Carbonated Drinks year 2005 up to 18.000 bph - 1
  • Used Aseptic PET Filling Bottling Complete Line for Still and Carbonated Drinks year 2005 up to 18.000 bph - 2
  • Used Aseptic PET Filling Bottling Complete Line for Still and Carbonated Drinks year 2005 up to 18.000 bph - 3
  • Used Aseptic PET Filling Bottling Complete Line for Still and Carbonated Drinks year 2005 up to 18.000 bph - 4
  • Used Aseptic PET Filling Bottling Complete Line for Still and Carbonated Drinks year 2005 up to 18.000 bph - 5
  • Used Aseptic PET Filling Bottling Complete Line for Still and Carbonated Drinks year 2005 up to 18.000 bph - 6
  • Used Aseptic PET Filling Bottling Complete Line for Still and Carbonated Drinks year 2005 up to 18.000 bph - 7
  • Used Aseptic PET Filling Bottling Complete Line for Still and Carbonated Drinks year 2005 up to 18.000 bph - 8
  • Used Aseptic PET Filling Bottling Complete Line for Still and Carbonated Drinks year 2005 up to 18.000 bph - 9
  • Used Aseptic PET Filling Bottling Complete Line for Still and Carbonated Drinks year 2005 up to 18.000 bph - 10
  • Used Aseptic PET Filling Bottling Complete Line for Still and Carbonated Drinks year 2005 up to 18.000 bph - 11
  • Used Aseptic PET Filling Bottling Complete Line for Still and Carbonated Drinks year 2005 up to 18.000 bph - 12
  • Used Aseptic PET Filling Bottling Complete Line for Still and Carbonated Drinks year 2005 up to 18.000 bph - 13
  • Used Aseptic PET Filling Bottling Complete Line for Still and Carbonated Drinks year 2005 up to 18.000 bph - 14
  • Used Aseptic PET Filling Bottling Complete Line for Still and Carbonated Drinks year 2005 up to 18.000 bph - 15
  • Used Aseptic PET Filling Bottling Complete Line for Still and Carbonated Drinks year 2005 up to 18.000 bph - 16
  • Used Aseptic PET Filling Bottling Complete Line for Still and Carbonated Drinks year 2005 up to 18.000 bph - 17
  • Used Aseptic PET Filling Bottling Complete Line for Still and Carbonated Drinks year 2005 up to 18.000 bph - 18
  • Used Aseptic PET Filling Bottling Complete Line for Still and Carbonated Drinks year 2005 up to 18.000 bph - 1
  • Used Aseptic PET Filling Bottling Complete Line for Still and Carbonated Drinks year 2005 up to 18.000 bph - 2
  • Used Aseptic PET Filling Bottling Complete Line for Still and Carbonated Drinks year 2005 up to 18.000 bph - 3
  • Used Aseptic PET Filling Bottling Complete Line for Still and Carbonated Drinks year 2005 up to 18.000 bph - 4
  • Used Aseptic PET Filling Bottling Complete Line for Still and Carbonated Drinks year 2005 up to 18.000 bph - 5
  • Used Aseptic PET Filling Bottling Complete Line for Still and Carbonated Drinks year 2005 up to 18.000 bph - 6
  • Used Aseptic PET Filling Bottling Complete Line for Still and Carbonated Drinks year 2005 up to 18.000 bph - 7
  • Used Aseptic PET Filling Bottling Complete Line for Still and Carbonated Drinks year 2005 up to 18.000 bph - 8
  • Used Aseptic PET Filling Bottling Complete Line for Still and Carbonated Drinks year 2005 up to 18.000 bph - 9
  • Used Aseptic PET Filling Bottling Complete Line for Still and Carbonated Drinks year 2005 up to 18.000 bph - 10
  • Used Aseptic PET Filling Bottling Complete Line for Still and Carbonated Drinks year 2005 up to 18.000 bph - 11
  • Used Aseptic PET Filling Bottling Complete Line for Still and Carbonated Drinks year 2005 up to 18.000 bph - 12
  • Used Aseptic PET Filling Bottling Complete Line for Still and Carbonated Drinks year 2005 up to 18.000 bph - 13
  • Used Aseptic PET Filling Bottling Complete Line for Still and Carbonated Drinks year 2005 up to 18.000 bph - 14
  • Used Aseptic PET Filling Bottling Complete Line for Still and Carbonated Drinks year 2005 up to 18.000 bph - 15
  • Used Aseptic PET Filling Bottling Complete Line for Still and Carbonated Drinks year 2005 up to 18.000 bph - 16
  • Used Aseptic PET Filling Bottling Complete Line for Still and Carbonated Drinks year 2005 up to 18.000 bph - 17
  • Used Aseptic PET Filling Bottling Complete Line for Still and Carbonated Drinks year 2005 up to 18.000 bph - 18
Components
Machine typeManufacturerModelYearNotes
Machine typeInjection Molding MachineManufacturerSipaModelPPS 72/48Year2005Notes
Machine typeBlow Moulding MachineManufacturerSipaModelSFR 12Year2005Notes
Machine typePremixManufacturerProcomacModelUnifluxYear2005Notes
Machine typeFilling TriblockManufacturerProcomacModelAseptic UniblockYear2005Notes
Machine typeLabelerManufacturerKronesModelContiroll 720 - 12Year2005Notes
Machine typeShrink WrapperManufacturerDimacModelST@R F45Year2005Notes
Components
Machine typeManufacturerModelYearNotes
Machine typeInjection Molding MachineManufacturerSipaModelPPS 72/48Year2005Notes
Machine typeBlow Moulding MachineManufacturerSipaModelSFR 12Year2005Notes
Machine typePremixManufacturerProcomacModelUnifluxYear2005Notes
Machine typeFilling TriblockManufacturerProcomacModelAseptic UniblockYear2005Notes
Machine typeLabelerManufacturerKronesModelContiroll 720 - 12Year2005Notes
Machine typeShrink WrapperManufacturerDimacModelST@R F45Year2005Notes

Description See more

Description of the main equipment for aseptic PET filling line:

 

1/. Injection machine PPS 72/48 – a machine with a continuous flow of plasticized PET for the production of preforms
Number of cavities in injection mold – 48 pcs.
All operating parameters are controlled by the SIMENS Logic Controller equipped with a touchscreen monitor.

Performance:
– Preform 26 g; neck 38 mm – 14000 pcs / hour; capacity in a corrugated box – 9024 pcs
– Preform 32 g, neck 38 mm – 13000 pcs / hour; capacity in a corrugated box – 7200 pieces
– Preform 40 g, neck 28 mm – 12000 pcs / hour capacity in a corrugated box – 6528 pcs.
– Preform 26 gr, 32 gr – for own production.
Power consumption – 300 kW / h
Weight – 3.5 t
Hopper capacity 2 t
Replaceable formats – 3 pieces
Possibility of producing non-transparent and colored preforms
Room ambient temperature from +5 to +35 degrees

 

 

2/. Rotary blow molding machine SFR – 12 – is designed for blowing bottles from preforms of our own production. The preforms are fed into the bottle blowing carousel with simple tangential grippers.
Equipped with molds – 12 pcs (type of molds “crocodile”)
Blown bottle formats 0.45L; 0.5l; 0.9L, 1L, 1.5L.
Machine productivity – 18000 bph
Before blowing, preforms are heated in an oven with infrared lamps.
After blowing out, the bottle is fed through an air pneumatic conveyor to the microbiological isolator.
Power consumption 90 kW / h
Weight – 1.5 t
Pressure 40 bar
Room ambient temperature from +5 to +35 degrees

 

 

3/. Air conveyor model CONVAIR 2000 – designed for pushing pet-bottles by the neck in a single air channel. During the movement of pet bottles from the production line to the filling unit, the bottles are kept in an environment controlled from pollution by air pre-filtration filters, as well as the first absolute HEPA filter and an additional absolute HEPA filter located after the air fan.

 

 

4/. UNICLEAN AS – a semi-automatic unit for washing blending and syrup equipment, has two tanks for two-component treatment of equipment with an alkaline solution and an acid solution. The volume of containers is 2000l

 

 

5/. UNICLEAN SPIN – automatic installation for two-component washing of equipment for microbiological equipment, aseptic tank, containers. UNIRAC installations. The volume of containers is 2000 l

 

 

6/. UNIDOX – an installation for the preparation and supply of a working disinfectant solution of peracetic acid for sterilization of the bottle, cap and equipment of the microbiological isolator. The volume of the container is 2000 l. Automatic titration unit MAZELLI.

 

 

7/. UNIFLUX – STERILTANK – buffer storage aseptic tank before filling – with a volume of 10,000 liters. STERILTANK is equipped with aseptic magnetic stirrer for pulp products.

 

 

8/. UNIFLUX-FOAM SPIN – liquid filtration and foaming system – sterilizes the energy carriers needed for the filling line (steam, air, nitrogen) through aseptic valves and filters. The system automatically sterilizes all filters before starting production. In addition, the built-in sterilizing solution dosing system allows sterilization of pipelines and fast sterilization of the filling area.

Parameters are recorded and controlled by a simple and instant operator interface through an integrated panel of the filling unit, fast and effective diagnosis of problems, full automation of all working phases of processes from the beginning to the end of sanitization.

 

 

9/. UNITHERM H – installation for the preparation and supply of sterile water for rinsing bottles, caps, sterilization of the equipment of the microbiological isolator. The volume of the container is 2000 l.

 

 

10/. UNIRAC – plant for the recovery of water after rinsing the bottle. 75% of the recovered water is returned to UNITHERM H for sterilization and supply to production. Water purification is carried out by a column with activated carbon.

 

 

11/. Clean room equipment – microbiological isolator:
Before production, the microbiological unit undergoes an electronic sanitization cycle of the UNIBLOC CIP-SIP equipment; the duration of aseptic time, continuous production without CIP is 120 hours for non-carbonated drinks, for carbonated drinks – 72 hours.
The UNIBLOC automation system continuously monitors critical process parameters such as the flow of fluids to the machines. The machines are equipped with electronic sensors to control the parameters and modes of all processes. A manifold that delivers sterile water as well as a manifold that delivers product during the production period they have steam barriers, the temperature of which is controlled.

 

 

12/. GRIPSTAR sterilizer:
a rotary sterilizer with a bottle grip under the neck and electronic control of the processing time, designed to sterilize the inner and outer surfaces of a pet bottle under aseptic conditions, the working sterilizing solution of peracetic acid is recirculated after sterilization to the UNIDOX installation.

 

 

INJECTION MOULDS

– Number of injection cavities                  4 x 12
– Number of injection moulds                         1
– Total number of injection cavities               48

 

GENERAL CHARACTERISTICS

– Dimensions, m                         12 x 2.6 x h4.0
– Weight of the machine                      31,0 Ton
– Oil tank capacity                               1100 L
– Colour  RAL                   GREY 7012 – 7001/5012

 

PRODUCTION  OF PREFORMS :

Nom.production, preform/h

23 gr. – 14.400 *

29 gr. – 13.300*

42 gr. – 12.300*

Machine efficiency  95%

 

All the functions, production parameters, partial and total cycle times, temperatures, plasticizing unit are controlled by SIEMENS PLC, provided with a colour monitor and Alpha-numeric board.

The PLC has a complete programmer of self-diagnostics, with synoptic panels and precise indications concerning the possible faulty components or the out-of-standard process parameter

 

 

SITE INTERFACES – 

-Electrical power3ph+N+G        400(±10%)V/50Hz
total installed                                      446* KW
average absorbed                                     323* KW

– Service compressed air
pressure                                            10 Bar
consumption                                 80 Nm3/h

– Mould cooling water
Thermal Power                             137 kw
flow rate                                     84 m3 / h
temperature inlet                           8° C
delta temperature inlet-outlet         1,4° C
pressure                                       4,5 Bar

– Preforms cooling water

Thermal Power                            30  kw
flow rate                                   11,7 m3 / h
temperature inlet                           8° C
delta temperature inlet-outlet         2,2° C
pressure                                       4,5 Bar

– Hydraulic unit cooling water
Thermal Power                              55 kw
flow rate                                   9,5 m3 / h
temperature inlet                         8-30 ° C
delta temperature inlet-outlet          5 ° C
pressure                                      4,5 Bar

–      Dry air requirements
Power consumption                      61 kw
flow rate                                    10,5 m3 / h
temperature inlet                            8° C
delta temperature inlet-outlet           5° C
pressure                                      4,5 Bar

– PET-Dryer  cooling
Thermal Power                           32,6 kw
flow rate                                   5,6 m3 / h
temperature inlet                         8-30 ° C
delta temperature inlet-outlet          5 ° C
pressure                                      4,5 Bar

 

SUPPLY:

¨     Soundproof cabin with conditioner;
¨     48 cavities complete injection mould to produce 29g preforms;
¨     Injection mould cold half with set of cooling caps and plates to produce 23 g preform;
¨     Injection mould cold half with set of cooling caps and plates to produce 42 g preform;
¨     Preform unloading and cooling system;
¨     PET dryer complete of with granule suction pump and platform;
¨     Chillier for cooling injection moulds and hydraulic circuit;
¨     L.P. compressor 10 bar + reciever + dryer;
¨     Master Batch ;

 

 

Blowing Machine SFR 12 DESCRIPTION

Thanks to the unique vertical mould movement of SIPA SFR series (so called “Crocodile moulds”), the  mould version is particularly effective: the preforms are fed into the blowing wheel by grippers with a simple tangential movement. With a given cycle time, this allows more time to blow the bottle. When blown, the bottles are then simply extracted from the cavity by another set of grippers with the same tangential movement.

 

BLOWING MOLDS
Number of blowing cavities12
Number of blow molds12
GENERAL CHARACTERISTICS
Dimensions LxBxHм5,9 x4 x3,4
Machine weightкг13.500
Preform hopper and feeder weightкг3.000
Cabin weightкг2.000
Total weight of operating machineкг18.500
Standard cabin colourRAL7001
ELECTRICAL POWER
Voltage 3Ph + N + GВ400  ±10%
FrequencyГц50 /60  ±2%
Total installed powerквт226
Average absorbed power **квт120
COMPRESSED AIR FOR SERVICE
Air pressureбар7
Air consumption for mechanical machine motin with speed 1500 b/cavм³/час71
COMPRESSED AIR FOR BLOWING
Air pressure **бар30 – 35
STANDARD MOLDS COOLING
Thermal power **квт28,2
Inlet water temperature°C10÷12
Inlet – Outlet delta temperature°C3
Cooling water flow rateм³/час8,1
Inlet pressureбар4,5
OVENS COOLING
Thermal power **квт33,6
Inlet water temperature°C10÷12
Inlet – Outlet delta temperature°C3
Cooling water flow rateм³/час9,6
Inlet pressureбар4,5

 

BASIC MACHINE with 12 blowing stations complete of:
·       Soundproof cabin;
·       Set for 12 blow mould shells for bottle size 1,0 Lt;
·       Additional set of blowing shells for bottle size 0,5lt;
·       Preforms load system unit with cartoons unloading device, hooper and feeding system;

 

AUXILIARY   EQUIPMENT to Sipa SFR 12:

40 bar Blowing Compressor oil free with air dryer, 2000L receiver under PED norms and outside air cooler  for compressor;

 

Machine chiller for machine mould working in close loop;

PROCOMAC CONVAIR 2000 represent a new generation of air conveyors and are the result of twenty years of experience in this particular application field. They have been designed with modularity in mind and  conceived for welding-free assembly; their structure is entirely made in stainless steel with bottle slipping guides made in a plastic material especially studied for this application. A remarkable study about aerodynamics and a careful examination of the past experience have lead PROCOMAC to design a conveyor featuring a single air duct. Bottles are moved by application of motion air on the neck area through an especially-designed profile. Air volume and air pressure have been calculated to obtain best performances as well as high reliability and low operating noise.

The basic design can be upgraded by adding personalised optional features to guarantee a low contamination bottle handling or a bottle handling suitable for insertion in aseptic filling lines.

 

 

CONVAIR 2000 air conveyors features:

– Bottle pushing on neck area with a single air duct;
– Base frame entirely made in AISI 304 stainless steel;
– Bottle slipping guides made in a plastic material especially studied for this application;
– Pneumatic-controlled adjustable bottle guides
– Passage ducts for motion air are integrated into a plastic profile and designed to intercept the bottle in the best area to obtain high performance;
– 1 inspection door per metre is provided; its location in the upper part of the air duct and its hand screw closures account for easy inspection of the air duct;
– Conveyors supports made in stainless steel with either 2 or 4 stainless steel feet. A rubber pad with special  is provided to offer high grip and reduce vibrations and operating noise.
– Main frame equipped with bottle path isolation structure made in clear polycarbonate; bottles are thus kept in a controlled contamination environment from bottle production system to filling bloc. The structure can be opened on both sides for easy access to bottle path.
– Filters housing entirely made in stainless steel, with dust pre-filter, first absolute filter (95 DOP) and supplemental absolute filter (99.99 DOP) placed after air fan.

 

 

Bottle inlet tunnel
The bottle inlet tunnel connects the bloc bottle infeed conveyor to the microbiological isolator which protects the bloc.

Area 1 – Sugar syrup preparation area

UNISOLV BS

This area has been designed to prepare the right amount of simple syrup enough to feed the final beverage preparation tanks.

The batch heat sugar dissolving unit is including n.1 tank (5.000 l). By a screw type elevator the sugar will be taken from a hopper (where the operator will cut the sugar sacs and feed the sugar) and dissolved in hot water (roughly 40°C) inside the tank. The amount of sugar will be predosed from the operator; the system will take all the sugar prepared. The hot water is prepared by a tubular heat exchanger installed on the feeding water line.

From the dissolution tank the sugar syrup will be pasteurised and stored into a tank.
1 screw type elevator for the sugar feeding to the dissolving tank

– capacity 8.000 kg/h
– stainless steel material AISI 304 complete of hopper
– 1 sugar dissolving unit for hot preparation,
– capacity 5.000 l.
– stainless steel AISI 304 material complete with:
– vertical type electro-mixing group
– conical type bottom and cover
– manhole DN 400
– adjustable stainless steel feet
– service connections
– washing spray-ball
– cleanable level indicator
– air vent

tubular heat exchanger for inlet water heating
centrifugal pump for filter feeding
filters for sugar solution at 60° Bx

 

 

UNITHERM S – Sugar syrup pasteurizer
Simple syrup pasteurisation plant, skid mounted, factory tested, indirect plate process, designed for flexible production
Technical data: 85% heat recovery, CIP cleanable

Operational capacity
Sugar syrup pasteurizer to                  60 – 65°Brix
Pasteurisation temperature                90°C
Holding time                                      30 s
Pasteurisation temperature precision T ± 1°C
Flow rate precision                            Q ± 5%

N° 1 plate type pasteurisation unit for sugar syrup at 60° Bx (thermal cycle 40-90-25°C), complete with:

– frame and plates made of stainless steel
– thermometers for the temperature control.
– capacity 8.000 l/h

 

 

UNISTORE S 1-15 – Sugar syrup storage tank
Pasteurised Simple syrup storage unit.
N.1 storage tank (15.000 l) with pneumatic valve for tank feeding.
The sugar syrup, by manually connection of a multiway plate, will be sent by a centrifugal pump to the Final Beverage Preparation Area.
N° 1 sugar syrup storage tank
–      capacity 15.000 l.
–      stainless steel AISI 304 material complete with:
–      vertical type electromixing group
–      conical type bottom and cover
–      manhole DN 400
–      adjustable stainless steel feet
–      service connections
–      washing spray-ball
–      level indicator, cleanable
–      air vent

N° 1 centrifugal pump to send the sugar syrup to preparation tanks
N° 1 mass flow meter for sugar syrup dosing to preparation tanks

Additional features

– AISI 304 piping for the connection of the above items
– Electrical and pneumatic material for the connection of the above items
– Service walkway in stainless steel with floor in galvanized steel for the access to the opening of the dissolution and storage tank

 

 

 

Area 2 – Final beverage preparation area

Within the range of the beverages with juice and purée based the high cost and variability of raw materials (Brix, pH, TA, etc.) imposes a batch technology for the preparation of the final beverage in order to allow updates and corrections to the recipe in progress.

 

 

UNISOLV MULTI 3-30
It has been considered 3 main mixing tanks insulated with agitators (3 of 30.000 l capacity) in order to mix different liquids  (water, concentrated juice, puree, citric acid, micro components..) using batch process in order to create a finished beverage to be sent to the pasteurizer. The tanks are equipped with level transmitter and min/max level probe.

N° 3 preparation tanks
– capacity 30.000 l each, made of stainless steel AISI 316
– vertical type mixing units
– bottom and cover, conical type
– manhole DN 400
– adjustable stainless steel feet
– service connections
– washing spray-ball
– level indicator, cleanable
– air vent
– sampling point
– satin finishing externally, 2b lamination internally

N° 3 weight cells for puree/concentrated juice

N° 2 magnetic flow meters for water feeding to citric acid mixer and final beverage preparation tanks

 

 

UNISOLV 1-1 + UNISOLV 1-0,5

2  tanks (one of 1000 l capacity and another one of 500 l) for powders dissolution (citric acid powder and micro components) are included.

The operator will manually dose the pre-weighted powders into the tanks with water automatic loading system through a magnetic flow meter.

N° 1 mixer for citric acid

capacity 1000 l, stainless steel material AISI 304, complete with:

–      mixing unit
–      adjustable stainless steel feet
–      washing spray ball

N° 1 mixer for micro components

capacity 500 l stainless steel material AISI 304, complete with:

–      mixing unit
–      adjustable stainless steel feet
–      washing spray ball

N° 1 centrifugal pump to send the ingredients to preparation tanks

N° 1 centrifugal pump to send the final beverage to pasteurizer

 

Juice empting station

One juice emptying station complete of 3 piston pumps with flexible pipes for drums emptying has been included (discharge of 2 or 3 juices at the same time is not possible). The puree/concentrate will be sent on the  feeding line of the main mixing tanks.

 

N° 3 mono pumps for puree/concentrated juice drums discharging

Service walkway in stainless steel with floor in galvanized steel for the access to the openings of the various tanks

AISI 304 piping for the connection of the above items

Electrical and pneumatic material for the connection of the above items

 

 

Area 3 – Final beverage treatment area

Product pasteurizer UNITHERM 18 – Tubular heat exchanger UHT plant

 

Max Capacity               18.000 l/h

Technology                  Tubular Heat Exchanger

 

 

Each tubular module is 6m 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 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 problem on 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

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 aseptic magnetic stirrer, in case of pulpy products

 

Sterile CO2 injector – UNIFLUX AS – Utilities 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

 

Area 4 – Cleaning station and Piping

 

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 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 steam line

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

–     Centrifugal boost pump for sending 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 located on board the machine with incorporated graphic control panel.

 

 

 

 

 

 

 

Piping UNIPIPE

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

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

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

Air pressure: 8 bar

 

 

 

Nominal line speed

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 CC UNIBLOC HA is a contamination controlled bottling line inclusive of microbiological isolator, especially designed for bottling products with a pH lower than 4,5.
The bottles sent to the UNIBLOC are firstly, sterilised internally with an oxidising solution and subsequently rinsed with sterile water prior to being fed to the filler. The bottles are filled by means of electronically controlled filling valves and capped by an aseptic type capper. The contents of the bottle is measured by means of a magnetic flow meter.

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 bloc bottle entrance and 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

–     Main frame 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 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.

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

–     The 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.

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

–     The 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

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 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

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

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

2nd Sterile air pre-filtration:         EU9 95% opacimetric

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

2nd 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 junction between walls and floor, outside the clean area.

3.     Aluminium profile, round corner, for 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

Drying tunnel PROCOMAC model DRYSTAR 3S

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.

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    DISCLAIMER: The operational status of each machine is monitored on a monthly basis. Therefore we will promptly update the current status of the machine only at the time of your request.